Abstract: An article of footwear includes an upper and a sole assembly secured to the upper. The sole assembly includes a first portion having a lower ground engaging surface, an upper surface, and a recess formed in the upper surface. The upper surface of the first portion is in contact with the upper. A second portion is seated in the recess in the first portion and has an upper surface, with the upper surface of the second portion being in contact with the upper. The second portion comprises a foam material having a density less than 0.25 g/cm3.

Abstract: An article of footwear includes an upper and a sole assembly secured to the upper. The sole assembly includes a first portion having a lower ground engaging surface, an upper surface, and a recess formed in the upper surface. The upper surface of the first portion is in contact with the upper. A second portion is seated in the recess in the first portion and has an upper surface, with the upper surface of the second portion being in contact with the upper. The second portion comprises a foam material having a density less than 0.25 g/cm3.

Abstract: Disclosed is a method for molding a foamed article, such as a midsole or outsole for footwear, in which first water, then a desired amount of thermoplastic polyurethane foam beads are placed in a compression mold in the shape of the article and the mold is brought to a peak temperature of from about 130° C. to about 180° C. over a period of from about 300 to about 1500 seconds, then cooled to from about 5° C. to about 80° C. over a period of from about 300 to about 1500 seconds within about 30 seconds after the peak temperature is reached. The foamed article made by the method has a density of from about 0.1 to about 0.45 g/cm3.

Abstract: A sole assembly is formed by preheating a mold assembly, placing a quantity of rubber in a first portion of a lower recess of a mold assembly; placing a middle plate in contact with a bottom plate, and an upper plate in contact with the middle plate; subjecting the top, middle, and bottom plates to heat to semi-cure the rubber in the lower recess to form an outsole member; separating the top plate, the middle plate, and the bottom plate; placing the top plate in contact with the bottom plate, with polyolefin forming a midsole above the semi-cured rubber; subjecting the top and bottom plates to heat such that the polyolefin expands within the sole recess and the polyolefin and rubber in the sole recess fully cure, cross-link, and bond to one another to form a sole assembly; cooling the top and bottom plates; and removing the sole assembly.

Abstract: A method of insert molding comprises placing in a first mold a curable rubber composition comprising a reactive species; placing on a surface of the rubber composition a first thermoplastic material in a film or layer comprising a group reactive with the reactive species of the rubber composition; curing the rubber composition in the mold to form a first molded article of cured rubber having a first thermoplastic material layer covalently bonded through reactive of the reactive species and the group; placing the first molded article as an insert into a second mold, the cured rubber contacting an inside surface of the second mold and the thermoplastic layer facing into the second mold cavity; closing the second mold and injecting into the second mold a second thermoplastic material that to form a second molded article comprising the first molded article thermally welded and/or covalently bonded to the second thermoplastic material.

Abstract: A method of insert molding comprises placing in a first mold a curable rubber composition comprising a reactive species; placing on a surface of the rubber composition a first thermoplastic material in a film or layer comprising a group reactive with the reactive species of the rubber composition; curing the rubber composition in the mold to form a first molded article of cured rubber having a first thermoplastic material layer covalently bonded through reactive of the reactive species and the group; placing the first molded article as an insert into a second mold, the cured rubber contacting an inside surface of the second mold and the thermoplastic layer facing into the second mold cavity; closing the second mold and injecting into the second mold a second thermoplastic material that to form a second molded article comprising the first molded article thermally welded and/or covalently bonded to the second thermoplastic material.

Abstract: Disclosed is a method for molding a foamed article, such as a midsole or outsole for footwear, in which a desired amount of thermoplastic polyurethane foam beads are placed in a compression mold in the shape of the article and the mold is brought to a peak temperature of from about 130° C. to about 180° C. over a period of from about 300 to about 1500 seconds, then cooled to from about 5° C. to about 80° C. over a period of from about 300 to about 1500 seconds within about 30 seconds after the peak temperature is reached. The foamed article made by the method has a density of from about 0.1 to about 0.45 g/cm3.

Abstract: A method of making an article of footwear may include providing a last shaped to resemble a human foot. The method may also include forming at least one footwear component at least in part from a susceptor material that is thermally reactive to an electromagnetic field. The method may further include covering at least a portion of the last with two or more footwear components, wherein the two or more footwear components includes the at least one footwear component formed at least in part from a susceptor material. In addition, the method may include applying an electromagnetic field to the susceptor material, causing induction heating of the susceptor material and joining the two or more footwear components by melding the two or more components with the induction heating.

Abstract: A method of insert molding comprises placing in a first mold a curable rubber composition comprising a reactive species; placing on a surface of the rubber composition a first thermoplastic material in a film or layer comprising a group reactive with the reactive species of the rubber composition; curing the rubber composition in the mold to form a first molded article of cured rubber having a first thermoplastic material layer covalently bonded through reactive of the reactive species and the group; placing the first molded article as an insert into a second mold, the cured rubber contacting an inside surface of the second mold and the thermoplastic layer facing into the second mold cavity; closing the second mold and injecting into the second mold a second thermoplastic material that to form a second molded article comprising the first molded article thermally welded and/or covalently bonded to the second thermoplastic material.

Abstract: An article of footwear includes an upper and a sole assembly secured to the upper. The sole assembly includes a first portion having a lower ground engaging surface, an upper surface, and a recess formed in the upper surface. The upper surface of the first portion is in contact with the upper. A second portion is seated in the recess in the first portion and has an upper surface, with the upper surface of the second portion being in contact with the upper. The second portion comprises a foam material having a density less than 0.25 g/cm3.

Abstract: An article of footwear includes an upper and a sole assembly secured to the upper. The sole assembly includes a first portion having a lower ground engaging surface, an upper surface, and a recess formed in the upper surface. The upper surface of the first portion is in contact with the upper. A second portion is seated in the recess in the first portion and has an upper surface, with the upper surface of the second portion being in contact with the upper. The second portion comprises a foam material having a density less than 0.25 g/cm3.

Abstract: A method of insert molding comprises placing in a first mold a curable rubber composition comprising a reactive species; placing on a surface of the rubber composition a first thermoplastic material in a film or layer comprising a group reactive with the reactive species of the rubber composition; curing the rubber composition in the mold to form a first molded article of cured rubber having a first thermoplastic material layer covalently bonded through reactive of the reactive species and the group; placing the first molded article as an insert into a second mold, the cured rubber contacting an inside surface of the second mold and the thermoplastic layer facing into the second mold cavity; closing the second mold and injecting into the second mold a second thermoplastic material that to form a second molded article comprising the first molded article thermally welded and/or covalently bonded to the second thermoplastic material.

Abstract: A method of insert molding comprises placing in a first mold a curable rubber composition comprising a reactive species; placing on a surface of the rubber composition a first thermoplastic material in a film or layer comprising a group reactive with the reactive species of the rubber composition; curing the rubber composition in the mold to form a first molded article of cured rubber having a first thermoplastic material layer covalently bonded through reactive of the reactive species and the group; placing the first molded article as an insert into a second mold, the cured rubber contacting an inside surface of the second mold and the thermoplastic layer facing into the second mold cavity; closing the second mold and injecting into the second mold a second thermoplastic material that to form a second molded article comprising the first molded article thermally welded and/or covalently bonded to the second thermoplastic material.

Abstract: An article of footwear includes an upper and a sole assembly secured to the upper. The sole assembly includes a lower ground engaging surface portion and an upper surface portion. The upper surface of the first portion is in contact with the upper. At least part of the lower ground engaging surface portion is a polymer material formed from a blend of polybutadiene polymer and a carboxylated butadiene-acrylonitrile or partially hydrogenated carboxylated butadiene acrylonitrile; wherein the polymer material has a density of 1.00-1.25 g/cm3 and a hardness of at least 55 Asker C.

Abstract: An article of footwear includes an upper and a sole assembly secured to the upper. The sole assembly includes a first portion having a lower ground engaging surface, an upper surface, and a recess formed in the upper surface. The upper surface of the first portion is in contact with the upper. A second portion is seated in the recess in the first portion and has an upper surface, with the upper surface of the second portion being in contact with the upper. The second portion comprises a foam material having a density less than 0.25 g/cm3.

Abstract: A method of insert molding comprises placing in a first mold a curable rubber composition comprising a reactive species; placing on a surface of the rubber composition a first thermoplastic material in a film or layer comprising a group reactive with the reactive species of the rubber composition; curing the rubber composition in the mold to form a first molded article of cured rubber having a first thermoplastic material layer covalently bonded through reactive of the reactive species and the group; placing the first molded article as an insert into a second mold, the cured rubber contacting an inside surface of the second mold and the thermoplastic layer facing into the second mold cavity; closing the second mold and injecting into the second mold a second thermoplastic material that to form a second molded article comprising the first molded article thermally welded and/or covalently bonded to the second thermoplastic material.

Abstract: An article of footwear includes an upper and a sole assembly secured to the upper. The sole assembly includes a lower ground engaging surface portion and an upper surface portion. The upper surface of the first portion is in contact with the upper. At least part of the lower ground engaging surface portion is a polymer material formed from a blend of polybutadiene polymer and a carboxylated butadiene-acrylonitrile or partially hydrogenated carboxylated butadiene acrylonitrile; wherein the polymer material has a density of 1.00-1.25 g/cm3 and a hardness of at least 55 Asker C.