Abstract: A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion.

Abstract: A strapping system for footwear comprises a strap (1) that has a first end (3) connected to a first side of a heel portion (12) of footwear, passes over the instep of a foot, through a channel (31) extending through the midfoot of the footwear sole and back over the foot instep to thereby forming an X shape over the wearer's foot. The strap (1) has a second end (11) which may be adjustably connected to the second side of a heel portion (12) of a sole. The channel (31) is resilient and rigid so as to allow the strap freedom of movement during use: thereby achieving a dynamic and self adjusting strap fit. A footwear sole comprises relatively soft forefoot and heel portions with a more rigid shank portion therebetween to provide the sole with stiffness and torsional rigidity.

Abstract: A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion.

Abstract: A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and shaping the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet can be formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU). A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet can be shaped by compression molding in a mold cavity or by lasting to achieve the desired three-dimensional geometry.

Abstract: A method of manufacturing a multi-layer, composite footwear upper having a three-dimensional geometry includes the steps of forming a substantially planar composite sheet from two or more layers, heating the composite sheet, and compression molding the composite sheet into the three-dimensional geometry of the footwear upper. The composite sheet is formed by laminating a first layer of thermoplastic foam to a second layer of thermoplastic urethane (TPU), preferably in the form of a TPU film. A third layer of mesh fabric can be interposed between the first and second layers. The composite sheet is compressed after heating in a mold cavity to achieve the desired three-dimensional geometry. The composite sheet can be compression molded into separate sections which are assembled after molding to form the footwear upper. Alternatively, the composite sheet can be compression molded into a seamless, unitary footwear upper that requires minimal, if any, assembly for completion.

Abstract: A footwear heel stabilizing construction comprising an upper portion, a midsole fitted to said upper and having a heel cushion portion in said midsole, said heel cushion embraced in a frame in which the frame has a series of cushion retaining finger elements surrounding said cushion to retain said cushion in a configuration presented to the bottom of said footwear upper portion, and an outsole secured to said midsole to provide a walking surface for the footwear.

Abstract: A composite midsole for shoes comprising an energy absorbing cellular foam cushion having recesses extending inwardly from its undersurface, thermally bonded to a sheet of resilient material extending over the undersurface and into the recesses to form domes of the resilient material. Impact energy is partially absorbed by compression of the cushion and partially transmitted to cause spring-like deflection of the domes. The combined effect is selectively variable over the area of the midsole to produce the desired cushioning properties in localized areas of the midsole.

Abstract: Footwear construction having a comfort cradle device disposed in a midsole socket for support above the outsole contact with a walking or running surface and in which the cradle device is shaped to afford self centering and position stability for the wearer's foot. The cradle device is interlocked with the midsole through a system of fingers that move in response to the shift in applied load to return energy to the cradle.

Abstract: The process of molding a component of a sole unit for an athletic shoe comprising the steps of supporting a core of a first plastic material in a cavity of a mold, the core defining an integral part of the component and extending within a heel region toward a forefoot region, supporting at least one rigid plug member within the cavity juxtaposed and in partially surrounding relation to the core, injecting a second plastic material into the cavity to fill the cavity, to form a shell around the core, at least partially curing the injected plastic material, removing the plug member, and injecting a third plastic material which upon curing forms a second resilient plastic material having a hardness (Shore A) greater than that of the material of the core into the cavity to fill the area heretofore occupied by the plug member, the plug member being shaped such that the third plastic material forms a set of posts.

Abstract: The invention is in a sole unit for footwear including a midsole/wedge component (16, 30, 40, 60) of plastic material. The midsole/wedge component includes a core (26, 36, 46, 62) which may be characterized as a V-channel within a central longitudinal portion extending away from the back of the heel along substantially the longitudinal axis of the component. A pair of posts (22 and 24, 32 and 34, 42 and 44, 64 and 66) describing a lateral and medial post extend along the component at least to the region of the heel seat of the wedge. The density of the medial post (Shore A) may be equal to or greater than the density of the lateral post, and both posts have a density (Shore A) greater than that of the core to minimize excessive rear foot motion and instability.The invention also envisions several process for forming the midsole/wedge component.

Abstract: The manufacture of a sole unit for footwear, such as an athletic shoe including an integral midsole/wedge or a separable wedge for use with a midsole. The integral midsole/wedge unit and the separable wedge comprise a shell and a core at least partially encapsulated within the shell. In the manufacture the core is supported in a mold by a plurality of pins extending from an upper and lower mold half toward a parting line; or the core is supported on one or the other of an outsole or insole of the sole unit and closed in the mold. The material of the shell is poured or injected into the mold.

Abstract: Footwear including an upper and a sole with a plurality of cleats extending from the sole arranged in groupings of cleats adapting the footwear to field sports. A control device extends upwardly of the sole around the heel, a pair of spines extend along the sole between cleats of a grouping of cleats within the region of the ball and heel of the foot, and a flex area is provided in the sole in the general off-center alignment of the heads of the metatarsal bones.

Abstract: The manufacture of a sole unit for footwear, such as an athletic shoe including an integral midsole/wedge or a separable wedge for use with a midsole. The integral midsole/wedge unit and the separable wedge comprise a shell and a core at least partially encapsulated within the shell. In the manufacture the core is supported in a mold by a plurality of pins extending from an upper and lower mold half toward a parting line; or the core is supported on one or the other of an outsole or insole of the sole unit and closed in the mold. The material of the shell is poured or injected into the mold.

Abstract: An athletic shoe for runners, joggers, and the like includes a backtab at the upper heel/counter portion of the shoe which extends somewhat along both the lateral and medial sides of the shoe. The backtab is characterized as a cushioning member and it includes a cut-out or notch to accommodate the Achilles tendon of the foot to reduce or substantially eliminate stress and pressure on the Achilles tendon which may result in aggravation or injury to the tendon.

Abstract: A sole unit for footwear such as an athletic shoe includes an integral midsole/wedge or a wedge for use with a midsole. The integral midsole/wedge unit and the wedge for use with a midsole both are formed by a shell and an encapsulated core. The shell and core comprise plastic materials which have individual strengths and weaknesses in a shoe construction, yet provide, as a composite improved results in a shock dispersion and memory system. In a second aspect, the integral midsole/wedge is a single density or a two-density unit precompressed from a low density material.

Abstract: An athletic shoe includes an outsole assembly and a shoe upper whose quarter sections extend above the ankles. A cut out area extends over one ankle, around the heel and over the ankle within the quarter sections, and a collar closes the cut out area. The collar includes a high density foam lamina to support and protect the ankles, and, because of its pliability, potential pressure points exerted on the foot with accompanying irritation are substantially eliminated.