Abstract: A footwear cushioning system including an insole and a midsole that define a chamber containing multiple, hollow, inverted, truncated cones. The insole includes a plate having a downwardly extending rib to define a recess. The midsole includes a midsole plate including an upwardly extending wall and multiple upwardly opening hollow, inverted frusto-conical cushion cells. The wall interfits within the rib, and the cushion cells abut against the insole plate. An outsole shell is direct-attached to the cushioning system with polyurethane. Preferably, the polyurethane pre-compresses the cushion cells and adds cushioning and energy return characteristics. To assemble the cushion system, an upper is stapled to the insole rib. The midsole is interfitted within the rib. The insole and midsole are heated to fuse the cushion cells to the insole. Polyurethane is poured into the outsole shell and the shell is direct attached to the upper/cushioning system.

Abstract: A footwear cushioning system including an insole and a midsole that define a chamber containing multiple, hollow, inverted, truncated cones. The insole includes a plate having a downwardly extending rib to define a recess. The midsole includes a midsole plate including an upwardly extending wall and multiple upwardly opening hollow, inverted frusto-conical cushion cells. The wall interfits within the rib, and the cushion cells abut against the insole plate. An outsole shell is direct-attached to the cushioning system with polyurethane. Preferably, the polyurethane pre-compresses the cushion cells and adds cushioning and energy return characteristics. To assemble the cushion system, an upper is stapled to the insole rib. The midsole is interfitted within the rib. The insole and midsole are heated to fuse the cushion cells to the insole. Polyurethane is poured into the outsole shell and the shell is direct attached to the upper/cushioning system.

Abstract: A shoe construction having an outsole direct attached to a midsole with a mechanical interlock. The outsole includes a bottom and a wall extends upwardly therefrom, optionally around the entire periphery of the outsole. At a pre-selected distance above the bottom, a rib or a plurality of protrusions extend inwardly from the wall so that a void is defined between the protrusions and the bottom. The midsole is direct attached to the upper, the bottom, the wall and the protrusions. The protrusions enhance the mechanical securement of the midsole to the outsole. To assemble the construction, the outsole and the upper are positioned in a mold a pre-selected distance apart to form a cavity. A plastic material is injected into the cavity and direct attaches to the outsole and upper. As the plastic material fills the cavity, it seeps into the void defined between the projections and the upper surface.

Abstract: A footwear cushioning system including an insole and a midsole that define a chamber containing multiple, hollow, inverted, truncated cones. The insole includes a plate having a downwardly extending rib to define a recess. The midsole includes a midsole plate including an upwardly extending wall and multiple upwardly opening hollow, inverted frusto-conical cushion cells. The wall interfits within the rib, and the cushion cells abut against the insole plate. An outsole shell is direct-attached to the cushioning system with polyurethane. Preferably, the polyurethane pre-compresses the cushion cells and adds cushioning and energy return characteristics. To assemble the cushion system, an upper is stapled to the insole rib. The midsole is interfitted within the rib. The insole and midsole are heated to fuse the cushion cells to the insole. Polyurethane is poured into the outsole shell and the shell is direct attached to the upper/cushioning system.

Abstract: A footwear cushioning system including an insole and a midsole that define a chamber containing multiple, hollow, inverted, truncated cones. The insole includes a plate having a downwardly extending rib to define a recess. The midsole includes a midsole plate including an upwardly extending wall and multiple upwardly opening hollow, inverted frusto-conical cushion cells. The wall interfits within the rib, and the cushion cells abut against the insole plate. An outsole shell is direct-attached to the cushioning system with polyurethane. Preferably, the polyurethane pre-compresses the cushion cells and adds cushioning and energy return characteristics. To assemble the cushion system, an upper is stapled to the insole rib. The midsole is interfitted within the rib. The insole and midsole are heated to fuse the cushion cells to the insole. Polyurethane is poured into the outsole shell and the shell is direct attached to the upper/cushioning system.

Abstract: A shoe construction having a sole with an outsole shell that is filled with a filling material, such as polyurethane foam, and secured to the upper by a welt. The sole includes an insole having a downwardly extending rib, an outer shell defining a void containing the filling material, and a welt that interconnects the outsole shell and the insole with the upper. To assemble the construction, the upper is lasted and either stitched or stapled to the insole. The welt is then stitched or stapled to the insole/upper combination. Next, the filling material is poured into the void in the outsole shell and the shell is directly attached by the filling material to the upper/insole/welt assembly. The outsole welt is stitched to the shell around the entire periphery of the sole. The stitch extends between a stitch groove in the welt and a stitch groove in the outsole shell.

Abstract: A footwear outsole assembly including an outsole body, a pair of cleated windows, and a pair of cushioning inserts on top of the windows. The cleated windows form a portion of the outsole wear surface. Each insert is visible through the corresponding cleated window. The cleated windows extend below the outsole body so that impact forces are absorbed by the windows and inserts.