Abstract: A footwear construction including an upper, a midsole including a midsole flange, and an outsole shell including an outsole flange. The flanges can project outwardly, away from the upper in the forefoot portion. The flanges can be joined with a direct attach bond and a lock stitch. The flanges can each terminate short of the heel portion. The lock stitch can terminate short of the heel portion, and can be visible above and below the joined flanges. The midsole can include a fully exposed and viewable portion in the heel portion of the footwear. The midsole can include a heel cup integrally formed with the midsole flange. A method for constructing the footwear includes direct attaching a midsole to an upper and an outsole including an outsole flange. The midsole can form with a midsole flange, and the midsole flange and outsole flange can be stitched together with a lock stitch.

Abstract: A welted footwear construction with a direct-attach outsole and an internal tray containing a low density cushioning material. The welt may be secured to the upper and insole by one line of stitching and to the tray by a second line of stitching. The tray may include separate heel and forefoot cavities, each containing a low density cushioning material. The tray may be manufactured from thermoplastic urethane (“TPU”) and may contain low-density polyurethane (“PU”). The low-density PU may be molded in place within the cavities in the tray. The outsole may be directly attached to the undersurface of the tray, and may be manufactured from high-density PU.

Abstract: A welted footwear construction with a direct-attach outsole and an internal tray containing a low density cushioning material. The welt may be secured to the upper and insole by one line of stitching and to the tray by a second line of stitching. The tray may include separate heel and forefoot cavities, each containing a low density cushioning material. The tray may be manufactured from thermoplastic urethane (“TPU”) and may contain low-density polyurethane (“PU”). The low-density PU may be molded in place within the cavities in the tray. The outsole may be directly attached to the undersurface of the tray, and may be manufactured from high-density PU.

Abstract: A footwear construction including an upper, a midsole including a midsole flange, and an outsole shell including an outsole flange. The flanges can project outwardly, away from the upper in the forefoot portion. The flanges can be joined with a direct attach bond and a lock stitch. The flanges can each terminate short of the heel portion. The lock stitch can terminate short of the heel portion, and can be visible above and below the joined flanges. The midsole can include a fully exposed and viewable portion in the heel portion of the footwear. The midsole can include a heel cup integrally formed with the midsole flange. A method for constructing the footwear includes direct attaching a midsole to an upper and an outsole including an outsole flange. The midsole can form with a midsole flange, and the midsole flange and outsole flange can be stitched together with a lock stitch.

Abstract: An outsole construction having an integral display layer. The outsole includes a main body and a plurality of lugs extending from the main body to define a plurality of ground engaging elements. The display layer is disposed at the surface of the main body such that it is visible in the main body of the outsole and is spaced away from the surface of the lugs such that it is not visible on the surface of the lugs. The display layer may include a printed pattern, such as a camouflage pattern. The present invention also provides a method for manufacturing an outsole including the general steps of (a) providing a mold defining a main body and a plurality of lugs extending from the main body, (b) placing a permeable display layer in the mold and (c) injecting sole material into the mold. In this method, the permeability of the display layer and/or the viscosity of the sole material may be selected so that the display layer lies along the surface of the main body of the sole but not the surface of the lugs.

Abstract: An outsole for an article of footwear including a base and a plurality of lugs extending from the base in the forefoot and in the heel portions of the outsole. The lugs each include a leading edge and a trailing edge, and are individually contoured to include a profile increasing in height relative to the base from the leading edge to the trailing edge. The plurality of lugs can also collectively form a contour having an increasing height profile from toe to heel in both the forefoot portion and the heel portion of the outsole. The shape of the lugs, both individually and collectively, permits efficient energy return when walking and simultaneously provides localized, independent reactivity to accommodate a wearer's pressure profile and gait.