Abstract: An article of footwear having a self-cleaning surface and a method of making an article of footwear are disclosed. The article of footwear may generally include a sole plate having cleats associated with resilient members. The resilient members may be disposed on a bottom surface of the sole plate in an area near the cleats. For example, a resilient member may be disposed in on the bottom surface of the sole plate in the peripheral area of a cleat. The resilient members may prevent mud from accumulating on the cleats and/or a bottom surface of the sole plate by compressing against a surface of the ground and then springing back, preventing mud from sticking to the resilient member.

Abstract: A full length composite plate to be used as part of an outsole assembly in an article of footwear is disclosed. The full length composite plate comprises a composite material that has a certain percent elongation. The full length composite plate can include a heel cup for heel stability and improved traction. The full length composite plate also can include two angled portions along an arch region that provide arch support, as well as two flattened edges along the arch region to minimize or eliminate buckling. The forefoot region can be relatively flatter than the arch and heel regions, and notches are preferably included along a portion of the forefoot to increase flexibility.

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 has a sole structure with frusto-conical structures. The sole structure includes a sole plate and outer sole assembly. The outer sole assembly is placed on the outer surface of the sole plate. The outer sole assembly provides frusto-conical structures that protrude towards the outer surface of the sole plate. The frusto-conical structures have recesses facing the ground surface.

Abstract: A full length composite plate to be used as part of an outsole assembly in an article of footwear is disclosed. The full length composite plate comprises a composite material that has a certain percent elongation. The full length composite plate can include a heel cup for heel stability and improved traction. The full length composite plate also can include two angled portions along an arch region that provide arch support, as well as two flattened edges along the arch region to minimize or eliminate buckling. The forefoot region can be relatively flatter than the arch and heel regions, and notches are preferably included along a portion of the forefoot to increase flexibility.

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 composite shell for an upper may include a base layer and a fiber-reinforced layer. The base layer may comprise a mesh or other type of textile material and may extend at least over sides of a generally foot-shaped interior region of the upper. The fiber-reinforced layer may be at least partially bonded to the base layer. The fiber-reinforced layer may extend at least from a lower portion of the base layer generally corresponding to a footbed perimeter to at least a top portion of the base layer generally corresponding to part of an instep region. The fiber-reinforced layer may include a plurality of strips extending from the lower portion to the top portion, the strips separated by inter-strip gaps in the fiber-reinforced layer.

Abstract: An article of footwear has a sole structure with frusto-conical structures. The sole structure includes a sole plate and outer sole assembly. The outer sole assembly is placed on the outer surface of the sole plate. The outer sole assembly provides frusto-conical structures that protrude towards the outer surface of the sole plate. The frusto-conical structures have recesses facing the ground surface.

Abstract: An article of footwear having a self-cleaning surface and a method of making an article of footwear are disclosed. The article of footwear may generally include a sole plate having cleats associated with resilient members. The resilient members may be disposed on a bottom surface of the sole plate in an area near the cleats. For example, a resilient member may be disposed in on the bottom surface of the sole plate in the peripheral area of a cleat. The resilient members may prevent mud from accumulating on the cleats and/or a bottom surface of the sole plate by compressing against a surface of the ground and then springing back, preventing mud from sticking to the resilient member.

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: 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: A full length composite plate to be used as part of an outsole assembly in an article of footwear is disclosed. The full length composite plate comprises a composite material that has a certain percent elongation. The full length composite plate can include a heel cup for heel stability and improved traction. The full length composite plate also can include two angled portions along an arch region that provide arch support, as well as two flattened edges along the arch region to minimize or eliminate buckling. The forefoot region can be relatively flatter than the arch and heel regions, and notches are preferably included along a portion of the forefoot to increase flexibility.

Abstract: A composite shell for an upper may include a base layer and a fiber-reinforced layer. The base layer may comprise a mesh or other type of textile material and may extend at least over sides of a generally foot-shaped interior region of the upper. The fiber-reinforced layer may be at least partially bonded to the base layer. The fiber-reinforced layer may extend at least from a lower portion of the base layer generally corresponding to a footbed perimeter to at least a top portion of the base layer generally corresponding to part of an instep region. The fiber-reinforced layer may include a plurality of strips extending from the lower portion to the top portion, the strips separated by inter-strip gaps in the fiber-reinforced layer.

Abstract: A full length composite plate to be used as part of an outsole assembly in an article of footwear is disclosed. The full length composite plate comprises a composite material that has a certain percent elongation. The full length composite plate can include a heel cup for heel stability and improved traction. The full length composite plate also can include two angled portions along an arch region that provide arch support, as well as two flattened edges along the arch region to minimize or eliminate buckling. The forefoot region can be relatively flatter than the arch and heel regions, and notches are preferably included along a portion of the forefoot to increase flexibility.

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: Layers of an item may be temporarily assembled using a tacky surface on an adhesive layer. The adhesive layer may be activated by the application of energy to cause it to partially or entirely melt to bond layers together. The tacky layer may permit layers to be moved after initial positioning if the positioning is not acceptable. A tacky layer may cover all or part of the surface of an adhesive layer to permit the adhesive to flow without hindrance when activated.

Abstract: Layers of an item may be temporarily assembled using a tacky surface on an adhesive layer. The adhesive layer may be activated by the application of energy to cause it to partially or entirely melt to bond layers together. The tacky layer may permit layers to be moved after initial positioning if the positioning is not acceptable. A tacky layer may cover all or part of the surface of an adhesive layer to permit the adhesive to flow without hindrance when activated.