AU2016204359A1

AU2016204359A1 - Footwear

Info

Publication number: AU2016204359A1
Application number: AU2016204359A
Authority: AU
Inventors: Brenden MAYNE
Original assignee: BLUNDSTONE AUSTRALIA Pty Ltd
Current assignee: BLUNDSTONE AUSTRALIA Pty Ltd
Priority date: 2016-06-24
Filing date: 2016-06-24
Publication date: 2018-01-18

Abstract

An injection moulded midsole of a footwear sole includes different injection moulded sections (Ml, M2) of 5 the midsole (15) that provide the midsole with different shock (i.e. energy) absorption, cushioning and structural performance. Footwear comprises the injection moulded midsole (15). An injection moulding mould (17) that defines two mould cavities for injection moulding the io midsole (15) includes a base (4) of the mould cavity, an upper part of the mould cavity, a side mould (6, 6A) on each side of the mould cavity, and a heel midsole mould (7, 7A) that can be positioned in a heel region of the mould, with the mould being movable between an open 15 position and a closed position. 7902511_1 (GHMatters) P103198.AU.1 24/06/16 12 FIGURE 1 M2l 31 M2 2 122 -M FIGURE 2 SECTION"AA' SECTION"BB FIGURE 3

Description

Technical Field

The invention relates to footwear.

The invention relates particularly to an injection moulded midsole of footwear that provides good shock absorption, cushioning and wearer comfort, and thereby reduces fatigue of a foot, and structural performance.

The footwear may be any footwear including, by way of example, sports shoes/boots, casual shoes/boots, safety shoes/boots, and school shoes/boots. The terms shoes and boots are used interchangeably in this specification.

The invention also relates to an injection moulding mould for use in manufacturing the footwear midsole .

The invention also relates to an apparatus for 20 and a method of manufacturing the footwear using the injection moulding mould.

Background

Footwear generally comprises a sole and an upper.

The sole may be a single piece, but more commonly comprises multiple layers, typically an outer sole and a midsole.

The outer sole provides a tough, wear resistant layer and suitable tread for providing traction against the ground or a floor.

The midsole is the main part of the sole and is designed to absorb impact energy, for example on heel strike, and to provide structure {referred to herein

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 as structural performance) for the sole and the footwear generally.

Footwear designers have endeavoured to improve midsole shock absorption, especially absorption of shock caused by heel strike, and thereby contribute to providing an adequate level of cushioning for comfort, while maintaining the structural performance of the footwear. Balancing shock (i.e. energy) absorption, comfort and structural performance is not a straightforward exercise.

One option that has been proposed is a midsole having several zones or areas where elastomeric foam of different stiffness's is used to balance the need for shock absorption and structural integrity.

Different types of elastomeric foams have been proposed, including ethylene-vinyl acetate (EVA), polyethylene, and polyurethane foams.

Another option is a combination of a gas filled bladder (i.e. an air bag) and elastomeric foam materials. The combination of the air bag and foam materials provides a mechanism for adjusting the impact response characteristics of different parts of a sole to desired requirements and the need to provide sufficient structural performance.

Both options described in the preceding paragraphs require inserts to be layered into a sole as part of a method of manufacturing the sole or otherwise incorporated into the footwear during manufacture of the footwear to achieve required sole performance.

The manufacturing requirements for these options are labour intensive at high levels of tolerances to the end product footwear in both performance and quality.

The above description should not be taken to be an admission of the common general knowledge in

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016

Australia or elsewhere .

Summary of the disclosure

The invention provides an injection moulded midsole of a footwear sole that includes different injection moulded sections of the midsole that provide the midsole with different shock (i.e. energy) absorption, cushioning and structural performance.

The midsole may include an injection moulded midsole region (Ml) in a heel of the midsole that has greater energy absorbance than the remainder of the midsole .

The injection moulded midsole region (Ml) may be in an upper part of the heel of the midsole.

The injection moulded midsole region (Ml) may extend across the width of the heel of the midsole.

The midsole may include an injection moulded 20 primary midsole region (M2) having greater rebound energy than the remainder of the midsole. Greater rebound energy means that a higher percentage of input energy is returned during rebound of the midsole. This is an indication of higher structural performance.

The injection moulded primary midsole region (M2) may be in a forepart of the midsole.

The injection moulded primary midsole region (M2) may also be in the heel of the midsole.

The injection moulded primary midsole region (M2) may also be in a lower part of the heel of the midsole below the heel midsole region (Ml).

The injection moulded primary midsole region (M2) may be a continuous region across the width and along the length of the sole.

The materials for the heel midsole region (Ml)

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 and the primary midsole region (M2) may be any suitable material or materials that can be injection moulded and produce the different requirements for energy absorbance and rebound energy in the regions (Ml) and (M2). The materials may be different types of urethanes. The material may be one material that is injection moulded to form the regions (Ml) and (M2) with different densities.

The invention also provides footwear comprising: 10 (a) a sole, including the above-described injection moulded midsole; and (b) an upper extending from the sole.

The sole may also include an outer sole.

The outer sole may be injection moulded with the midsole.

The outer sole may be provided as a pre-made component that is separately attached to the midsole.

The upper may be formed from a single layer or from two or more layers.

The invention also provides an injection moulding mould that defines two mould cavities for injection moulding the above-described midsole, the mould including a base of the mould cavity, an upper part of the mould cavity, a side mould on each side of the mould cavity, and a heel midsole mould that can be positioned in a heel region of the mould, with the mould being movable between an open position and a closed position.

The heel midsole mould may include two half heel midsole moulds that can be positioned on a respective one of the side moulds in the heel region of the mould and that form the heel midsole mould when the mould is in a closed position.

The mould described in the preceding paragraph defines two mould cavities, with a 1^st cavity being provided for injection moulding the heel midsole

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 region (Ml) in a 1^st injection moulding step and a 2^ndcavity being provided for injection moulding the primary midsole region (M2) of the midsole in a 2^ndinjection moulding step.

When the mould is in the closed position, the

1^st mould cavity may be defined by the upper part of the mould cavity and the heel midsole moulds.

When the heel midsole moulds are removed from the mould and the mould is in the closed position, the 2^nd mould cavity may be defined by the upper part of the mould cavity, the heel midsole region (Ml), the base of the mould, and the side moulds.

The injection moulding mould may include:

(a) a mounting block that facilitates mounting the mould to an injection moulding apparatus; and (b) a mechanism that interconnects the mounting block and the footform and is operable to change height position of the footform during the sole moulding process to form the primary midsole region (M2) of the midsole.

The invention also provides a method of injection moulding footwear that includes:

(a) providing an upper of the footwear; and (b) positioning the above-described mould in 25 relation to the upper, with the heel midsole mould positioned in the heel region of the mould;

(c) closing the mould;

(d) injection moulding the heel midsole region (Ml) in the mould;

(e) opening the mould and removing the heel midsole mould;

(f) closing the mould; and (g) injection moulding the primary midsole region (M2) of the midsole.

The method forms the midsole in two separate injection moulding steps that can be performed on a

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 single injection moulding apparatus that has separate injection moulding stations for supplying soleforming material to the 1^st and the 2^nd mould cavities of the mould.

The method may include injection moulding an outer sole of the footwear.

Alternatively, the outer sole may be provided as a pre-made component that is separately attached to the midsole rather than injection moulded in the above method.

The invention also provides an apparatus for injection moulding the above-described midsole of a footwear sole that includes a plurality of the abovedescribed injection moulding mould and two injection moulding stations for supplying sole-forming material to the 1^st and the 2^nd mould cavities of the mould to form the midsole .

The injection moulding apparatus may comprise a rotatable turret that supports the plurality of the above-described injection moulding mould on the perimeter of the turret, a 1^st injection moulding station for supplying sole-forming material to the 1^st mould cavity of each mould to form the heel midsole region (Ml) when the mould is rotated to the

1^st injection moulding station, and a 2nd injection moulding station for supplying sole-forming material to the 2^nd mould cavity of each mould to form the primary midsole region (M2) when the mould is rotated to the 2^nd injection moulding station.

The injection moulding apparatus may comprise an injection moulding station for supplying sole-forming material to each mould to form the outsole of the footwear sole .

The injection moulding apparatus may be a modification of a conventional injection moulding apparatus .

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016

The layout of the injection moulding apparatus and the operating software of the apparatus may be configured differently to the conventional apparatus.

However, an advantage of the invention is that 5 the injection moulding apparatus may not be significantly different in terms of layout etc. to the conventional direct moulding apparatus and therefore it can be a relatively straightforward exercise to modify the conventional apparatus.

Brief Description of the Drawings

Embodiments of the invention are now described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a vertical cross-sectional of one, although not the only, embodiment of a boot according to the invention;

Figure	2	is	a	sectional	view	along the line A-A
Figure 1;
Figure	3	is	a	sectional	view	along the line B-B
Figure 1;
Figure	4	is	a	plan view	of one, although not the

only, embodiment of an injection moulding apparatus 25 for manufacturing the boot shown in Figures 1 to 3;

Figure 5 is an exploded perspective view of an initial set-up of one, although not the only, embodiment of an injection moulding mould for manufacturing the boot shown in Figures 1 to 3, with the injection moulding mould forming part of the injection moulding apparatus shown in Figure 4;

Figure 6 is an exploded perspective view of a subsequent set-up of the injection moulding mould for manufacturing the boot shown in Figures 1 to 3;

Figure 7 is a side view of a support structure for a footform that forms part of the injection

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 moulding mould shown in Figures 5 and 6 in a raised position; and

Figure 8 is a side view of a support structure for a footform that forms part of the injection moulding mould shown in Figures 5 and 6 in a lowered position.

Detailed Description of Embodiments

In the following detailed description, reference is made to the accompanying drawings, which form a part thereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments may be utilised, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are explicitly contemplated herein.

The embodiment of the midsole of a sole of the boot shown in Figures 1 to 3 is based on the use of three materials made of various types of urethanes (or any other suitable materials) located in specific areas of the sole. Each material is formulated to perform a specific function which relates to what is required to provide overall superior comfort for the wearer.

Wearer comfort is a combination of factors including shock absorption, cushioning and structural performance of the footwear.

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016

In accordance with an embodiment of the invention, all of the materials are directly injected to form the shoe by the use of the embodiment of the injection moulding apparatus shown in Figure 4 that is specifically configured and programmed to injection mould footwear using the embodiment of the mould shown in Figures 5 and 6. As is described further below, the mould includes two mould cavities that allow all materials to be injected directly into the cavities to form the midsole of the boot in a sequence of moulding steps without the use of additional structure, such as component inserts.

The boot shown in Figures 1 to 3 comprises a sole 13 and an upper 12 extending from the sole 13.

The sole 13 comprises a midsole 15 and an outer sole 11. The midsole 15 has a primary midsole region (M2) and a heel midsole region (Ml) made from different materials, such as different urethanes, that provide different properties for the midsole 15. The

Ο Π TflSt'lSY’i s Ί Ί ΛΠ T Η ΏΓ Ί & Υ<=»ί?Ί ffcTTl £ 9 9<T3L XbB Ab XpB. Of ^^F ΧχΒ B^B ^^B* *~|— B^B X^B A ί X^B B^. JL· JL· X. Baal X^3x Atf A I 3-.JL. X^JL X^B- B^B ^^B* *XX ^^B A A

Ii «? wi Tb Hi rsr? «2τ' πίr^Titt·^ Ί

V A f ttB Xb? XB* XO* <4 i ΧΒ» ^XB* tt. <4 & *Χβ» ΧΛ ΐΠΓ <^B. Lx A A jfF <4b XBB XT <^B. *xA ttB <4 & .J tt? Xb> <BB XxB ΧΒ» ΒΛ <4b Xxt s4>

performance for the midsole and rebound energy particularly in a forepart of the midsole 15. The ίτί^τθτι 1 τπγ t*H1 τηί Η1 <& t \ fl j. X<pX 3^. ^^Β ΧΒ. ^^F *^Β> “X ΧχΒ βΒ Χ^Β Λ A X Α Β. ΧβΒ Α * X —X— ΧΒ. Χ^Β xj^ X^Jj ^KB X^B A A V A A a^a g

XS ΟΟΤ1ζ!β·ΧΤ1θζ1 J3a>rtrOU;.J»sXrl^* ^^PJLt 1^1 JZ^rOi^^JLCiLm.C^' en>erc^^j^ absorption in the heel of the midsole 15. The outer « B»x T s j «Βχ 4¹¾ 4P 4*l « <a 4» j*** *r* 4» 4«* 4**. z\?**i4* ««»4·^ v* <a 95« j·^. j«3

SUXC JL bL φ L. X» So GL wJL v Ow iUULWSwx. <51X101 ~L,5s LuxiUSQ

Fatti 9 Μίί τΉ si ί e β^Ί nrrixzi

XyB Abb 9^3L *~i— a A “ A4b<bA *~|— xJa bb <px b^b *^B* A X—x x^ ^^b X^4 ^^f XxB b^b *^b. *~|— xj^ X-B. *~i— JaA Jfa IF Ba x^B-XZ-.

hardness for the sole 13.

As described further below, the midsole 15 and the outer sole 11 are injection moulded in an ί η π ί λπ τπλιι Ί Η ΐ ϊί snns γ*9111 ί ή 9 δΩτι nF ^ΚΒ A A 9 ^^Β* *~|— Β^Β Χ^Β A A Α β ^_Γ*Χ A A x^fl ΧΒΒ 9^* ΧΒ- <βΑ *~|— ΧΒβ ΕΧβ* α Α <βΑ Χ^Β *^β> ^^β xJa ΕΧβ* χ^β ^κβ a A 9 ^^Β* *~|— Β^Β Χ^Β A A moulding steps in a mould of the apparatus. In other words, these components of the sole 13 of the boot o r a ·?*& vm <a/4 4 η αόώ 1 Η ϊ tsfi efiriii <st*s i°\F

O © <3. Ab XB JL XnZ Ax lixxwx XbM. xA. A A XBxx XxX *ix A Α Ϊ vix L* Lb bL. XnZ A A AbSXnZ XBB bA. LbAbJL A A Xxj S3 LA vix A A Nb XxX \b> bLx

St in ί ή r?l ί η ί^γ’Τ ί λπ τπλιι Id T t ί « η γ^τ «=»H t* H 9

X||B ^^B- VAr X^4 OB A A XBB Χχ4 b^b A A B-fB ^^B xJa bb A A 9 *^b> *~i— b^b x^b A A A X xx^B ^A ^^B ^_r*X 9 x^ ^^B X^S A A x^i— JL JL· x^B. 9^x

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 the outer sole 11 may be pre-made as a separate component and separately fitted to the midsole 15.

The boot also comprises an insole 3 located inside the boot on top of the sole 13. The insole 3 provides foot support for a wearer of the boot. The insole 3 may be formed as a separate component which is inserted into the boot or may be integrally formed with the sole 13 and/or the upper 12.

The embodiment of the injection moulding mould generally identified by the numeral 17 in Figures 5 and 6 and also shown in Figures ? and 8 comprises defines two mould cavities for separately injection moulding the heel midsole region (Ml) and the primary midsole region (M2).

The injection moulding mould includes a sole base 4 that has an upper profiled surface that defines a tread of the sole 13. A dummy base mould may be used to provide a thin bottom layer of the sole 13 of a material that is different to the material used in the primary midsole region (M2).

This optional layer can be manufactured from materials that will provide greater resistance associated with conditions facing the tread of the sole 13.

The injection moulding mould also includes a footform 5 that is a vehicle onto which the soleforming materials can be directly injected to form the sole 13.

With reference to Figures 7 and 8, the injection moulding mould 17 also includes:

(a) a mounting block 16 that facilitates mounting the mould to an injection moulding apparatus; and (b) a mechanism 8 that interconnects the mounting block 16 and the footform 5 and is operable to change height position of the footform 5 during

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 the sole moulding process to form the primary midsole region (M2) of the midsole 15.

The height adjustment mechanism 8 comprises a series of retractable/extendable pins 18 that interconnect the mounting block 16 and the footform 5 and a lever 9 that is coupled to the pins 18 and can retract or extend the pins 18 by moving the lever 9 as shown in Figures 7 and 8 and thereby vertically move the footform 5 between the raised position shown in Figure 7 and the lowered position shown in Figure 8.

The injection moulding mould also includes a pair of side moulds 6, 6A and two heel midsole moulds 7, 7A.

With reference to Figures 5 and 6, in an initial mould set-up position, the side moulds 6, 6A and the heel midsole moulds 7, 7A are positioned as indicated in the Figure. More particularly, the heel midsole moulds 7, 7A are positioned on the respective side moulds 6, 6A in a heel section of the mould. The heel midsole moulds 7, 7A and the side moulds 6, 6A may include locating pins/openings that facilitate positioning the components together. The Figures show the mould in an open position in this initial set-up position. In order to close the mould, the assemblies of the side moulds 6, 6A and the heel midsole moulds 7, 7A are moved inwardly and the footform 5 is moved downwardly.

Each heel midsole mould 7, 7A is formed to define one half of a 1^st cavity for sole-forming material to be injected to form the heel midsole region (Ml) to provide heel energy absorption in a 1^st step of an injection moulding method. The 1^stcavity is defined by the footform 5 and the heel midsole moulds 7, 7A. In the closed position described in the preceding paragraph, the inner side

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 edges of the heel midsole moulds 7, 7A are in contact to define the 1^st cavity. The heel midsole moulds 7, ΊΚ are formed to define a shallow dish shape as shown in the Figures .

The base 4, the heel midsole region (Ml), the footform 5, and the side moulds 6, 6A, define a 2^ndcavity for sole-forming material to be injected to form the primary midsole region (M2) as a region of rebound material in a 2^nd step of an injection moulding method. The 2^nd cavity is formed after the heel midsole region (Ml) has been injection moulded in the 1^st step and the heel midsole moulds 7, 7A have been removed.

The height adjustment mechanism 8 facilitates positioning the boot to begin the direct injection moulding process and re-positioning the boot during the process, as described below. The height adjustment mechanism 8 makes it possible to use the injection moulding mould with a conventional injection moulding apparatus with minor modifications only to the apparatus.

One embodiment of a method of direct injection moulding the boot shown in Figures 1 to 3 in accordance with the invention is as follows:

® The heel midsole moulds 7, 7A are fitted to the side moulds 6, 6A as shown in Figures 5 and 6. A boot upper 12 (single layer or multiple layer) requiring a sole 13 is fitted onto the footform

5. The height mechanism 8 is activated to raise the footform 5.

® The side moulds 6, 6A with the fitted heel midsole moulds 7, 7A are coated with a release agent and are closed around the heel region of the boot to form the above-described 1^st cavity and allow sole-forming material to be injected into the 1^st cavity to form the heel midsole

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 region (Ml) of the boot. The 1^st injection step is automatically performed by the injection moulding apparatus to a pre-set amount of material.

® The mould remains closed for a predetermined time so the midsole material in the heel midsole region (Ml) has a chance to complete its chemical reaction prior to de-moulding.

® After the predetermined time has elapsed, the mould is opened, thereby exposing the injection moulded heel midsole region (Ml).

® The heel midsole moulds 7, 7A are removed from the side moulds 6, 6A and stored for repeat operation.

® A soling material is then injected to form an outer sole 11.

® The footform 5 is lowered via the height adjustment mechanism 8 to define the abovedescribed 2^nd cavity.

® Sole-forming material is then injected into the 2^nd cavity to form the primary midsole region (M2) in a 2^nd injection moulding step. The 2^ndinjection step is automatically performed by the injection machine to a pre-set amount of material.

® After the predetermined time has elapsed, the mould is opened, thereby exposing the moulded primary midsole region (M2).

• The mould is then opened to expose the completed sole onto the boot, and the completed boot is removed from the footform 5 and sent for further processing to complete the boot for sale.

® The heel midsole mould 7, 7A is fitted to the side moulds 6, 6A again to repeat the abovedescribed process.

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016

The embodiment of the injection moulding apparatus shown in Figure 4 includes a plurality of the injection moulding moulds 17 shown in Figures 5 and 6 that are supported in a circular array on a perimeter of a rotatable turret 21, an injection moulding station RGE1 for injecting soling material to form the heel midsole region (Ml) of a boot in each one of the injection moulding moulds 17 in the 1^st step of the above described method, an outer sole injection station 23 for injection moulding the outer sole of each boot, and an injection moulding station RGE2 for injecting soling material to form the primary midsole region (M2) of a boot in each one of the injection moulding moulds 17 in the 2^nd step of the above described method.

The mounting block 16 facilitates mounting each injection moulding mould 17 to the rotatable turret 21. The rotatable turret 21 may be a conventional turret 21, with the height adjustment mechanism 8 making it possible to adapt the conventional rotatable turret 21 and other parts of an existing conventional injection moulding apparatus for use with the injection moulding moulds 17 of the invention, with these moulds being used to carry out two injection moulding operations in tandem on the same apparatus .

In use, the rotatable turret 21 moves the injection moulding moulds 17 successively to the station RGR1, the outer sole injection station 23, and the station RGE2 and the above-described operations are carried out at each station to form the soles of boots.

Many modifications may be made to the embodiments of the invention described in relation to the Figures without departing from the spirit and scope of the invention.

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016

By way of example, whilst the embodiment of the midsole shown in Figures 1 to 3 has one injection moulded primary midsole region (M2) and one injection moulded heel midsole region (Ml) having different functionality, it can readily be appreciated that the invention is not limited to this embodiment and the invention extends to midsoles having more than two injection moulded regions that have different functionality. In this situation, the invention extends to moulds that define more than two mould cavities .

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word comprise or variations such as comprises or comprising is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016

Claims

1. An injection moulded midsole of a footwear sole that includes different injection moulded sections of the

5 midsole that provide the midsole with different shock (i.e. energy) absorption, cushioning and structural performance .

2. The midsole defined in claim 1 includes an injection moulded midsole region (Ml) in a heel of the midsole that

10 has greater energy absorbance than the remainder of the midsole .

3. The midsole defined in claim 2 wherein the injection moulded midsole region (Ml) is in an upper part of the heel of the midsole.

15 4. The midsole defined in claim 1 or claim 2 wherein the injection moulded midsole region (Ml) extends across the width of the heel of the midsole.

5. The midsole defined in any one of the preceding claims includes an injection moulded primary midsole

20 region (M2) having greater rebound energy than the remainder of the midsole.

6. The midsole defined in claim 5 wherein the injection moulded primary midsole region (M2) is in a forepart of the midsole .

25 7. The midsole defined in claim 5 or claim 6 wherein the injection moulded primary midsole region (M2) is in the heel of the midsole.

8. The midsole defined in claim 7 wherein the injection moulded primary midsole region (M2) is in a lower part of

30 the heel of the midsole below the heel midsole region (Ml) .

9. The midsole defined in any one of claims 5 to 8 wherein the injection moulded primary midsole region (M2) is a continuous region across the width and along the

35 length of the sole.

10. Footwear comprising:

(a) a sole, including the injection moulded midsole

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 defined in any one of the preceding claims; and (b) an upper extending from the sole.

11. Footwear defined in claim 10 wherein the sole also includes an outer sole.

5 12. Footwear defined in claim 11 wherein the outer sole is injection moulded with the midsole.

13. An injection moulding mould that defines two mould cavities for injection moulding the midsole defined in any one of claims 1 to 9, the mould including a base of the

10 mould cavity, an upper part of the mould cavity, a side mould on each side of the mould cavity, and a heel midsole mould that can be positioned in a heel region of the mould, with the mould being movable between an open position and a closed position.

15 14. The mould defined in claim 13 wherein the heel midsole mould includes two half heel midsole moulds that can be positioned on a respective one of the side moulds in the heel region of the mould and form the heel midsole mould when the mould is in a closed position.

20 15. The mould defined in claim 13 or claim 14 defines two mould cavities, with a 1st cavity being provided for injection moulding the heel midsole region (Ml) in a 1^stinjection moulding step and a 2^nd cavity being provided for injection moulding the primary midsole region (M2) of the

25 midsole in a 2^nd injection moulding step.

16. The mould defined in claim 15 wherein, when the mould is in the closed position, the 1^st mould cavity is defined by the upper part of the mould cavity and the heel midsole mould.

30 17. The mould defined in claim 16 wherein, when the heel midsole mould is removed from the mould and the mould is in the closed position, the 2^nd mould cavity is defined by the upper part of the mould cavity, the heel midsole region (Ml), the base of the mould, and the side moulds.

35 18. A method of injection moulding footwear defined in any one of claims 10 to 12 that includes:

(a) providing an upper of the footwear; and

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016 (b) positioning the mould defined in any one of claims 13 to 17 in relation to the upper, with the heel midsole mould positioned in the heel region of the mould;

(c) closing the mould;

(d) injection moulding the heel midsole region (Ml) in the mould;

(e) opening the mould and removing the heel midsole mould;

19. An apparatus for injection moulding the midsole of a footwear sole defined in any one of claims 1 to 9 that includes a plurality of the injection moulding mould defined in claims 13 to 17 and two injection moulding stations for supplying sole-forming material to the 1^st and the 2^nd mould cavities of the mould to form the midsole.

7902511_1 (GHMatters) P103198.AU.1 24/06/16

2016204359 24 Jun 2016

1/5

2016204359 24 Jun 2016

2/5

2016204359 24 Jun 2016

3/5

2016204359 24 Jun 2016

4/5

2016204359 24 Jun 2016

FIGURE 7

FIGURE 8

5/5