WO2019191323A1

WO2019191323A1 - Footwear outsoles having resilient inserts and their manufacture

Info

Publication number: WO2019191323A1
Application number: PCT/US2019/024420
Authority: WO
Inventors: Jeff WAMMER
Original assignee: Chinook Asia Llc
Priority date: 2018-03-27
Filing date: 2019-03-27
Publication date: 2019-10-03

Abstract

Footwear manufacturing methods described herein may include use of an outsole mold having one or more receptacles bounded by vertical lips and an outsole body-forming cavity disposed outboard of the receptacles. One or more resilient inserts may be placed into the receptacles. Each resilient insert is shaped to conform to an inner wall of the lip of its receptacle, and has a top surface with a peripheral flange extending outward therefrom. A dummy mold is mated to the outsole mold, securing the resilient inserts in the receptacles such that the peripheral flange of each insert seals a perimeter of the insert by filling a space between the dummy mold and the outsole mold. A molten material is then injected into the outsole cavity to form an outsole comprising the resilient insert.

Description

FOOTWEAR OUTSOLES HAVING RESILIENT INSERTS AND THEIR

MANUFACTURE

CROSS-REFERENCES

This application claims the benefit under 35 U.S.C. § 119(e) of the priority of U.S. Provisional Patent Application Serial No. 62/648,865, filed March 27, 2018, the entirety of which is hereby incorporated by reference for all purposes.

FIELD

This disclosure relates to systems and methods for footwear. More specifically, the disclosed embodiments relate to footwear outsoles incorporating resilient inserts, and related manufacturing methods.

INTRODUCTION

Resilient materials, such as natural or synthetic rubbers, offer many properties that may be advantageous when used in footwear outsoles, including superior durability and grip when compared with alternative materials. However, outsoles formed entirely of rubber may appear oversized and unattractive. Rubber also adds weight to the outsole, which may make the resulting shoe or boot less comfortable to wear.

Injection molding techniques and associated thermoplastic materials have expanded the design possibilities available to footwear manufacturers, offering greater flexibility in material choice, form, and color. Injection-molded outsoles may also exhibit significant weight savings when compared to all-rubber outsoles. However, materials that are suitable for use in injection molding may exhibit deficiencies in other properties. Outsoles that have been entirely formed using injection molding and injection-molded materials may exhibit a less-than-desirable coefficient of friction on various surfaces, susceptibility to abrasion or chemical attack, and a tendency to suffer cracks when exposed to cold temperatures.

SUMMARY

The present disclosure provides systems, apparatuses, and methods relating to footwear having outsoles that incorporate resilient components into an injection- molded outsole body, thereby exhibiting improved traction and durability, while remaining lightweight and attractive.

In some embodiments, a method of manufacturing an article of footwear may include: placing a resilient insert into a receptacle of an outsole mold, wherein the receptacle is bounded by a lip, wherein the resilient insert is shaped to conform to an inner wall of the lip and has a top surface, an opposing ground-contacting surface, and a peripheral flange, and wherein the resilient insert is placed into the receptacle with the top surface exposed and the peripheral flange resting on top of the lip; mating a dummy mold to the outsole mold, wherein the resilient insert is mechanically secured in the receptacle of the outsole mold by the dummy mold, an outsole cavity is formed by a combination of the outsole mold and the dummy mold, and a perimeter of the insert is sealed by the peripheral flange; and injecting a thermoplastic material into the outsole cavity to form an outsole comprising the resilient insert.

In some embodiments, a method of manufacturing an article of footwear may include: applying a heat-activated adhesive to a top surface of a body of an outsole insert comprising a resilient material and having a peripheral flange extending outward from the top surface and a ground-contacting surface opposite the top surface; placing the insert into a receptacle of an outsole mold, wherein the receptacle is bounded by a lip, wherein the resilient insert is shaped to conform to an inner wall of the lip and a peripheral flange of the resilient insert abuts a top surface of the lip; mating a dummy mold to the outsole mold, wherein the resilient insert is mechanically secured in the receptacle of the outsole mold by the dummy mold, an outsole cavity is formed by a combination of the outsole mold and the dummy mold, and a perimeter of the insert is sealed by the peripheral flange; and injecting a thermoplastic material into the outsole cavity to form an outsole comprising the resilient insert.

In some embodiments, a method of manufacturing an article of footwear may include: providing an outsole mold having a receptacle bounded by a lip and an outsole body-forming cavity disposed outboard of the receptacle; placing a resilient insert into the receptacle of the outsole mold, wherein the resilient insert is shaped to conform to an inner wall of the lip and has a top surface, an opposing ground- contacting surface, and a peripheral flange extending outward from the top surface, and wherein the resilient insert is placed into the receptacle with the top surface exposed and the peripheral flange abutting a top surface of the lip; mating a dummy mold to the outsole mold, wherein the resilient insert is mechanically secured in the receptacle of the outsole mold by the dummy mold, the outsole body-forming cavity is capped by the dummy mold, and the peripheral flange seals a perimeter of the insert by filling a space between the dummy mold and the outsole mold; and injecting a molten material into the outsole cavity to form an outsole comprising the resilient insert.

Features, functions, and advantages may be achieved independently in various embodiments of the present disclosure, or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is bottom view of an illustrative article of footwear including resilient insert portions in accordance with aspects of the present disclosure.

Fig. 2 is an oblique isometric view of an illustrative resilient insole in accordance with the present teachings.

Fig. 3 is a bottom view of an illustrative resilient insole suitable for incorporation into an outsole according to the present disclosure.

Fig. 4 is a bottom view of an alternative illustrative resilient insole suitable for incorporation into an outsole according to the present disclosure.

Fig. 5 is a partial cross-sectional view of an illustrative article of footwear in accordance with aspects of the present disclosure, depicting relationships between various components.

Fig. 6 is a schematic sectional view of an illustrative mold and die system for manufacturing outsoles of the present disclosure.

Fig. 7 is a top perspective view of an illustrative mold for manufacturing of outsoles including resilient insert portions in accordance with aspects of the present disclosure. Fig. 8 is a flow chart depicting steps of an illustrative method for manufacturing an outsole including resilient insert portions according to the present disclosure.

DETAILED DESCRIPTION

Various aspects and examples of articles of footwear having outsoles incorporating resilient inserts, as well as related systems and methods, are described below and illustrated in the associated drawings. Unless otherwise specified, footwear in accordance with the present teachings, and/or its various components, may contain at least one of the structures, components, functionalities, and/or variations described, illustrated, and/or incorporated herein. Furthermore, unless specifically excluded, the process steps, structures, components, functionalities, and/or variations described, illustrated, and/or incorporated herein in connection with the present teachings may be included in other similar devices and methods, including being interchangeable between disclosed embodiments. The following description of various examples is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. Additionally, the advantages provided by the examples and embodiments described below are illustrative in nature and not all examples and embodiments provide the same advantages or the same degree of advantages.

This Detailed Description includes the following sections, which follow immediately below: (1 ) Definitions; (2) Overview; (3) Examples, Components, and Alternatives; (4) Advantages, Features, and Benefits; and (5) Conclusion. The Examples, Components, and Alternatives section is further divided into subsections A through D, each of which is labeled accordingly.

Definitions

The following definitions apply herein, unless otherwise indicated.

“Substantially” means to be more-or-less conforming to the particular dimension, range, shape, concept, or other aspect modified by the term, such that a feature or component need not conform exactly. For example, a “substantially cylindrical” object means that the object resembles a cylinder, but may have one or more deviations from a true cylinder.

“Comprising,”“including,” and“having” (and conjugations thereof) are used interchangeably to mean including but not necessarily limited to, and are open- ended terms not intended to exclude additional, unrecited elements or method steps.

Terms such as“first”,“second”, and“third” are used to distinguish or identify various members of a group, or the like, and are not intended to show serial or numerical limitation.

“AKA” means“also known as,” and may be used to indicate an alternative or corresponding term for a given element or elements.

“Coupled” means connected, either permanently or releasably, whether directly or indirectly through intervening components.

“Resilient” describes a material or structure configured to respond to normal operating loads (e.g., when compressed) by deforming elastically and returning to an original shape or position when unloaded.

“Rigid” describes a material or structure configured to be stiff, non- deformable, or substantially lacking in flexibility under normal operating conditions.

“Elastic” describes a material or structure configured to spontaneously resume its former shape after being stretched or expanded.

“Providing,” in the context of a method, may include receiving, obtaining, purchasing, manufacturing, generating, processing, preprocessing, and/or the like, such that the object or material provided is in a state and configuration for following steps to be carried out.

Overview

In general, an article of footwear in accordance with the present teachings may include one or more resilient inserts formed within the body of an outsole constructed of a different material. Accordingly, the outsole may comprise at least one resilient insert coupled to an outsole body. In addition to benefits of the inserts themselves, this arrangement also facilitates beneficial changes to various material and structural properties of the associated outsole. The inserts may include any suitable resilient material, such as a natural or synthetic rubber or other suitable elastomer. The inserts may be any suitable size up to and including the size of the outsole. Furthermore, the inserts may be any shape and/or thickness suitable to provide a ground-contacting surface generally coplanar with the outsole body and capable of being fixed, e.g., within an injection mold configured to receive the inserts.

Each insert has one or more perimetric flanges configured to form a seal or gasket-like lip when coupled with a complementary outsole mold for manufacture of the outsole. The inserts may have one or more of a variety of tread patterns configured to provide traction or support, each of which may include one or more channels or recesses. The insert may have adhesive applied to its top surface prior to its insertion into the complementary outsole mold. When utilized, this adhesive bonds the resilient insert to the outsole body. In some examples, the adhesive also bonds the insert to a midsole of a shoe or boot including the outsole assembly.

The outsole body is configured to be coupled with the resilient insert(s), contacting and at least partially embracing the insert on peripheral edges thereof. The outsole body may comprise any material suitable for use in injection molding, such as a thermoplastic elastomer. The outsole body interfaces with a given insert at upper and peripheral surfaces of a perimetric flange of the insert. In some examples, the outsole body may further wrap around peripheral edges of the flange and at least partially contact bottom surfaces of the flange.

The outsole body may include any suitable tread pattern configured to provide one or more structural or aesthetic properties of the outsole body, such as grip or a color. The outsole body and resilient inserts may be bonded at contact surfaces, using an adhesive applied to the surface of the resilient insert prior to the formation of the outsole body (e.g., by injection molding).

A system for manufacturing an outsole in accordance with the present teaching may include an outsole mold configured to receive one or more resilient inserts, and a dummy mold.

The resilient insert may be configured to mate with or be received within insert receptacles formed in the outsole mold, the mold being designed specifically to receive the insert. Each resilient insert may comprise a peripheral flange and an expanse, plate, or block of resilient material having a tread pattern on a ground- contacting surface. The peripheral flange of the insert is configured to produce a seal when contacting a lip of the complementary outsole mold, as described further below. An adhesive layer may be applied to the resilient insert prior to outsole manufacture. This adhesive layer may comprise any suitable adhesive configured for bonding a resilient component with an injection-molded component, e.g., a heat- activated adhesive.

The outsole mold may comprise one or more insert receptacles (also referred to as recesses), one or more vertical lips circumscribing and defining the insert receptacles, and a mold cavity. Each insert receptacle is bounded or defined by a respective vertical lip. An upper surface of each vertical lip is configured to produce a seal when mated with the peripheral flange of a resilient insert received within the insert receptacle, e.g., when the outsole mold is exposed to heat or pressure, as during injection molding. The mold cavity may include castellations or the like configured to produce complementary recesses or channels in the outsole body upon receiving injection-molded material. When present, these complementary recesses form a tread pattern along the ground-contacting surface of the outsole body and/or add aesthetic features to the outsole. Each insert receptacle may include one or more pins, bosses, or other protrusions configured to mate with the tread pattern of a resilient insert received therein. These protrusions function to secure the resilient inserts in place during outsole manufacture.

A dummy mold is provided to mate with the outsole mold during the manufacturing process. The dummy mold is configured to exert pressure on top surfaces of the resilient inserts, e.g., to fix the inserts into place during the injection- molding process that creates the outsole body and couples the outsole body to the insert(s). In some examples, the dummy mold includes pins that pierce the top surfaces of the resilient inserts to fix them in place within the insert receptacles of the outsole mold. The dummy mold may additionally or alternatively include bars that exert pressure on the resilient inserts during the injection-molding process. The dummy mold is configured to bound the upper edge of the outsole mold cavity, and may contact or abut a top surface of a vertical wall defining the mold cavity.

A method of producing outsoles incorporating one or more resilient inserts formed within the body of the outsole may include producing a resilient insert comprising a first material, applying adhesive to a top surface of the insert, placing the insert within a mold such that it is automatically fixed in place, and injecting a second material into the mold, thereby producing an outsole having a resilient insert incorporated into an outsole body.

Examples, Components, and Alternatives

The following sections describe selected aspects of illustrative footwear having outsoles incorporating resilient inserts, as well as related systems and/or methods. The examples in these sections are intended for illustration and should not be interpreted as limiting the scope of the present disclosure. Each section may include one or more distinct embodiments or examples, and/or contextual or related information, function, and/or structure.

A. Illustrative Outsole

This section describes an illustrative outsole assembly 10, as shown in Figs. 1 -5. Outsole assembly 10 is an example of the outsoles described above in the Overview. Outsole assembly 10 may be incorporated into any suitable article of footwear, such as a boot or shoe, and therefore may be coupled to a corresponding upper of the footwear. Outsole assembly 10 has a first or top surface, defined as the surface of the outsole proximate the wearer’s foot. Outsole assembly 10 further has a second or bottom surface interchangeably referred to as a ground-contacting or lower surface, defined as the surface opposite the top surface. Analogous ground- contacting surfaces of other outsole components are generally aligned with or coplanar with outsole assembly 10, unless otherwise stated.

Fig. 1 is a bottom view of outsole assembly 10, which includes a first resilient insert 12 and a second resilient insert 16 incorporated into an outsole body 20. Resilient inserts 12 and 16 contact outsole body 20 on peripheral or outer edges of the inserts. Inserts 12 and 16 are positioned such that ground-contacting surfaces 14, 18 of resilient inserts 12 and 16 and a ground-contacting surface 22 of outsole body 20 produce a substantially flat overall ground-contacting surface when outsole assembly 10 is in normal use. Insert 12 is positioned within outsole assembly 10 to be disposed beneath the heel of a wearer’s foot. Insert 16 is positioned within outsole assembly 10 to be disposed beneath a forefoot region of the wearer’s foot. Alternatively, inserts 12 and 16 (or more or fewer inserts) may be positioned at any suitable location within outsole assembly 10, e.g., with the ground-contacting surfaces of the inserts generally coplanar with ground-contacting surface 22 of outsole body 20. Outsole assembly 10 may comprise a single insert or multiple inserts positioned within the outsole, the inserts being configured to provide structural or material properties not exhibited by the outsole body including, but not limited to, grip, durability, flexibility, compressibility, and/or any alternative properties. Inserts 12 and 16 may be positioned to facilitate impact absorption, such as when the inserts are positioned beneath the ball and heel of the foot. Inserts 12 and 16, in conjunction with additional inserts, may be positioned along the perimeter of the outsole for either cosmetic reasons, or to improve traction, or both. Top surfaces of inserts 12 and 16 may have had an adhesive 38 added, forming an adhesive layer, where the adhesive is configured to bond the inserts to outsole body 20 and to midsole 44 of a shoe or boot. Adhesive 38 may be heat-activated or may be any other form of adhesive suitable for bonding an injection-molded component with a pre-formed resilient component.

Outsole body 20 is formed (e.g., injected) around the periphery of inserts 12 and 16 such that it contacts the inserts on peripheral or outer edges of a flange disposed around the perimeter of an upper surface of the insert. Outsole body 20 includes tread pattern 24. Tread pattern 24 may be configured to increase traction or to improve any other properties related to shoe function. Tread pattern 24 includes channels or recesses that open toward ground-contacting surface 22. The channels or recesses of tread pattern 24 extend from the ground-contacting surface of the outsole body upward toward a top surface of the outsole body. In some examples, outsole body 20 may also include molded patterns or shapes chosen for aesthetic reasons.

Inserts 12 and 16 may include any suitable resilient material, such as natural or synthetic rubber or other elastomer, configured to provide elasticity, resilience, traction, durability, ruggedization, and/or any combination of these. The resilient material may be selected to remedy deficiencies in properties of the other material(s) used in outsole body 20. Inserts 12 and 16 may be pre-formed prior to the manufacture of outsole assembly 10. Outsole body 20 may include a material suitable for injection molding, such as a thermoplastic elastomer (TPE). This material may be chosen for properties including, but not limited to, weight, ease of manufacture, or overall appearance. Suitable thermoplastic elastomers may include, without limitation, thermoplastics based upon styrenes (S-TPE, SBS, SEBS), copolyesters (COPE), polyurethanes (TPU), polyamides (PEBA), polyolefins (TPO), polyolefin alloys (TPV), reactor TPOs (R-TPO), polyolefin plastomers (POP), or polyolefin elastomers (POE).

Fig. 2 depicts resilient insert 12. Resilient insert 12 is configured to be disposed beneath a wearer’s heel, and may be interchangeably referred to as resilient insert at heel or heel insert. Heel insert 12 comprises a body 26, a peripheral flange 28, and a recessed tread pattern 30. Heel insert 12 has a top surface or face 13 and a ground-contacting or bottom surface or face 14. These surfaces are disposed generally parallel to each other, with a vertical wall 32 extending between the two faces. A distance between top surface 13 and ground-contacting surface 14 defines a thickness, depth, or other vertical dimension 33 of insert 12. Vertical dimension 33 generally corresponds to the distance between the top surface and the ground-contacting surface of outsole assembly 10. Heel insert 12 may have any suitable shape, and in this example is generally semicircular on one end, with a trapezoidal extension protruding from the base of the semicircle such that the base of the trapezoid is also the base of the semicircle.

Peripheral flange 28 is a lip or flange extending around the perimeter of top surface 13 of resilient insert 12. Peripheral flange 28 is configured to produce a seal or gasket-like lip when insert 12 is received in a corresponding receptacle of a selected injection mold (described further below).

Heel insert 12 exhibits a slight upward curvature corresponding to the toe region of outsole assembly 10. Peripheral flange 28 may curve upward toward the body of a shoe or boot including the outsole assembly or exhibit any other shaping complementary with the shaping of insert 12. Top surface 13 and bottom surface 14 of resilient insert 12 may be substantially flat or may exhibit any amount of curvature configured to complement the shape of the foot of the wearer of a boot or shoe incorporating the outsole. This curvature may be configured to increase support or comfort for the wearer. Top surface 13 and perimetric surfaces of peripheral flange 28 may have an adhesive 34 applied prior to outsole body manufacture. Adhesive 34 may be applied at any time after the manufacture of resilient insert 12. In some examples, the adhesive must dry completely prior to injection-molding. When used, adhesive 34 is configured to bond resilient insert 12 to outsole body 20. Adhesive 34 may further bond resilient insert 12 to a midsole (see Fig. 5) of the footwear. Adhesive 34 may be heat-activated, and may bond the midsole or outsole material to another component (e.g., the resilient insert) when molten material is injected into a mold containing the insert. The midsole and outsole material may be injected into the mold in two steps.

Fig. 3 shows a bottom plan view of heel insert 12. As demonstrated here, tread pattern 30 of insert 12 includes channels or recesses configured to improve or modify the properties of outsole assembly 10 (see Fig. 1 ). The channels or recesses of tread pattern 30 are configured such that they open toward the bottom of resilient insert 12. Tread pattern 30 may be configured to enhance the grip properties of resilient insert 12. As shown in this example, tread pattern 30 may include channels or recesses defined by a series of alternating trapezoids. Tread pattern 30 may include recesses of any suitable shape and size selected to modify structural or aesthetic properties of the outsole. Channel or recess shapes may be selected to increase grip, reduce weight of the boot or shoe including the insert, absorb impact, or provide cushioning for the wearer. Recess shapes may be configured to mate with complementary pins, bosses, or other protrusions disposed on the selected injection mold, these protrusions being configured to secure the resilient insert during injection molding.

Fig. 4 shows a bottom view of resilient insert 16. Resilient insert 16 is configured to be disposed beneath the forefoot or ball of a wearer’s foot, and may be interchangeably referred to as resilient insert at toe or toe insert or forefoot insert. Toe insert 16 is substantially similar to resilient insert 12, but with a different overall shape and a slightly different tread pattern configuration, such that insert 12 is generally suitable for a heel portion of the footwear, and insert 16 is generally suitable for a forefoot portion. Toe insert 14 comprises an insert body 36, a peripheral flange 38, and a tread pattern 40. Toe insert 14 also includes a vertical wall and a vertical dimension defined as a distance between a top surface of toe insert 14 and ground-contacting surface 18 of the insert. Toe insert 14 is generally semi-elliptical in shape, although any suitable shape may be utilized. Insert body 36 and peripheral flange 38 are substantially as described with respect to insert 12. Tread pattern 40 of toe insert 14 may be substantially similar to that of insert 12, with additional trapezoidal recesses and curved recesses disposed around the periphery of ground-contacting surface 18 of the insert. Toe insert 14 may also exhibit slight curvature complementary with the curvature of the sole. Toe insert 14 may include adhesive 34 on its top surface.

Fig. 5 shows a cross-sectional view of illustrative outsole assembly 10. Resilient insert 12 is positioned such that the recesses in tread pattern 30 open toward the bottom of outsole assembly 10. Resilient insert 12 is configured such that the top surface 13 of the resilient insert is generally coplanar with a top surface 21 of outsole body 20 and such that the ground-contacting surface 14 of the resilient insert is generally coplanar with a ground-contacting surface 22 of outsole body 20. Outsole body 20 contacts resilient insert 12 at a top surface and outer edges of peripheral flange 28. Outsole body 20 may extend slightly beneath peripheral flange 28 producing a mating fit between the flange and the outsole body. This mating fit physically secures the insert to the outsole body. A gap or recess may be disposed between an interior or inboard vertical surface of outsole 20 and vertical wall 32 of insert 12. In other words, in some examples the outsole body may not touch or be attached to the insert, other than at peripheral flange 28. Outsole body 20 may have a outboard peripheral vertical dimension 46 that is greater than the vertical dimension 33 of resilient insert 12 and defines an external wall contacting and partially wrapping around a midsole 44 of the footwear. Top surface 13 of resilient insert 12 is bonded to outsole body 20 and to a lower surface of midsole 44, e.g., using an adhesive. Toe insert 14 is similarly positioned within outsole body 20.

B. Illustrative Manufacturing System

As shown in Figs. 6-7, this section describes an illustrative system 50 for manufacturing outsoles incorporating resilient insert portions in accordance with aspects of the present disclosure. As shown in Fig. 6, system 50 includes a dummy mold 52, and an outsole mold 54 configured to receive resilient insert 12. When the system is utilized for the manufacture of outsoles incorporating resilient insert portions, insert 12 is fixed within outsole mold 54 and secured by the outsole mold and/or dummy mold 52.

Outsole mold 54 is configured to secure the insert such that the insert will not move substantially or be deformed during the manufacturing process, which typically involves high temperatures and pressures. Pins, bosses, or protrusions of the outsole mold are configured to mate with features of tread pattern 30, to prevent movement of the insert. Furthermore, an upper surface of vertical lip 62 of outsole mold 54 is configured to abut and seal with a lower surface of peripheral flange 28 of the insert. Peripheral flange 28 may extend slightly beyond vertical lip 62, allowing for the outsole body to partially contact a lower surface of flange 28 when molded in place. This wrapping of the outsole body around the flange may assist with securing insert 12 in outsole body 20. The space produced by vertical lip 62 may result in a gap between an inboard surface of outsole 20 and an outboard surface (i.e. , vertical wall 32) of resilient insert 12 when outsole material is injected into outsole mold 54. Accordingly, a gap may exist around part or all of the periphery of the resilient insert (See, e.g., Fig. 1 ).

Outer edges of vertical wall 32 of the insert contact the inner surface of vertical lip 62 in a friction fit. The fit between resilient insert 12 and vertical lip 62, in combination with other features, secures the insert in place while it is exposed to pressure and heat during the injection-molding process. In some examples, an adhesive is applied to top surface 13 of resilient insert 12 prior to placement within outsole mold 54. Adhesive 34 is completely dried prior to injection-molding, as uncured adhesive could cause insert 12 to adhere to dummy mold 52. Adhesive 38 may be heat-activated, or otherwise selected to be activated when molten outsole or midsole material comes into contact with the adhesive.

Dummy mold 52 is configured to further secure resilient insert 12 within outsole mold 54. Dummy mold 52 includes a lower insert-contacting surface 56. Insert-contacting surface 56 is configured to exert pressure on resilient insert 12. Insert-contacting surface 56 may be generally flat or may be curved in a manner complementary to the curvature of top surface 13 of resilient insert 12. In other words, insert-contacting surface 56 may conform to the resilient insert. In some examples, dummy mold 52 includes protrusions or other features 58 configured to fix resilient insert 12 into position during the injection-molding process. Protrusions 58 may include one or more pins configured to pierce resilient insert 12 through top surface 13. Protrusions 58 may alternatively or additionally consist of raised bars configured to apply pressure to the upper surface of resilient insert 12. Dummy mold 52 may contact outsole mold 54 at top surfaces of the outsole mold wall to define outsole cavity 64.

Fig. 7 shows an illustrative outsole mold 54 suitable for the manufacture of outsoles incorporating resilient insert portions as described above. Outsole mold 54 includes an insert receptacle 60, a vertical lip 62, and an outsole cavity 64. Insert receptacle 60 is configured to fix resilient insert 12 into position during the injection molding process. Accordingly, insert receptacle 60 is configured to produce a mating or friction fit when resilient insert 12 is positioned therein.

Outsole mold 54 may include one or more receptacles 60, each shaped and sized to accommodate a corresponding resilient insert. Outsole mold 54 may include a receptacle configured to accommodate resilient toe insert 14. Each receptacle is configured to have a secure fit with each insert, ensuring that the insert will not move or shift during the injection molding process.

Receptacle 60 is bounded on its perimeter by vertical lip 62. An upper mating surface of vertical lip 62 is configured to contact flange 28 at a lower face of the flange, so that a seal is produced when thermoplastic elastomer (TPE), or other injection-molding material is injected into the cavity of outsole mold 54. Receptacle 60 is constructed to be of a depth similar to vertical dimension 33 of resilient insert 12, enabling the insert to rest firmly on a base of receptacle 60 while flange 28 rests on a top surface 63 of lip 62. The interface between lip 62 and flange 28 is configured to a produce a clean edge during the manufacturing process and to prevent substantial migration of material of the insert or outsole body outside of their prescribed shapes. Vertical wall 32 of resilient insert 12 may contact interior surfaces of vertical lip 62. The fit between wall 32 and lip 62 may further secure insert 12, as lip 62 may exert force on peripheral edges of insert 12, which may counteract any horizontal deformation caused by compression in the vertical dimension of the insert. Receptacle 60 may include pins, bosses, or other protrusions 66 configured to mate with tread pattern 30 of resilient insert 12. These protrusions or bosses may ensure that resilient inserts 24 do not move laterally within the mold while the inserts are in high-pressure conditions.

Outsole cavity 64 is configured to produce outsole body 20. Outsole cavity 64 comprises a vertical wall 68 defining the outer peripheral edges of the mold cavity. Outsole cavity 64 is further bounded on interior edges by vertical lip 62 of insert receptacle 60. Vertical wall 68 defines vertical dimension 46 of the periphery of outsole body 20.

The top surface of outsole assembly 10 is further defined by dummy mold 52, which may contact the outsole mold at top surfaces of vertical wall 68. Outsole cavity 64 may comprise a variety of protrusions and castellations 70 designed to produce tread pattern 24 of outsole body 20. These protrusions may be roughly cubic, designed to produce corresponding square or rectangular tread pattern recesses.

C. Illustrative Manufacturing Method

This section describes steps of an illustrative method 100 for manufacturing outsoles incorporating resilient insert portions; see Fig. 8. Aspects of an illustrative outsole incorporating resilient insert portions and an illustrative system for manufacturing outsoles incorporating resilient insert portions may be utilized in the method steps described below. Where appropriate, reference may be made to components and systems that may be used in carrying out each step. These references are for illustration, and are not intended to limit the possible ways of carrying out any particular step of the method.

Fig. 8 is a flowchart illustrating steps performed in an illustrative method, and may not recite the complete process or all steps of the method. Although various steps of method 100 are described below and depicted in Fig. 8, the steps need not necessarily all be performed, and in some cases may be performed simultaneously or in a different order than the order shown.

At step 102, one or more resilient inserts are formed or otherwise provided for incorporation into an outsole assembly according to the present disclosure. Inserts may be formed using a variety of methods of manufacture suitable for use with resilient materials. Inserts may be designed in conjunction with a complementary outsole mold, allowing for the inserts to be fixed securely in place during the injection molding process. Inserts may be designed to include a tread pattern configured such that the physical properties of a ground-contacting surface of the insert may be optimized for grip, durability, flexibility, or compressibility, or any alternative properties of the outsole assembly.

At step 104, an adhesive is applied to the resilient insert or inserts on top surfaces thereof. This adhesive may be selected to be activated by the heat of a thermoplastic elastomer or other molten material injected into the mold. The adhesive is dried prior to insert deposition within the outsole mold, to prevent adhering to the dummy mold.

At step 106, the resilient insert or inserts are placed into corresponding insert receptacles of an outsole mold complementary to the previously provided resilient insert. The fit between insert and insert receptacle is such that the insert is fixed into place during the injection molding process. The outsole mold is configured to include a respective vertical lip surrounding each of the insert receptacles. A flange around the perimeter of the upper surface of the resilient insert is configured to sealingly abut the vertical lip of the outsole mold. The outsole mold further includes a mold cavity configured to receive injected thermoplastic material adjacent the insert(s) during the molding process. The outsole mold may also include castellations designed to form receptacles of a tread pattern in an outsole body formed using the mold. The outsole mold may have pins or protrusions configured to mate with features (e.g., the tread pattern) of the resilient inserts, which may fix the insert or insert into place within the mold.

At step 108, a dummy mold is mated to the outsole mold such that the dummy mold defines the top boundaries of the outsole cavity. The dummy mold exerts pressure onto top surfaces of resilient inserts disposed within receptacles of the dummy mold, which fixes the inserts into place during the injection-molding step. The insert or inserts may additionally or alternatively be fixed into place by structures of the dummy mold, such as pins that pierce the top surface of the resilient insert or bars that apply pressure to the top surface of the resilient insert. At step 110, a thermoplastic or other suitable material is injected into the mold cavity, forming the outsole body. The thermoplastic material exerts heat and pressure on the resilient insert, which is secured so that the outsole can be formed around the insert without material migration or bleeding. The present manufacturing method, through a combination of vertical lip 62 within mold 54 preventing lateral movement, and pressure on top and bottom surfaces of flange 28 around the upper periphery of insert 12, when squeezed between contact surface of dummy and vertical lip 62 within mold 54, permits the resilient insert 12 to be fixed securely in position within mold 54 so that it will not move or be deformed under the pressure of the injected material filling the mold. The heat of the thermoplastic material also activates the adhesive applied to the resilient insert, allowing the insert to bond to the outsole body during material injection. The injection of the thermoplastic material forming the outsole body may be followed by the injection of an additional thermoplastic material into a space between the outsole and an upper of a shoe containing the outsole assembly to form a midsole.

D. Illustrative Combinations and Additional Examples

This section describes additional aspects and features of systems and methods for manufacturing footwear having outsoles of the present disclosure, presented without limitation as a series of paragraphs, some or all of which may be alphanumerically designated for clarity and efficiency. Each of these paragraphs can be combined with one or more other paragraphs, and/or with disclosure from elsewhere in this application, in any suitable manner. Some of the paragraphs below expressly refer to and further limit other paragraphs, providing without limitation examples of some of the suitable combinations.

A0. A method of manufacturing an article of footwear, the method comprising:

placing a resilient insert into a receptacle of an outsole mold, wherein the receptacle is bounded by a lip, wherein the resilient insert is shaped to conform to an inner wall of the lip and has a top surface, an opposing ground-contacting surface, and a peripheral flange, and wherein the resilient insert is placed into the receptacle with the top surface exposed and the peripheral flange resting on top of the lip; mating a dummy mold to the outsole mold, wherein the resilient insert is mechanically secured in the receptacle of the outsole mold by the dummy mold, an outsole cavity is formed by a combination of the outsole mold and the dummy mold, and a perimeter of the insert is sealed by the peripheral flange; and

injecting a thermoplastic material into the outsole cavity to form an outsole comprising the resilient insert.

A1. The method of AO, further comprising:

applying a heat-activated adhesive to the top surface of the resilient insert.

A2. The method of A1 , wherein the resilient insert comprises a first material, the outsole comprises a second material, and the method further comprises:

injecting a molten third material into a space between the outsole and an upper to form a midsole.

A3. The method of A2, wherein a heat of the molten third material activates the heat-activated adhesive on the resilient insert, such that the midsole bonds to the top surface of the resilient insert as the third material cools.

A4. The method of any one of paragraphs AO through A3, wherein the dummy mold comprises one or more pins configured to pierce the resilient insert when the dummy mold is mated with the outsole mold.

A5. The method of any one of paragraphs AO through A4, wherein the outsole mold further comprises at least one protrusion configured to mate with a tread pattern on the ground-contacting surface of the resilient insert.

A6. The method of any one of paragraphs AO through A5, wherein the peripheral flange extends outward from the top surface of the resilient insert.

A7. The method of A6, wherein the peripheral flange is generally coplanar with the top surface of the resilient insert.

BO. A method of manufacturing an article of footwear, the method comprising:

applying a heat-activated adhesive to a top surface of a body of an outsole insert comprising a resilient material and having a peripheral flange extending outward from the top surface and a ground-contacting surface opposite the top surface; placing the insert into a receptacle of an outsole mold, wherein the receptacle is bounded by a lip, wherein the resilient insert is shaped to conform to an inner wall of the lip and a peripheral flange of the resilient insert abuts a top surface of the lip; mating a dummy mold to the outsole mold, wherein the resilient insert is mechanically secured in the receptacle of the outsole mold by the dummy mold, an outsole cavity is formed by a combination of the outsole mold and the dummy mold, and a perimeter of the insert is sealed by the peripheral flange; and

B1. The method of BO, wherein the resilient insert comprises a first material, the outsole comprises a second material, and the method further comprises:

B2. The method of B1 , wherein a heat of the molten third material activates the heat-activated adhesive on the resilient insert, such that the midsole bonds to the top surface of the resilient insert as the third material cools.

B3. The method of any one of paragraphs BO through B2, wherein the dummy mold comprises one or more pins configured to pierce the resilient insert when the dummy mold is mated with the outsole mold.

B4. The method of any one of paragraphs BO through B3, wherein the outsole mold further comprises at least one protrusion configured to mate with a tread pattern on the ground-contacting surface of the resilient insert.

B5. The method of any one of paragraphs BO through B4, wherein the peripheral flange is generally coplanar with the top surface of the resilient insert.

CO. A method of manufacturing an article of footwear, the method comprising:

providing an outsole mold having a receptacle bounded by a lip and an outsole body-forming cavity disposed outboard of the receptacle;

placing a resilient insert into the receptacle of the outsole mold, wherein the resilient insert is shaped to conform to an inner wall of the lip and has a top surface, an opposing ground-contacting surface, and a peripheral flange extending outward from the top surface, and wherein the resilient insert is placed into the receptacle with the top surface exposed and the peripheral flange abutting a top surface of the lip;

mating a dummy mold to the outsole mold, wherein the resilient insert is mechanically secured in the receptacle of the outsole mold by the dummy mold, the outsole body-forming cavity is capped by the dummy mold, and the peripheral flange seals a perimeter of the insert by filling a space between the dummy mold and the outsole mold; and

injecting a molten material into the outsole cavity to form an outsole comprising the resilient insert.

C1. The method of CO, further comprising:

applying a heat-activated adhesive to the top surface of the resilient insert.

C2. The method of C1 , wherein the resilient insert comprises a first material, the outsole comprises a second material, and the method further comprises:

C3. The method of C2, wherein a heat of the molten third material activates the heat-activated adhesive on the resilient insert, such that the midsole bonds to the top surface of the resilient insert as the third material cools.

C4. The method of any one of paragraphs CO through C3, wherein the dummy mold comprises one or more pins configured to pierce the resilient insert when the dummy mold is mated with the outsole mold.

C5. The method of any one of paragraphs CO through C4, wherein the outsole mold further comprises at least one protrusion configured to mate with a tread pattern on the ground-contacting surface of the resilient insert.

DO. An article of footwear comprising:

an outsole including a resilient insert comprising a first material and having a peripheral flange coupled to an outsole body comprising a second material;

a midsole coupled to both the resilient insert and the outsole body, wherein the midsole is coupled to an upper face of the resilient insert by an adhesive. Advantages, Features, and Benefits

The different embodiments and examples of the outsole incorporating resilient insert portions and associated systems and methods described herein provide several advantages over known outsoles and methods of manufacture. For example, illustrative embodiments and examples described herein allow for the incorporation of an insert comprising resilient materials within an injection-molded body. These inserts may be configured to provide the outsole with the grip and durability of an all- rubber insole, while allowing the outsole to remain lightweight and aesthetically attractive.

Additionally, and among other benefits, illustrative embodiments and examples described herein allow a resilient insert portion to be securely fixed within an outsole mold, allowing for injection-molding to occur without insert deformation. This fixation of the insert portion ensures that the resilient inserts will be able to be successfully incorporated within an injection-molded outsole without material migration and with the structural integrity of the insert remaining intact.

Additionally, and among other benefits, illustrative embodiments and examples described herein allow the ground-contacting surfaces of a boot or shoe to have grip wear, or any other relevant properties modified by the use of different materials for different areas within the outsole.

No known system or device can perform these functions, particularly in the manufacture of footwear. Thus, the illustrative embodiments and examples described herein are particularly useful for the production of boots, shoes, or any other articles of footwear that requiring improved grip and durability while remaining lightweight. However, not all embodiments and examples described herein provide the same advantages or the same degree of advantage. Conclusion

The disclosure set forth above may encompass multiple distinct examples with independent utility. Although each of these has been disclosed in its preferred form(s), the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense, because numerous variations are possible. To the extent that section headings are used within this disclosure, such headings are for organizational purposes only. The subject matter of the disclosure includes all novel and nonobvious combinations and subcombinations of the various elements, features, functions, and/or properties disclosed herein. The following claims particularly point out certain combinations and subcombinations regarded as novel and nonobvious. Other combinations and subcombinations of features, functions, elements, and/or properties may be claimed in applications claiming priority from this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.

Claims

WHAT IS CLAIMED IS:

1. A method of manufacturing an article of footwear, the method comprising:

placing a resilient insert into a receptacle of an outsole mold, wherein the receptacle is bounded by a lip, wherein the resilient insert is shaped to conform to an inner wall of the lip and has a top surface, an opposing ground-contacting surface, and a peripheral flange, and wherein the resilient insert is placed into the receptacle with the top surface exposed and the peripheral flange resting on top of the lip;

mating a dummy mold to the outsole mold, wherein the resilient insert is mechanically secured in the receptacle of the outsole mold by the dummy mold, an outsole cavity is formed by a combination of the outsole mold and the dummy mold, and a perimeter of the insert is sealed by the peripheral flange; and

2. The method of claim 1 , further comprising:

applying a heat-activated adhesive to the top surface of the resilient insert.

3. The method of claim 2, wherein the resilient insert comprises a first material, the outsole comprises a second material, and the method further comprises:

4. The method of claim 3, wherein a heat of the molten third material activates the heat-activated adhesive on the resilient insert, such that the midsole bonds to the top surface of the resilient insert as the third material cools.

5. The method of claim 1 , wherein the dummy mold comprises one or more pins configured to pierce the resilient insert when the dummy mold is mated with the outsole mold.

6. The method of claim 1 , wherein the outsole mold further comprises at least one protrusion configured to mate with a tread pattern on the ground-contacting surface of the resilient insert.

7. The method of claim 1 , wherein the peripheral flange extends outward from the top surface of the resilient insert.

8. The method of claim 7, wherein the peripheral flange is generally coplanar with the top surface of the resilient insert.

9. A method of manufacturing an article of footwear, the method comprising:

applying a heat-activated adhesive to a top surface of a body of an outsole insert comprising a resilient material and having a peripheral flange extending outward from the top surface and a ground-contacting surface opposite the top surface;

placing the insert into a receptacle of an outsole mold, wherein the receptacle is bounded by a lip, wherein the resilient insert is shaped to conform to an inner wall of the lip and a peripheral flange of the resilient insert abuts a top surface of the lip; mating a dummy mold to the outsole mold, wherein the resilient insert is mechanically secured in the receptacle of the outsole mold by the dummy mold, an outsole cavity is formed by a combination of the outsole mold and the dummy mold, and a perimeter of the insert is sealed by the peripheral flange; and

10. The method of claim 9, wherein the resilient insert comprises a first material, the outsole comprises a second material, and the method further comprises:

11. The method of claim 10, wherein a heat of the molten third material activates the heat-activated adhesive on the resilient insert, such that the midsole bonds to the top surface of the resilient insert as the third material cools.

12. The method of claim 9, wherein the dummy mold comprises one or more pins configured to pierce the resilient insert when the dummy mold is mated with the outsole mold.

13. The method of claim 9, wherein the outsole mold further comprises at least one protrusion configured to mate with a tread pattern on the ground-contacting surface of the resilient insert.

14. The method of claim 9, wherein the peripheral flange is generally coplanar with the top surface of the resilient insert.

15. A method of manufacturing an article of footwear, the method comprising:

16. The method of claim 15, further comprising:

applying a heat-activated adhesive to the top surface of the resilient insert.

17. The method of claim 16, wherein the resilient insert comprises a first material, the outsole comprises a second material, and the method further comprises:

18. The method of claim 17, wherein a heat of the molten third material activates the heat-activated adhesive on the resilient insert, such that the midsole bonds to the top surface of the resilient insert as the third material cools.

19. The method of claim 15, wherein the dummy mold comprises one or more pins configured to pierce the resilient insert when the dummy mold is mated with the outsole mold.

20. The method of claim 15, wherein the outsole mold further comprises at least one protrusion configured to mate with a tread pattern on the ground-contacting surface of the resilient insert.