( 12 ) United States Patent
`Wan
`
`( 10 ) Patent No . : US 10 , 245 , 798 B2
`( 45 ) Date of Patent :
`* Apr . 2 , 2019
`
`US010245798B2
`
`( 54 ) METHOD FOR MANUFACTURING A
`MIDSOLE FORMED FROM TWO
`PREFORMS
`( 71 ) Applicant : NIKE , Inc . , Beaverton , OR ( US )
`( 72 ) Inventor : Tee L . Wan , Portland , OR ( US )
`Assignee : NIKE , Inc . , Beaverton , OR ( US )
`( 73 )
`Subject to any disclaimer , the term of this
`( * ) Notice :
`patent is extended or adjusted under 35
`U . S . C . 154 ( b ) by 173 days .
`This patent is subject to a terminal dis
`claimer .
`( 21 ) Appl . No . : 15 / 353 , 903
`( 22 ) Filed :
`Nov . 17 , 2016
`Prior Publication Data
`( 65 )
`US 2018 / 0133995 A1 May 17 , 2018
`( 51 ) Int . CI .
`B290 35 / 14
`B29C 44 / 02
`B29C 44 / 12
`B29C 44 / 34
`B29C 44 / 56
`B29D 35 / 04
`B29C 44 / 04
`B29C 44 / 08
`A43B 13 / 12
`B29K 23 / 00
`B29K 105 / 00
`B29L 31 / 50
`U . S . CI .
`CPC . . . . . . . . . . B29D 35 / 142 ( 2013 . 01 ) ; A43B 13 / 127
`( 2013 . 01 ) ; B29C 44 / 04 ( 2013 . 01 ) ; B29C 44 / 08
`( 2013 . 01 ) ; B29C 44 / 3415 ( 2013 . 01 ) ; B29C
`
`( 2010 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2010 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`( 2006 . 01 )
`
`( 52 )
`
`( 56 )
`
`( 58 )
`
`44 / 5627 ( 2013 . 01 ) ; B29K 2023 / 083 ( 2013 . 01 ) ;
`B29K 2105 / 253 ( 2013 . 01 ) ; B29K 2995 / 0021
`( 2013 . 01 ) ; B29L 2031 / 504 ( 2013 . 01 )
`Field of Classification Search
`CPC . . . . . . . . . . . . B29C 44 / 3465 ; B29C 44 / 3476 ; B29C
`44 / 3496 ; B29C 44 / 0453 ; B29C 44 / 08 ;
`B29C 44 / 04 ; B29C 44 / 5627 ; B29C
`44 / 3415 ; A43B 13 / 125 ; A43B 13 / 12
`See application file for complete search history .
`References Cited
`U . S . PATENT DOCUMENTS
`5 , 743 , 027 A
`4 / 1998 Barma
`7 , 056 , 459 B2
`6 / 2006 Park
`( Continued )
`Primary Examiner — Joseph S Del Sole
`Assistant Examiner — Mohamed K Ahmed Ali
`( 74 ) Attorney , Agent , or Firm — Banner & Witcoff , Ltd .
`ABSTRACT
`( 57 )
`A method of manufacturing a midsole for an article of
`footwear includes placing first and second preforms in a first
`mold , closing and heating the first mold to produce a
`midsole preform with a peripheral preform flange , removing
`the midsole preform from the first mold and allowing it to
`further expand and cool , placing the midsole preform in a
`second mold , with a volume of a midsole recess of the
`second mold being less than a volume of the midsole
`preform , and a volume of a peripheral recess of the second
`mold being less than a volume of the peripheral preform
`flange , closing the second mold thereby compressing the
`midsole preform and the peripheral preform flange , and
`heating the second mold to form a midsole with a peripheral
`flange , allowing the second mold to cool , opening the
`second mold , and cutting away a peripheral flange of the
`midsole .
`
`15 Claims , 4 Drawing Sheets
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`MacNeil Exhibit 2166
`Yita v. MacNeil IP, IPR2020-01139, Page 1
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`US 10 , 245 , 798 B2
`Page 2
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`( 56 )
`
`References Cited
`U . S . PATENT DOCUMENTS
`7 , 107 , 235 B2
`9 / 2006 Lyden
`8 , 662 , 875 B2
`3 / 2014 Lim et al .
`8 , 844 , 170 B2
`9 / 2014 Ferrigan et al .
`A43B 13 / 127
`2013 / 0036627 A1 *
`2 / 2013 Wan
`36 / 83
`2013 / 0199711 A1 *
`8 / 2013 Davis . . . . . . . . . . . . . . . . . . . B29D 35 / 00
`156 / 245
`2013 / 0291409 Al 11 / 2013 Reinhardt et al .
`2016 / 0135537 Al
`5 / 2016 Wawrousek et al .
`* cited by examiner
`
`MacNeil Exhibit 2166
`Yita v. MacNeil IP, IPR2020-01139, Page 2
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`atent
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`Apr . 2 , 2019
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`Sheet 1 of 4
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`MacNeil Exhibit 2166
`Yita v. MacNeil IP, IPR2020-01139, Page 3
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`Apr . 2 , 2019
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`Sheet 2 of 4
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`US 10 , 245 , 798 B2
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`MacNeil Exhibit 2166
`Yita v. MacNeil IP, IPR2020-01139, Page 4
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`Apr . 2 , 2019
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`Sheet 3 of 4
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`US 10 , 245 , 798 B2
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`MacNeil Exhibit 2166
`Yita v. MacNeil IP, IPR2020-01139, Page 5
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`Apr . 2 , 2019
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`MacNeil Exhibit 2166
`Yita v. MacNeil IP, IPR2020-01139, Page 6
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`

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`US 10 , 245 , 798 B2
`
`METHOD FOR MANUFACTURING A
`MIDSOLE FORMED FROM TWO
`PREFORMS
`
`FIG . 2 is a section view of first and second portions of a
`first mold used to form the midsole of FIG . 1 .
`FIG . 3 is a plan view of the first portion of the first mold
`of FIG . 2 .
`FIG . 4 is a section view of the first and second portions
`FIELD
`of the first mold of FIG . 2 , shown with first and second
`preforms positioned in a preform recess of the first mold .
`Aspects of this invention relate generally to a method of
`FIG . 5 is a section view of the first mold of FIG . 2 , shown
`manufacturing a midsole and , in particular , manufacturing a
`in a closed position after the first and second preforms have
`midsole of two preforms , which may have different colors
`10 expanded and become a midsole preform .
`BACKGROUND
`FIG . 6 is a section view of the midsole preform of FIG .
`5 , shown after being removed from the first mold .
`FIG . 7 is a section view of a second mold used to form the
`Conventional articles of athletic footwear include two
`midsole of FIG . 1 , shown with the midsole preform of FIG .
`primary elements , an upper and a sole assembly . The upper
`provides a covering for the foot that comfortably receives 15 6 being compressed therein .
`and securely positions the foot with respect to the sole
`FIG . 8 is a section view of the midsole formed in the
`assembly . In addition , the upper may have a configuration
`second mold of FIG . 7 , shown after being removed from the
`that protects the foot and provides ventilation , thereby
`second mold .
`cooling the foot and removing perspiration . The sole assem -
`FIG . 9 is an elevation view of the midsole of FIG . 8 ,
`bly is secured to a lower portion of the upper and is generally 20 shown after having a peripheral flange of the midsole cut
`positioned between the foot and the ground . In addition to
`away .
`attenuating ground reaction forces , the sole assembly may
`The figures referred to above are not drawn necessarily to
`provide traction , control foot motions ( e . g . , by resisting over
`scale , should be understood to provide a representation of
`pronation ) , and impart stability , for example . Accordingly ,
`particular embodiments of the invention , and are intended to
`the upper and the sole assembly operate cooperatively to 25 concisely illustrate the principles involved . Some features of
`provide a comfortable structure that is suited for a wide
`the mold assembly used to form a sole assembly formed of
`variety of activities , such as walking and running . An insole
`different preforms and related methods of manufacture
`may be located within the upper and adjacent to a plantar
`depicted in the drawings have been enlarged or distorted
`( i . e . , lower ) surface of the foot to enhance footwear comfort ,
`relative to others to facilitate explanation and understanding .
`30 In general , the same reference numbers are used in the
`and is typically a thin , compressible member .
`The sole assembly may incorporate multiple layers . Some
`drawings for similar or identical components and features
`shown in various alternative embodiments . Mold assemblies
`articles of footwear include only a midsole , while others
`may also include an outsole secured to a bottom surface of
`used for forming midsoles as disclosed herein would have
`the midsole . The midsole , which is conventionally secured
`configurations and components determined , in part , by the
`to the upper along the length of the upper , is primarily 35 intended application and environment in which they are
`responsible for attenuating ground reaction forces . The
`used .
`midsole may also form the ground - contacting element of
`DETAILED DESCRIPTION OF EXEMPLARY
`footwear . In such embodiments , the midsole may include
`texturing , such as projections and recesses or grooves , in
`EMBODIMENTS
`order to improve traction . The outsole , when present , forms 40
`It would be desirable to provide a midsole formed from
`the ground - contacting element and may be fashioned from a
`durable , wear - resistant material .
`two or more portions and a method and mold for manufac
`turing such a midsole that reduces or overcomes some or all
`The midsole may be primarily formed from a resilient ,
`of the difficulties inherent in prior known devices . Applicant
`polymer foam material , such as ethyl vinyl acetate ( EVA ) ,
`that extends throughout the length of the footwear . The 45 recognizes that the principles of the invention may be used
`properties of the polymer foam material in the midsole are
`to advantage to provide a method of manufacturing a
`primarily dependent upon factors that include the dimen -
`midsole formed of portions having different colors as well as
`sional configuration of the midsole and the specific charac -
`different performance characteristics .
`teristics of the material selected for the polymer foam ,
`In accordance with a first aspect , a method of manufac
`including the density of the polymer foam material . By 50 turing a midsole for an article of footwear includes placing
`varying these factors throughout the midsole , the relative
`first and second preforms in contact with one another in a
`stiffness and degree of ground reaction force attenuation
`preform recess in a first mold , first and second portions of
`may be altered to meet the specific demands of the activity
`the first mold cooperating to define the preform recess and
`for which the footwear is intended to be used . In addition to
`a peripheral overflow chamber extending about a periphery
`polymer foam
`materials , conventional midsoles may 55 of the preform recess ; closing the first mold by positioning
`include , for example , one or more fluid - filled bladders and
`the first and second portions in contact with one another ;
`heating the first mold for a predetermined period of time at
`moderators .
`The midsole may be formed of two or more portions , with
`a predetermined temperature such that the first and second
`some or all of the portions having different colors . When a
`preforms expand within the preform recess and into the
`midsole is formed in a mold assembly , such as with EVA , the 60 peripheral overflow chamber to produce a midsole preform
`color or boundary line between the different colored portions
`with a peripheral preform flange extending about a periphery
`may bleed , decreasing the aesthetic appeal of the footwear .
`of the midsole preform ; removing the midsole preform from
`the first mold ; allowing the midsole to further expand and
`BRIEF DESCRIPTION OF THE DRAWINGS
`cool ; placing the midsole preform in a midsole recess of a
`65 second mold and the peripheral preform flange in a periph
`FIG . 1 is an elevation view of a midsole formed from two
`eral recess of the second mold , first and second portions of
`preforms .
`the second mold cooperating to define the midsole recess
`
`MacNeil Exhibit 2166
`Yita v. MacNeil IP, IPR2020-01139, Page 7
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`

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`US 10 , 245 , 798 B2
`
`and the peripheral recess extending about a periphery of the
`secured beneath an upper , in conventional fashion . In other
`midsole recess , with a volume of the midsole recess being
`embodiments , the bottom surface of midsole 10 itself may
`less than a volume of the midsole preform , and a volume of
`serve as the ground - engaging portion ( or other contact
`the peripheral recess being less than a volume of the
`surface - engaging portion ) of an article of footwear .
`peripheral preform flange ; closing the second mold by 5
`Midsole 10 serves , among other things , to provide shock
`positioning the first and second portions in contact with one
`attenuation and energy - absorption for an article of footwear .
`another , thereby compressing the midsole preform and the
`Midsole 10 can be used for any of various articles of casual
`peripheral preform flange to produce a midsole with a
`footwear having configurations suitable , for example , for
`peripheral flange ; heating the second mold for a predeter
`walking or lounging . Midsole 10 may also be included as
`mined period of time at a predetermined temperature ; allow - 10 part of a wide range of athletic footwear styles , including
`ing the second mold to cool ; opening the second mold ; and
`shoes that are suitable for soccer , running , basketball , base
`cutting away the peripheral flange of the midsole .
`ball , cross - training , football , rugby , tennis , and volleyball ,
`In accordance with another aspect , a method of manufac
`for example . An individual skilled in the relevant art will
`turing a midsole for an article of footwear includes placing
`a first preform having a first preform peripheral flange and 15 appreciate , therefore , that the concepts disclosed herein with
`regard to midsole 10 may be applied to a wide variety of
`a second preform having a second preform peripheral flange
`in contact with one another in a preform recess in a first
`footwear styles , in addition to the specific styles discussed
`mold , the first and second preforms being positioned in
`a
`herein and depicted in the accompanying figures .
`preform recess in the first mold , a first recess formed in a
`Midsole 10 includes a first portion 12 , which may be
`first portion of the first mold and a second recess formed in 20 formed of a first material and may have a first color , and a
`a second portion of the first mold cooperating to define the
`second portion 14 , which may be formed of a second
`preform recess , the first and second preform peripheral
`material and may have a second color . The second color may
`flanges being positioned in a peripheral overflow chamber of
`be a different color than the first color . In the illustrated
`the first mold , a first overflow recess formed in the first
`embodiment , second portion 14 is positioned above first
`portion of the first mold and a second overflow recess 25 portion 12 . However , it is to be appreciated that first portion
`formed in the second portion of the first mold cooperating to
`12 and second portion 14 can be oriented in any desired
`define the peripheral overflow chamber ; closing the first
`manner with respect to one another .
`mold by positioning the first and second portions in contact
`The discussion of midsole 10 herein primarily describes
`with one another ; heating the first mold for a predetermined
`midsole 10 as being formed of a first portion 12 and a second
`period of time at a predetermined temperature such that the 30 portion 14 . However , it is to be appreciated that midsole 10
`first and second preforms expand within the preform recess
`can include more than just these two portions .
`and the first and second preform peripheral flanges expand
`In certain embodiments , the first and second materials
`within the peripheral overflow chamber to produce a mid -
`may also have different physical properties from one another
`sole preform with a peripheral preform flange extending
`and , therefore , different performance characteristics . For
`about a periphery of the midsole preform ; removing the 35 example , the hardness of the various portions may be
`midsole preform from the first mold ; allowing the midsole to
`different from one another . It is to be appreciated that any of
`further expand and cool ; placing the midsole preform in a
`the known physical properties or performance characteris
`midsole recess of a second mold and the peripheral flange in
`tics for sole assemblies can be different for the different
`a peripheral recess of the second mold , a first recess in the
`portions of midsole 10 , thereby altering the support , cush
`first portion of the second mold and a second recess in the 40 ioning , load carrying capability , wear characteristics , and
`second portion of the second mold cooperating to define the
`tread life of midsole 10 , for example . Other suitable physical
`midsole recess , a first peripheral recess in the first portion of
`properties or performance characteristics will become read
`the second mold and a second peripheral recess in the second
`ily apparent to those skilled in the art , given the benefit of
`portion of the second mold cooperating to define and the
`this disclosure .
`peripheral recess extending about a periphery of the midsole 45
`For purposes of reference in the following description ,
`recess , with a volume of the midsole recess being less than
`midsole 10 may be divided into three general regions : a
`a volume of the midsole preform and a volume of the
`forefoot region 16 , a midfoot region 18 , and a heel region 20 .
`peripheral recess being less than a volume of the peripheral
`Regions 16 - 20 are not intended to demarcate precise areas of
`flange ; closing the second mold by and compressing the
`midsole 10 . Rather , regions 16 - 20 are intended to represent
`midsole preform and the peripheral preform flange by align - 50 general areas of midsole 10 that provide a frame of reference
`ing the first recess in the first portion of the second mold and
`during the following discussion . Although regions 16 - 20
`the second recess in the second portion of the second mold
`apply generally to midsole 10 , references to regions 16 - 20
`and bringing the first and second portions into contact with
`also may apply specifically to first portion 12 , second
`one another to form a midsole with a peripheral flange ;
`portion 14 , or individual components or portions of midsole
`heating the second mold for a predetermined period of time 55 10 .
`at a predetermined temperature ; allowing the second mold to
`For purposes of reference , midsole 10 includes a medial
`cool ; opening the second mold ; and cutting away the periph -
`side 22 and an opposite lateral side 24 . Lateral side 24 is
`positioned to extend along a lateral side of the foot ( i . e . , the
`eral flange of the midsole .
`By providing a method for manufacturing such a midsole ,
`outside ) and generally passes through each of regions 16 - 20 .
`footwear with improved aesthetic appeal and / or perfor - 60 Similarly , medial side 22 is positioned to extend along an
`mance can be produced . These and additional features and
`opposite medial side of the foot ( i . e . , the inside ) and gen
`advantages disclosed here will be further understood from
`erally passes through each of regions 16 - 20
`the following detailed disclosure of certain embodiments .
`As noted above , a separate outsole member may be
`A sole assembly or midsole 10 for an article of footwear
`secured to a bottom surface 26 of midsole 10 , and serve as
`is depicted in FIG . 1 . It is to be appreciated that in certain 65 the ground - engaging surface of the footwear . In other
`embodiments , an outsole ( not shown ) may be secured to the
`embodiments , bottom surface 26 itself may serve as the
`bottom surface of midsole 10 , and midsole 10 may be
`ground - engaging surface of the footwear .
`
`MacNeil Exhibit 2166
`Yita v. MacNeil IP, IPR2020-01139, Page 8
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`US 10 , 245 , 798 B2
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`first mold or mold assembly 30 used to form midsole 10
`In known fashion , an upper may be secured to the upper
`is illustrated in FIGS . 2 - 5 , and includes a bottom or first
`surface of midsole 10 in order to fully form the footwear .
`portion 32 , and a top or second portion 34 . A first recess 36
`The upper may be secured to midsole 10 with an adhesive ,
`formed in an upper or top surface 38 of first portion 32 and
`or in any other known fashion . The upper is not shown here
`as those skilled in the art are well aware of how an upper is 5 a second recess 40 formed in a lower or bottom surface 42
`secured to a midsole , and , therefore , such a drawing is not
`of second portion 34 cooperate to define a midsole preform
`recess 44 . In the illustrated embodiment , first portion 32 ,
`necessary for an understanding of the invention .
`which is positioned beneath second portion 34 , forms a
`The materials used to form first portion 12 and second
`bottom surface of a preform formed in first mold 30 , while
`portion 14 of midsole 10 may be injection phylon ( ethylene
`vinyl acetate or “ EVA ” ) . The EVA may have a vinyl acetate 10 second portion 34 forms a top surface of the preform formed
`in
`first mold 30 . It is to be appreciated that in other
`( VA ) level between approximately 9 % and approximately
`embodiments , first and second portions 32 , 34 can have a
`40 % . Suitable EVA resins include Elvax® , provided by E . I .
`different positional relationship with respect to one another .
`du Pont de Nemours and Company , and EngageTM , provided
`First portion 32 includes a first overflow recess 46 formed
`by the Dow Chemical Company , for example . In certain 15 in ton surface 38 . First overflow 46 recess extends along an
`entire peripheral top edge of first recess 36 . as se
`embodiments , the EVA may be formed of a combination of
`entire peripheral top edge of first recess 36 , as seen most
`high melt index and low melt index material . For example ,
`clearly in FIG . 3 . has a depth that is less than a depth of first
`the EVA may have a melt index between approximately 1
`recess 36 . A corresponding second overflow recess 48 is
`and approximately 50 .
`formed in the bottom surface 42 of second portion 34 ,
`As used herein , the term approximately is intended to 20 extends along an entire peripheral bottom edge of second
`mean about or approximately , within the constraints of
`recess 40 , and has a depth that is less than a depth of second
`sensible , manufacturing tolerances , commercial engineering
`recess 40 . The ratio between the depths of the first and
`objectives , costs and capabilities in the field of footwear
`second overflow recesses and the first and second recesses
`manufacturing
`can vary , depending on the particular footwear design and
`The EVA may also include various components including 25 materials used . First overflow recess 46 and second overflow
`a blowing agent . The blowing agent may have a percent
`recess 48 cooperate to define a peripheral overflow chamber
`weight between approximately 10 % and approximately
`50 when first mold 30 is closed with first portion 32 and
`20 % . Suitable blowing agents include azodicarboamide , for
`second portion 34 in contact with one another , as seen in
`example . In certain embodiments , a peroxide - based curing
`FIG . 5 .
`agent , such as dicumyl peroxide may be used . The amount 30
`In one method of forming midsole 10 , a first preform 52
`of curing agent may be between approximately 0 . 6 % and
`and a second preform 54 are first formed in known fashion
`approximately 1 . 5 % . The EVA may also include homog -
`in one or more separate mold assemblies . First preform 52
`enizing agents , process aids , and waxes . For example , a
`may have a first peripheral preform flange 53 extending
`mixture of light aliphatic hydrocarbons such as Struktol®
`about an entire peripheral upper edge of first preform 52 .
`60NS , available from Schill + Seilacher “ Struktol ” GmbH , 35 Similarly , second preform 54 may have a second peripheral
`may be included . The EVA may also include other constitu -
`preform flange 55 extending about an entire peripheral lower
`ents such as a release agent ( e . g . , stearic acid ) , activators
`edge of second preform 54 . First preform 52 with first
`( e . g . , zinc oxide ) , fillers ( e . g . , magnesium carbonate ) , pig -
`peripheral preform flange 53 and second preform 54 with
`second peripheral preform flange 55 are positioned in mid
`ments , and clays .
`Other suitable materials for first portion 12 and second 40 sole preform recess 44 of first mold 30 , which has been
`heated , with first peripheral preform flange 53 and second
`portion 14 will become readily apparent to those skilled in
`peripheral preform flange 55 being positioned within periph
`the art , given the benefit of this disclosure .
`As noted above , first portion 12 may be formed of a
`eral overflow chamber 50 . The interface between first pre
`material having a first color , while second portion 14 may be
`form 52 and second preform 54 , and between first peripheral
`formed of a material having a second color that is different 45 preform flange 53 and second peripheral preform flange 55
`than the first color . First and second portions 12 , 14 may also
`is positioned in line with the interface between first portion
`have different values for various physical properties in order
`32 and second portion 34 of first mold 30 .
`to alter or enhance the performance characteristics of the
`As seen here , first preform 52 and second preform 54 have
`footwear . For example , first and second portions 12 , 14 may
`approximately the same thickness . However , it is to be
`have different hardnesses , densities , specific gravities , or 50 appreciated that the relative thicknesses of first preform 52
`any other beneficial physical property . Other suitable physi -
`and second preform 54 can vary . Thus , as seen in FIG . 1 , the
`cal properties for which the first and second portions may
`relative thicknesses of first portion 12 and second portion 14
`have different values will become readily apparent to those
`vary along the length of midsole 10 . The thicknesses of the
`portions of midsole 10 and , therefore , the preforms used to
`skilled in the art , given the benefit of this disclosure .
`As seen in FIG . 1 , a color line or boundary 28 is formed 55 produce midsole 10 , can vary along footwear 10 to accom
`at the boundary or interface between first portion 12 and
`modate different design considerations , and may also vary
`second portion 14 of midsole 10 . It is desirable to minimize
`based on the particular materials used .
`the bleeding between the two different colors of first portion
`First preform 52 and second preform 54 combine to form
`12 and second portion 14 , which can occur during the
`a midsole preform 56 , with a peripheral preform flange 62
`molding process . It is to be appreciated that the aesthetics of 60 being formed about a periphery of midsole preform 56 , as
`midsole 10 are improved by minimizing bleeding during the
`seen in FIGS . 5 and 6 and described below . As discussed
`above , in certain embodiments , first and second preforms
`manufacture of midsole 10 .
`It is to be appreciated that more than two portions can be
`52 , 54 may be formed of EVA .
`used to form midsole 10 , in order to introduce additional
`A release agent may be applied to the exposed surface of
`colors and additional performance characteristics to midsole 65 first and second preforms 52 , 54 and / or the surfaces of
`10 . It is to be appreciated that any number of colors can be
`midsole preform recess 44 of first mold 30 in order to
`facilitate the separation of midsole preform 54 from first
`used for different portions of midsole 10 .
`
`MacNeil Exhibit 2166
`Yita v. MacNeil IP, IPR2020-01139, Page 9
`
`

`

`US 10 , 245 , 798 B2
`
`15
`
`that is less than a depth of first recess 80 . A corresponding
`mold 30 after its formation . The release agent may be a spray
`second peripheral recess 92 is formed in the bottom surface
`release agent or any other suitable release agent . Suitable
`86 of second portion 78 , extends along an entire peripheral
`materials for the release agent include , for example , siloxane
`bottom edge of second recess 84 , and has a depth that is less
`and water . Other suitable release agents will become readily
`apparent to those skilled in the art , given the benefit of this 5 than a depth of second recess 84 . The ratio between the
`depths of the first and second peripheral recesses and the first
`disclosure .
`First mold 30 is then closed so that first portion 32 is in
`and second recesses can vary , depending on the particular
`contact with second portion 34 , with first and second pre -
`footwear design and materials used . First peripheral recess
`forms 52 , 54 seated within midsole preform recess 44 and
`90 and second peripheral recess 92 cooperate to define a
`first peripheral preform flange 53 and second peripheral 10 peripheral chamber 94 when second mold 74 is closed with
`preform flange 55 seated within peripheral overflow cham -
`first portion 76 and second portion 78 in contact with one
`ber 50 . First portion 32 and second portion 34 of first mold
`another , as seen in FIG . 7 . Peripheral chamber 94 has a
`30 may be hinged together , or they may be separate elements
`volume that is less than a volume of peripheral preform
`that are suitably aligned and placed in contact with one
`flange 62 .
`Midsole preform 56 is positioned within midsole recess
`another .
`Heat is then supplied to first mold 30 with first preform 52
`88 in second mold 74 , with peripheral preform flange 62
`and second preform 54 contained therein for a predeter -
`being positioned within peripheral recess 92 , when second
`mined period of time . In certain embodiments , first mold 30
`mold 74 is cool , that is , at an ambient or lower temperature
`is heated at a temperature of approximately 130° C . for
`and not heated . Second mold 74 is then closed so that second
`approximately 15 - 20 minutes , thereby causing first and 20 portion 78 is in contact with first portion 76 . In this embodi
`second preforms 52 , 54 to partially expand into midsole
`ment , midsole recess 88 , and first and second preforms 56 ,
`preform recess 44 , and first peripheral preform flange 53 and
`58 are sized such that first and second preforms 56 , 58 are
`second peripheral preform flange 55 expanding into periph
`compressed when second mold 74 is closed . First portion 76
`eral overflow chamber 50 . It is to be appreciated that the
`and second portion 78 of second mold 74 may be hinged
`specific temperature and time period used to form midsole 25 together , or they may be separate elements that are suitably
`preform 56 in first mold 30 can be varied , in known fashion ,
`aligned and placed in contact with one another .
`depending on the particular EVA , or other material , used . As
`Second mold 74 is then heated for a predetermined period
`used herein , the term “ approximately ” is intended to mean
`of time . In certain embodiments , second mold 74 is heated
`approximately or about , within the constraints of sensible ,
`to approximately 140° C . for approximately 15 minutes ,
`commercial engineering objectives , costs , and capabilities in
`30 thereby forming midsole 10 with first portion 12 , second
`portion 14 and a peripheral flange 98 . The specific tempera
`the field of footwear manufacture .
`This expansion forms midsole preform 56 with first
`tures and time periods used to heat second mold 74 can be
`portion 58 and second portion 60 , peripheral preform flange
`varied , in known fashion , depending on the particular EVA ,
`62 extending about a periphery of midsole preform 56 , and
`or other material , used .
`a preform boundary 63 that defines the interface between 35
`While second mold 74 is still closed , it is cooled , allowing
`first portion 58 and second portion 60 and bisects peripheral
`midsole 10 to fully cure and stabilize . This compression
`molding process provides midsole 10 with a finished con
`preform 62 , as can be seen in FIG . 5 .
`After this heating step is complete , first mold 30 is
`figuration that has the same dimensions as that of midsole
`opened , and midsole preform 56 with peripheral preform
`recess 88 . In certain embodiments , second mold 74 is cooled
`flange 62 further expands in known fashion after it is 40 in a closed condition for approximately 15 minutes until the
`removed from first mold 30 . The process of bonding within
`temperature of second mold 74 is below approximately 35°
`first mold 30 , and the expansion of midsole preform 56 and
`C .
`peripheral preform flange 62 , can produce bleeding between
`Once midsole 10 is completely stabilized and cured ,
`the different colors of first portion 58 and second portion 60 ,
`second mold 74 is opened , and midsole 10 including first
`which may create an uneven bleeding line at boundary