Footwear article and method of manufacturing a footwear article

Abstract

A sole structure for a footwear item includes an integral cushioning member that includes a plurality of waste foam blocks configured as a plurality of different polyhedral shapes and a resin binder that secures the waste foam blocks to one another. The sole structure can include a midsole that includes an outer shell defining a central cavity. The cushioning member can be disposed as a core of the midsole within the central cavity. A method of manufacturing a footwear item includes cutting a waste foam body into blocks, mixing the blocks with a resin binder, and compression molding the mixed blocks and resin binder in a mold to form a cushioning member of the sole structure of the footwear item.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims the benefit of priority of U.S. Application No. 16 / 662,273, filed on October 24, 2019, which is hereby incorporated by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to articles of footwear and methods of manufacturing articles of footwear.

[0004] Background

[0005] Footwear typically includes many components of many different materials. An article of footwear typically includes a sole structure that is configured to be located beneath a wearer's foot to space the foot from the ground. The sole structure in athletic footwear is typically configured to provide cushioning, motion control, and / or rebound. The footwear manufacturing industry endeavors to provide high - quality, durable footwear in an environmentally friendly manner. Brief Description of the Drawings

[0007] The drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary and not limiting of the scope of the present disclosure.

[0008] Figure 1 is a lateral side view of an article of footwear including an upper, a sole structure, and a heel counter.

[0009] Figure 2 is a perspective view of the sole structure of the heel counter of an article of footwear including a midsole and Figure 1 , with the upper not shown.

[0010] Figure 3 is Figure 2 a perspective view of the core of the midsole.

[0011] Figure 4 is Figure 2 a lateral side view of the sole structure and the heel counter.

[0012] Figure 5 is Figure 2 a medial side view of the sole structure and the heel counter.

[0013] Figure 6 is Figure 2 a rear view of the sole structure.

[0014] Figure 7 is Figure 2 a front view of the sole structure.

[0015] Figure 8 is Figure 2 a bottom view of the sole structure.

[0016] Figure 9 is taken at Figure 2 section line 9-9 in Figure 2 a cross-sectional view of the sole structure and the heel stabilizer.

[0017] Figure 10 is taken at Figure 2 section line 10-10 in Figure 2 a cross-sectional view of the sole structure and the heel stabilizer.

[0018] Figure 11 is taken at Figure 2 section line 11-11 in Figure 2 a cross-sectional view of the sole structure and the heel stabilizer.

[0019] Figure 12 is taken at Figure 2 section line 12-12 in Figure 2 a cross-sectional view of the sole structure and the heel stabilizer.

[0020] Figure 13 is taken at Figure 2 section line 13-13 in Figure 2 a cross-sectional view of the sole structure and the heel stabilizer.

[0021] Figure 14 is Figure 2 a top view of the outer shell included in the sole structure.

[0022] Figure 15 is Figure 14 a bottom view of the outer shell.

[0023] Figure 16 is Figure 14 a top view of the inner shell body of the outer shell.

[0024] Figure 17 is Figure 16 a bottom view of the inner shell body.

[0025] Figure 18 is Figure 14 a top view of the outer shell body of the outer shell.

[0026] Figure 19 is Figure 18 a bottom view of the outer shell body.

[0027] Figure 20 is Figure 2 a top view of the heel stabilizer.

[0028] Figure 21 Is Figure 2 The bottom view of the heel stabilizer.

[0029] Figure 22 Is the perspective view of the waste foam body.

[0030] Figure 23 Is Figure 22 The perspective view of the container of the chopped pieces of the waste foam body and the dyed resin binder of

[0031] Figure 24 Is the perspective view of a single chopped piece of the waste foam body coated with the resin binder.

[0032] Figure 25A Is for manufacturing Figure 1 The first part of the flowchart of an exemplary method of manufacturing a footwear item of

[0033] Figure 25B Is for manufacturing Figure 1 The second part of the flowchart of an exemplary method of manufacturing a footwear item of

[0034] Describes

[0035] The present disclosure generally relates to articles of footwear and methods of manufacturing articles of footwear that may include using waste foam for at least one cushioning component. In other words, a waste foam body from a first footwear application may be used in a second footwear application to reduce waste. Waste foam blocks may be produced by cutting one or more waste foam bodies. More specifically, in one aspect of the present disclosure, a sole structure may include a cushioning component that includes a plurality of waste foam blocks and a resin binder that secures the blocks to one another. The cushioning component may consist only of the waste foam blocks, the resin binder, and in some embodiments, a dye added to the binder. A foaming agent, the original foam material, or other additives are not included in the cushioning component. Most waste foam bodies may be recycled under this method because, considering that the waste foam bodies are cut into smaller blocks when used in the second footwear application (e.g., by shredding the waste foam bodies into shredded blocks), the initial shape of the waste foam bodies is largely unimportant. Since the waste foam bodies are cut, most of the waste foam blocks may be configured in a plurality of different polyhedral shapes. For example, a cutting blade may impart relatively straight faces on the blocks and angles between the faces of the blocks, resulting in mostly polyhedral-shaped blocks. Since a series of cutting operations may be employed, the blocks may have different sizes and different polyhedral shapes. Thus, the waste foam bodies are not wasted but are reused as a cushioning component (e.g., a midsole component) of a footwear sole structure. For example, cut blocks of different polyhedral shapes provide a more uniform (e.g., smoother) outer surface compared to a plurality of torn or broken blocks of similar size, having denser edges and a larger surface area. The relatively smooth outer surface may provide greater comfort at the foot-facing surface, as well as denser edges for the structural stability of the cushioning component. Additionally, the relatively smooth outer surface may provide a better bonding surface for the outer shell described herein.

[0036] In one example, a dye may be mixed into the resin binder before mixing the blocks of the waste foam body with the resin binder. In one or more embodiments, the waste foam blocks include Pebax thermoplastic elastomer foam, and the resin binder includes polyurethane. However, it should be understood that within the scope of the present disclosure, other materials may be used for the waste foam blocks and / or for the resin binder.

[0037] The cushioning member can be a midsole core, and the sole structure can further include an additional cushioning member of an outer shell configured to define a central cavity. The midsole core can be disposed in the central cavity as the core of the midsole. Thus, the outer shell at least partially surrounds the midsole core and acts as a protective cage to protect the midsole core around the perimeter of the midsole core. For example, the outer shell can include an outer shell body extending along the outer side surface of the midsole core and an inner shell body extending along the inner side surface of the midsole core. The outer shell body can be coupled to the inner shell body in front of the midsole core and behind the midsole core. For example, each shell body can have a longitudinally extending mating surface. The midsole core can be a first foam material, and the outer shell can be a second foam material different from the first foam material. For example, the midsole core can be Pebax and the outer shell can be Phylon.

[0038] The central cavity defined by the outer shell can be a through hole, and the upper and lower surfaces of the midsole core can be exposed in the central cavity. Additionally, the upper surface of the midsole core can be flush with the outer shell body and the inner shell body, the lower surface of the midsole core can be flush with the outer shell body and the inner shell body, or both the upper and lower surfaces of the midsole core can be flush with the outer shell body and the inner shell body. Further, at least one of the inner shell body or the outer shell body can have an inner side and an outer side, and at least one through hole extending from the inner side to the outer side, wherein the midsole core extends across the through hole at the inner side.

[0039] In one aspect, the outer shell body and the inner shell body can each have an inner edge extending inwardly into the cavity. The midsole core can cooperate with the outer side body and the inner side body at the inner edge such that the inner edge rests on the midsole core. The inner edge can be located at the front portion and / or the rear portion of each of the outer shell body and the inner shell body. A notch in the midsole core can cooperate with the inner edge. The inner edge and the notch can be referred to as complementary positioning features that assist in correctly aligning the shell body and the midsole core during assembly.

[0040] The outer shell body may have a mating surface located in front of the midsole core, and the inner shell body may have a mating surface located in front of the midsole core. The mating surface of the inner shell body is adjacent to and joined to the mating surface of the outer shell body that is located in front of the midsole core. The mating surfaces may be joined to each other, for example, by applying an adhesive to the mating surfaces and then placing the mating surfaces in contact with each other. In one aspect, applying the adhesive may include applying a primer and then applying a cement to the mating surfaces.

[0041] Similarly, the outer shell body may have a mating surface located behind the core, and the inner shell body may have a mating surface located behind the core. The mating surface of the inner shell body is adjacent to and joined to the mating surface of the outer shell body that is located behind the midsole core. The mating surfaces may extend in the longitudinal direction of the footwear item and may be planar.

[0042] In one aspect, the sole structure may include an outsole that extends across and is fixed to the lower surface of the midsole core, the lower surface of the outer shell body, and the lower surface of the inner shell body. In one or more embodiments, the outsole may be at least partially transparent such that the outer shell body, the midsole core, and the inner shell body can be seen through the outsole.

[0043] In some embodiments, a heel stabilizer may be fixed to the upper surface of the outer shell body and the upper surface of the inner shell body in the heel region of the footwear item. The heel stabilizer may also be fixed to the upper surface of the footwear item, such as fixed to the outer surface of the upper surface around the rear of the heel portion of the upper surface.

[0044] In another aspect, the footwear item may include a midsole that includes a first cushioning member configured as a midsole core and a second cushioning member configured as an outer shell that defines a central cavity. The midsole core may be disposed within the central cavity, wherein the outer shell abuts the outer and inner sides of the midsole core and defines a plurality of through-holes that expose the outer and inner sides of the midsole core. The midsole core may or may not include the cut and discarded foam blocks as discussed above.

[0045] A method of manufacturing a footwear article can include receiving a waste foam body, cutting the waste foam body into pieces, and mixing the pieces with a resin binder to form a mixture. The method can further include compression molding the mixture in a mold to form a cushioning member of a sole structure of the footwear article. As discussed herein, due to the cutting, the pieces can be configured as polyhedra of a plurality of different shapes. When assembled in the completed footwear article, the pieces retain their polyhedral shape (except that they can be slightly reshaped to conform to the mold in which they are compression molded) in the cushioning member and are not ground, melted, granulated, or otherwise processed in a manner that changes their cut polyhedral shape under the methods disclosed herein.

[0046] In one aspect, the method can include drying the mixture and pouring the mixture into the mold before compression molding the mixture in the mold. In another aspect, the method can include adding a dye to the resin binder before mixing the pieces with the resin binder. Accordingly, the cushioning member made of the mixture of the pieces of the waste foam body and the resin binder can be dyed to a desired color.

[0047] In another aspect, the cushioning member can be a midsole core, and the manufacturing method can further include attaching an inner shell body to an inner side surface of the midsole core and attaching an outer shell body to an outer side surface of the midsole core such that the inner shell body and the outer shell body form an outer shell defining a central cavity, wherein the midsole core is disposed in the central cavity. Attaching the inner shell body to the inner side surface of the midsole core can include applying an adhesive to the inner shell body, applying an adhesive to the inner side surface of the midsole core, and pressing the inner shell body against the inner side surface of the midsole core. Similarly, attaching the outer shell body to the outer side surface of the midsole core can include applying an adhesive to the outer shell body, applying an adhesive to the outer side surface of the midsole core, and pressing the outer shell body against the outer side surface of the midsole core. Applying the adhesive can include applying a primer and applying a bonding agent.

[0048] In one aspect, the manufacturing method can further include aligning the inner shell body and the outer shell body with the midsole core by mating alignment features of the inner shell body and alignment features of the outer shell body with complementary alignment features of the midsole core before pressing the inner shell body against the inner side surface of the midsole core and pressing the outer shell body against the outer side surface of the midsole core.

[0049] In addition, a method of manufacturing a footwear item can also include attaching an outsole to the lower surface of a midsole core, the lower surface of a lateral shell body, and the lower surface of a medial shell body. Further, the manufacturing method can also include attaching a heel stabilizer to the upper surface of the lateral shell body and the upper surface of the medial shell body in a heel region of the footwear item.

[0050] When understood in conjunction with the accompanying drawings, the above and other features and advantages of the teachings will become apparent from the following detailed description of modes for practicing the teachings.

[0051] Referring to the accompanying drawings, wherein like reference numerals refer to like components throughout the views, Figure 1 is a lateral side view of a footwear item 10 having a sole structure 12 and an upper 14 attached to the sole structure 12. The upper 14 forms a foot receiving cavity 16 that is configured to receive a foot. The upper 14 can be of various materials, such as leather, textile, polymer, cotton, foam, composite materials, etc., and is shown as having laces 15 for tightening the upper 14 around the foot.

[0052] The footwear 10 illustrated herein is depicted as a sports shoe configured for sports or for wearing as a casual shoe, but the footwear 10 is not limited to sports shoes or casual shoes. The footwear 10 (including its components described herein) can be a sports shoe, a casual shoe, a dress shoe, a work shoe, a sandal, a slipper, a boot, or any other category of footwear. As Figure 1 indicated, the footwear 10 can be divided into a forefoot region 18, a midfoot region 20, and a heel region 22, which are also the forefoot region, midfoot region, and heel region of the sole structure 12 and the upper 14, respectively. The forefoot region 18 generally includes the portion of the footwear item 10 corresponding to the toes and the joints connecting the metatarsals and phalanges. The midfoot region 20 generally includes the portion of the footwear item 10 corresponding to the arch region and instep of the foot, and the heel region 22 corresponds to the posterior portion of the foot including the calcaneus. The forefoot region 18, midfoot region 20, and heel region 22 are not intended to demarcate precise regions of the footwear 10, but rather are intended to represent approximate regions of the footwear 10 to facilitate the following discussion.

[0053] The sole structure 12 includes a midsole 24 and an outsole 26. An insole (not shown) can be disposed on the sole structure 12 within the foot receiving cavity 16. The midsole 24 attenuates ground reaction forces (e.g., provides cushioning) when compressed between the foot and the ground during walking, running, or other locomotive activities. The midsole 24 includes a plurality of components incorporated as a single unit, and with reference to Figure 2is described in more detail. The outsole 26 establishes the ground engaging surface of the footwear item 10 and can be a one-piece unit or can be several discrete outsole components. In one example, the outsole 26 can be formed from a wear-resistant material that can be textured to impart traction. For example, the outsole 26 can include natural rubber or synthetic rubber.

[0054] When the foot is located within the foot receiving cavity 16 of the footwear 10, the foot is supported on the foot-facing surface of the midsole 24. The foot-facing surface of the midsole 24 can be covered by a strobel (not shown) that is secured to the lower region of the upper 14. Additionally, an insole (not shown) can rest on the strobel or, in embodiments without a strobel, directly on the sole structure 12, in which case the foot is supported by both the sole structure 12 and the insole.

[0055] The footwear 10 has an outer side 28 ( Figure 1 shown in) and an inner side 30 ( Figure 5 best shown in). As will be understood by those skilled in the art, the outer side 28 and the inner side 30 extend through each of the shoe front region 18, the shoe mid region 20, and the shoe heel region 22, with the outer side 28 and the inner side 30 each falling on opposite sides of the longitudinal midline LM ( Figure 2 ) of the footwear item 10. The longitudinal midline LM extends along the longitudinal axis of the footwear item 10. Thus, the inner side 30 is considered opposite the outer side 28.

[0056] Figure 2 is a perspective view of the sole structure 12, which includes a midsole 24 and a heel stabilizer 32. The midsole 24 includes an integral cushioning member, herein referred to as the midsole core 34, which includes cut blocks 36 of a discarded foam body 38 (as Figure 22 shown) coated with a resin binder 40, and the resin binder 40 secures these blocks 36 to one another. As described herein, the cut blocks 36 are obtained by cutting (a process also referred to as shredding) the discarded foam body 38. Thus, the blocks 36 can be referred to as cut blocks or shredded blocks. Additionally, a dye can be mixed in the resin binder before mixing the shredded blocks 36 with the resin binder 40. In a non-limiting example, the discarded foam body 38 (and thus the cut blocks 36) includes Pebax thermoplastic elastomer foam and can be sold by Nike, Inc. under the trade name ZoomX. The resin binder 40 can include a water-based polyurethane dispersion. The discarded foam body 38, the resulting blocks 36, and the resin binder 40 can be other materials than those within the scope of the present disclosure.

[0057] Figure 22 The waste foam body 38 shown is the remainder of a foam sheet after layers of a plurality of one-piece midsole inserts used in a first footwear application (e.g., other footwear items of a different configuration than the footwear item 10) have been cut away leaving a plurality of recesses or holes 38A and a remaining material 38B surrounding the recesses or holes 38A. The foam sheet may initially have a generally uniform thickness T. Prior to the cutting process that produces the chunks, the remaining material 38B of the sheet may also be segmented to reduce the thickness. Thus, when the remaining material 38B is cut, at least most of the shredded chunks 36 may have substantially consistent thickness dimensions. If the cutting process is controlled to provide width and length dimensions for most of the cut chunks 36 within a predetermined size, the volume of most of the resulting individual shredded chunks will be within a predetermined volume range. The cutting process may subject the waste foam body 38 to a series of passes through a cutting machine having a straight cutting blade that is set at different angles relative to the direction of movement of the blade. Additionally, as the chunks 36 pass through the cutting machine, the chunks 36 may be set in different orientations on a conveyor, thereby producing three-dimensional chunks having a plurality of different polyhedral shapes. For example, at least some (if not most) of the chunks will have flat faces, which are produced by the cutting plane of the cutting blade passing through the remaining material 38B, subsequent cutting of the first-stage chunks, and subsequent cutting of the second-stage chunks, etc. These chunks 36 thus have a plurality of different polyhedral shapes, such as best shown in Figure 3 , Figures 8 - 13 and Figures 23 - 24 . For example, the cut chunks of different polyhedral shapes provide a more uniform (e.g., smoother) outer surface compared to a plurality of torn or broken chunks of similar size, having denser edges and a greater surface area. The relatively smooth outer surface may provide greater comfort at the foot-facing surface, as well as denser edges for the structural stability of the midsole core 34. Additionally, the relatively smooth outer surface may provide a better bonding surface for the outer shells 60, 62.

[0058] In addition to the midsole core 34, the midsole 24 includes additional cushioning components that are outer shells 60, 62 configured to define a central cavity 44, as best shown in Figure 14 and Figure 15 , where the midsole core 34 is disposed within and fills the central cavity 44, as shown in Figure 2 . The midsole core 34 is bonded to the outer shells 60, 62 and includes complementary positioning features 46A, 46B (shown in Figure 3Best shown in), the complementary locating features 46A, 46B assist in correctly aligning the midsole core 34 to the outer shells 60, 62 during assembly. More specifically, the midsole core 34 has a front outer boss 46A in the forefoot region 18 of the shoe and a rear outer boss 46B in the heel region 22 of the shoe. The bosses 46A and 46B are defined by a front notch 48A and a rear notch 48B between the upper surface 50 and the side surface 52 of the midsole core 34. The notches 48A, 48B and the accompanying bosses 46A, 46B each extend around a portion of the perimeter of the midsole core 34. The front notch 48A and the front outer boss 46A extend around the perimeter from the outer side surface 28 to the inner side surface 30 at a forward extent 54 in front of the midsole core 34. Similarly, the rear notch 48B and the rear outer boss 46B extend around the perimeter from the outer side surface 28 to the inner side surface 30 at a rearward extent 56. The midsole core 34 is shown in Figure 3 to be formed after mixing, drying, and compression molding a mixture of chopped pieces 36, a resin binder 40, and a dye (if used).

[0059] The outer shells 60, 62 include an outer shell body 60 and an inner shell body 62 that are joined to each other in front of and behind the midsole core 34. The outer shell body 60 and the inner shell body 62 can each be formed by compression molding an injection-molded phylon preform. As Figure 4 shown, the outer shell body 60 extends along the outer side surface 28 of the midsole core 34 (e.g., along the surface of the outer sidewall 71). As Figure 5 shown, the inner shell body 62 extends along the inner side surface 30 of the midsole core 34 (e.g., along the surface of the inner sidewall 76). For example, as Figure 2 and Figures 9 - 13 shown, the upper surface 50 of the midsole core 34 is flush with the upper surface 61 of the outer shell body 60 and the upper surface 63 of the inner shell body 62. Similarly, for example, as Figures 9 - 13As shown, the lower surface 70 of the midsole core 34 is flush with the lower surface 72 of the outer shell body 60 where the surfaces 70, 72 meet, and the lower surface 70 of the midsole core 34 is flush with the lower surface 74 of the inner shell body 62 where the surfaces 70, 74 meet. In other embodiments, only the upper surface 50 is flush with the upper surfaces 61, 63, and the lower surface 70 is not flush with the lower surfaces 72, 74, or only the lower surface 70 is flush with the lower surfaces 72, 74, and the upper surface 50 is not flush with the upper surfaces 61, 63. Similarly, the lower surface 70 of the midsole core 34 is flush with the lower surface 72 of the outer shell body 60 where the surfaces 70, 72 meet, and the lower surface 70 of the midsole core 34 is flush with the lower surface 74 of the inner shell body 62.

[0060] As Figure 4 and Figure 5 shown, each of the outer shell body 60 and the inner shell body 62 defines a plurality of through-holes 64A, 64B that respectively extend completely through the shell bodies 60, 62. More specifically, the through-hole 64A in the outer shell body 60 extends from the outer side 66 of the outer shell body 60 to the inner side 68 of the outer shell body 60, as Figure 11 and Figure 14 best shown in. The outer sidewall 71 of the midsole core 34 extends across the through-hole 64A at the inner side 68. Similarly, the through-hole 64B in the inner shell body 62 extends from the outer side 75 of the inner shell body 62 to the inner side 77 of the inner shell body 62, as Figure 11 and Figure 14 best shown in. The inner sidewall 76 of the midsole core 34 extends across the through-hole 64B at the inner side 77. The outer sidewall 71 and the inner sidewall 76 of the midsole core 34 are respectively exposed at the through-holes 64A, 64B and are visible from the outside of the sole structure 12. The through-holes 64A, 64B reduce the total weight of the shell bodies 60, 62. Additionally, the compressibility of the shell bodies 60, 62 is increased at those regions that extend across the through-holes 64A or 64B.

[0061] The outer shell body 60 and the inner shell body 62 and the midsole core 34 have complementary positioning features that help to correctly align the shell bodies 60, 62 and the midsole core 34 during assembly. For example, as Figures 14 - 15 and Figures 18 - 19 shown, the outer shell body 60 has an inner edge 86A that extends inwardly into the central cavity 44 at the rear of the central cavity 44 and an inner edge 86B that extends inwardly into the central cavity 44 at the front of the central cavity 44. As Figure 9 and Figures 14 - 17As shown, the inner housing body 62 has an inner edge 88A that extends inwardly into the central cavity 44 at the rear of the central cavity 44 and an inner edge 88B that extends inwardly into the central cavity at the front of the central cavity 44. The midsole core 34 cooperates with the outer housing body 60 and the inner housing body 62 at the inner edges 86A, 86B, 88A, and 88B such that the inner edges rest on and are bonded to the bosses 6A, 46B of the midsole core 34. More specifically, the inner edges 86A, 88A fit into the notch 48B and overlap and are adjacent to the rear outer boss 46B. The inner edges 86B, 88B fit into the notch 48A and overlap and are adjacent to the front outer boss 46A. The inner edges 86A, 86B, 88A, 88B and the notches 48A, 48B can be referred to as complementary positioning features.

[0062] The outer housing body 60 can be coupled to the inner housing body 62 in front of the midsole core 34 (as Figure 2 shown) and coupled to the inner housing body 62 behind the midsole core 34 (as Figure 6 best shown therein). More specifically, when the outer housing body 60 and the inner housing body 62 are coupled to the side walls 71, 76 of the midsole core 34, the outer housing body 60 and the inner housing body 62 can be coupled to each other at the mating surface. For example, as Figure 16 shown, the inner housing body 62 has a front mating surface 90A that is disposed in front of the central cavity 44 and thus in front of the midsole core 34 when the inner housing body 62 is assembled to the midsole core 34. The inner housing body 62 has a rear mating surface 90B that is disposed behind the central cavity 44 and thus behind the midsole core 34 when the inner housing body 62 is assembled to the midsole core 34. As Figure 18 shown, the outer housing body 60 has a front mating surface 92A that is disposed in front of the central cavity 44 and thus in front of the midsole core 34 when the outer housing body 60 is assembled to the midsole core 34. The outer housing body 60 has a rear mating surface 92B that is disposed behind the central cavity 44 and thus behind the midsole core 34 when the outer housing body 60 is assembled to the midsole core 34. The mating surfaces 90A, 90B and / or 92A, 92B can extend in the longitudinal direction of the footwear item 10 (e.g., along or parallel to the longitudinal midline LM).

[0063] In the assembled footwear item 10, the bonding surface 90A abuts and is bonded to the bonding surface 92A in front of the midsole core 34, and the bonding surface 92A abuts and is bonded to the bonding surface 92B behind the midsole core 34. The bonding surfaces 90A, 90B and 92A, 92B can be planar surfaces as shown and can be bonded to each other, for example, by applying an adhesive (e.g., a primer and a bonding agent) on the bonding surfaces and then placing the bonding surfaces in contact with each other. For example, the primer and the bonding agent can be first applied to the side walls 71, 76 and the outer bosses 46A, 46B of the midsole core 34. The primer and the bonding agent can be applied to the inner sides 68, 77 of the outer shell body 60 and the inner shell body 62 and the bonding surfaces 90A, 90B, 92A, 92B. Then, by fitting the inner edge 86A to the rear outer boss 46B and the inner edge 86B to the front outer boss 46A, the midsole core 34 can be aligned with the outer shell body 60. The adjacent surfaces will abut and bond to each other. Then, by fitting the inner edge 88A to the rear outer boss 46B and the inner edge 88B to the front outer boss 46A, the inner shell body 62 can be aligned with the inner side wall 76 of the midsole core 34 and fit to the inner side wall 76 of the midsole core 34. The bonding surface 92A will abut and bond to the bonding surface 90A, and the bonding surface 92B will abut and bond to the bonding surface 90B.

[0064] The heel stabilizer 32 can be an injection molded polymer. Figure 4 and Figure 5 The heel stabilizer 32 is shown fixed to the upper surface 61 of the outer shell body 60 and the upper surface 63 of the inner shell body 62 such that the heel stabilizer 32 is disposed in the heel region 22 of the footwear item 10 as Figure 1 shown. For example, the heel stabilizer 32 can be bonded to the upper surfaces 61, 63 with a primer and a bonding agent. Figure 9 and Figure 14 、 Figure 16 and Figure 18 The upper surfaces 61, 63 are shown configured to have minute recesses 78, 80 that serve as positioning features to accurately position the heel stabilizer 32 on the surfaces 61, 63. The lower portions of the recess 78 in the upper surface 61 and the recess 80 in the upper surface 63 together receive the lower flange 82 of the heel stabilizer 32 (best shown in Figure 21 such that the front ends 82A, 82B of the lower flange 82 are respectively located at the front ends 78A, 80A of the recesses 78, 80 (see Figure 14)。The recesses 78, 80 each have surrounding side walls 81, 83 that surround the lower flange 82 outwardly. The recess 78 has a side wall 85A, the recess 80 has a side wall 85B, and each recess has a portion of a rear wall 85C, and these portions of the rear walls 85C together surround the outer peripheral edge of the heel stabilizer 32 to help position the heel stabilizer 32 correctly on the upper surfaces 61, 63. More specifically, the outer outer peripheral edge 87A abuts the side wall 85A of the heel stabilizer 32, the inner outer peripheral edge 87B abuts the side wall 85B of the heel stabilizer 32, and the rear edge 87C abuts the rear wall 85C of the heel stabilizer 32.

[0065] For example, Figure 6 and Figures 10 - 13 shows the outsole 26, which extends across and is fixed to the lower surfaces 70 of the midsole core 34, the lower surface 72 of the outer shell body 60, and the lower surface 74 of the inner shell body 62. For example, the outsole 26 can be bonded (e.g., adhered) to the lower surfaces 70, 72, 74 using a primer and an adhesive. The outsole 26 can be at least partially transparent, such that the outer shell body 60, the midsole core 34, and the inner shell body 62 can be seen through the outsole 26. Any suitable standardized test can be used to determine transparency, such as the American Society for Testing and Materials (ASTM) standard D1003-00, Standard Test Method for Haze and Luminous Transmittance of Transparent Plastics. The outsole 26 also extends over the front surfaces of the outer shell body 60 and the inner shell body 62, as Figure 7 shown. Figure 8 shows the outsole 26 including several integrally formed lugs 26A, 26B, only some of which are labeled. In Figure 8 , the midsole core 34 (including its discrete, shredded foam body blocks 36) is shown as visible through the transparent outsole.

[0066] Figure 25A and Figure 25B is a flowchart of an example of a method 200 for manufacturing an article of footwear (such as the article of footwear 10). The steps are shown in chronological order, although other orders are possible. The circled A indicates that Figure 25B the step shown in Figure 25A continues from the step shown in

[0067] The method 200 can include step 202 of receiving a waste foam body (such as Figure 22 the waste foam body 38). For example, the waste foam can be Pebax in sheet form Foam, in which layers of multiple midsole laminates of other footwear items with different configurations from the footwear item 10 have been cut or otherwise removed from the waste foam. The method 200 is not limited to using Pebax Foam. Most of the waste foam bodies can be recycled under the method 200 because after the waste foam bodies undergo potential segmentation and the cutting processes (e.g., shredding processes) described herein, the initial shape of the waste foam bodies is largely unimportant. Thus, the waste foam bodies 38 are not wasted but are reused as cushioning components (e.g., midsole laminate components) of the footwear sole structure.

[0068] Then, the method 200 proceeds to step 204 of cutting the waste foam body 38 into blocks 36. Cutting the waste foam body 38 into blocks 36 can be achieved by shredding the waste foam body 38 such that the blocks 36 are shredded blocks. If the waste foam body 38 is in the form of a sheet, step 204 may first include a sub-step of dividing the waste foam body 38 in the Z direction into thicknesses of approximately 10 millimeters (e.g., from approximately 8 millimeters to approximately 12 millimeters). Step 204 may include a sub-step of passing through one or more shredding machines multiple times. For example, the waste foam body 38 (or the body in the case of segmentation) can be placed to pass through a shredding machine for a first vertical cut, and then placed to pass through the shredding machine again for a second vertical cut, and then a third time through the shredding machine, which provides random cuts with blades of different angles. The cutting process of step 204 is selected to produce a plurality of different polyhedral shapes and sizes of blocks 36 that are configured to have dimensions within a target range of length, width, and height between 5 millimeters and 40 millimeters, accounting for more than 99% of the original waste foam body 38, as usable shredded blocks 36. Some of the blocks 36 produced from this process are approximately 10 - millimeter cubes. Compared to larger blocks, blocks of this size create fewer and smaller voids on the surface of the complete midsole core 34, resulting in a more uniform surface and denser edges of the complete midsole core 34 (for comfort at the foot - facing surface, for structural stability at the edges, and for a sufficient bonding surface for the outer shells 60, 62). In some examples, the waste foam body 38 can be divided into blocks in some other way (e.g., by crushing or tearing the waste foam body 38) in addition to cutting in step 204. However, compared to using other methods of dividing the waste foam body 38 (e.g., crushing or tearing), cutting the waste foam body 38 into cut blocks 36 using a cutting machine can achieve target dimensions with higher precision. Additionally, the polyhedral - shaped blocks 36 retain their shape after step 204. For example, the polyhedral - shaped blocks 36 do not melt into small balls, are not ground, do not foam again, etc.

[0069] Method 200 may include step 208 of mixing a dye with resin binder 40 to provide a desired color of resin binder 40. Alternatively, a resin binder 40 without a coloring dye may be used, in which case the method proceeds from step 204 (with possible sub-step 206) to step 210.

[0070] In step 210, cut blocks 36 are mixed with resin binder 40 (dyed or undyed) to form a mixture. The ratio of shredded blocks 36 to resin binder 40 (or resin binder 40 and dye mixture) may be 1:1.5 (e.g., 1 part cut blocks 36 to 1.5 parts resin binder 40 (or resin binder 40 and dye mixture)), which may be placed in a mixing container, and then the mixing container is placed inside a mixer and mixed thoroughly to coat all outer surfaces of cut blocks 36 with resin binder 40. For example, for a 20-liter volume, a mixing time of 5 to 6 minutes may be achieved in a commercial mixer. Figure 23 Shown are blocks 36 and dyed resin binder 40 in the mixture held in mixing container 98 prior to complete mixing.

[0071] After mixing in step 210, method 200 may proceed to step 212 to dry the mixture. For example, the resin-coated cut blocks 36 may be dried until only the solid resin binder 40 remains coating the outer surfaces of cut blocks 36. For example, the resin binder-coated cut blocks 36 may be removed from the mixer and placed in a dryer at 80 degrees Celsius for 30 minutes. Figure 24 Shown is an exemplary cut block 36 having a polyhedral shape, coated with resin binder 40, and after drying.

[0072] Once dried, method 200 moves to step 214 to weigh a quantity of the resin-coated blocks to provide a predetermined weight, and then, method 200 moves to step 216 to pour the weighed mixture of resin binder 40-coated blocks 36 (now in a dried state) into a compression mold that will compress the mixture together to provide a Figure 2 midsole core 34 having the shape and dimensions. For example, the weighed quantity may be poured into the bottom portion of the mold. Next, in step 218, the mold may be closed by closing the top portion to provide a compression ratio of approximately 150% to 160% of the resin-coated blocks 36.

[0073] In step 220, the mold can be heated to approximately 163 degrees Celsius and then in step 222 cooled to below 30 degrees Celsius. In step 224, the mold is opened, in step 226, the midsole core 34 is removed from the mold, and in step 228, the midsole core 34 is trimmed to remove any flash. Notably, the block 36 retains its shape in subsequent steps after the cutting step 204 (e.g., through drying, heating, and cooling steps, etc.), such that the complete midsole core disposed in the finished footwear item 10 includes randomly disposed foam blocks 36 having different polyhedral shapes and within a target size range determined by the spacing of the cutting blades in the cutting step 204.

[0074] The outer shell body 60 and the inner shell body 62 used in the sole structure 12 can have been obtained in a formed state (e.g., can be formed by different entities), or can be formed by the entity performing the method 200. Thus, if formed by the entity performing the method 200, the method 200 can include in step 230 injection molding a preform of each of the inner shell body 62 and the outer shell body 60 in a respective heated mold for a predetermined amount of time, and then in step 232 compression molding the preforms to provide the inner shell body 62 and the outer shell body 60. Step 232 can include sub-steps of heating and cooling while in the mold and then trimming, washing, and drying after removal from the mold. In an example, the inner shell body 62 and the outer shell body 60 comprise Phylon.

[0075] The method can include step 234 of joining the inner shell body 62 and the outer shell body 60 to the midsole core 34 by stock-fitting the components (e.g., manually assembling). Step 234 can include sub-step 236 of applying an adhesive to the inner shell body 62, applying an adhesive to the inner side surface of the midsole core 34, e.g., from the front extension 54 along the inner sidewall 76 to the rear extension 56. Similarly, sub-step 236 can include applying an adhesive to the outer shell body 60, and applying an adhesive to the outer side surface of the midsole core 34, e.g., from the front extension 54 along the outer sidewall 71 to the rear extension 56. For example, applying the adhesive in sub-step 236 can include applying a primer and applying a bonding agent.

[0076] Next, step 234 may include sub-step 238 of aligning the inner shell body 62 with the midsole core 34 by mating the alignment features (e.g., inner edges 88A, 88B) of the inner shell body 62 with complementary alignment features of the midsole core 34 (e.g., the rear notch 48B mates with the rear inner edge 88A, and the front notch 48A mates with the front inner edge 88B such that the edge 88A rests on the rear outer boss 46B and the edge 88B rests on the front outer boss 46A). Once the alignment is complete, method 200 moves to step 240 of pressing the inner shell body 62 against the inner side surface of the midsole core 34. In step 242, the outer shell body 60 is aligned with the midsole core 34 by mating the alignment features (e.g., inner edges 86A, 86B) of the outer shell body 60 with complementary alignment features of the midsole core 34 (e.g., the rear notch 48B mates with the rear inner edge 86A, and the front notch 48A mates with the front inner edge 86B such that the edge 86A rests on the rear outer boss 46B and the edge 86B rests on the front outer boss 46A). In step 244, the outer shell body 60 is pressed against the outer side surface of the midsole core 34.

[0077] Thus, in step 234, the inner side 77 of the inner shell body 62 is joined to the inner side wall 76 and bosses 46A, 46B of the midsole core 34, the inner side 68 of the outer shell body 60 is joined to the outer side wall 71 and bosses 46A, 46B of the midsole core 34, and the laterally extending joining surfaces 92A, 92B are joined to the joining surfaces 90A, 90B.

[0078] Step 234 may be referred to as pre-assembling the shell bodies 60, 62 to the midsole core 34 when manually completing the assembly and pressing. After pre-assembling the components to each other, method 200 may move to step 246 where the outer shells 60, 62 and the midsole core 34 to which the outer shells 60, 62 are joined are further compressed by a machine (e.g., in a deep well press) to ensure a secure bond.

[0079] After step 246 and after removing the outer shells 60, 62 and the midsole core 34 from the machine press in step 248, method 200 may further include step 250 of attaching the outsole 26 to the lower surfaces 70 of the midsole core 34, the lower surface 72 of the outer shell body 60, and the lower surface 74 of the inner shell body 62.

[0080] In addition, method 200 may include step 252 of attaching a heel stabilizer 32 to the upper surface 61 of the outer shell body 60 and the upper surface 63 of the inner shell body 62 in the heel region 22.

[0081] Additional steps of method 200 may include assembling various components of upper 14 by stitching, adhesives, heat bonding, etc. Alternatively, upper 14 may be assembled by different entities so that it is ready for lasting and / or attachment to the strobel. In step 254, upper 14 may be attached to sole structure 12 and heel stabilizer 32. This may include various sub-steps, such as attaching the strobel to upper 14 on a last, applying adhesives (e.g., a primer and a bonding agent) to the strobel and heel stabilizer 32, pressing the upper surface 50 of insole core 34 and the upper surfaces 61, 63 of outer shells 60, 62 against the strobel, and pressing heel stabilizer 32 against the rear of upper 14 in heel region 22.

[0082] Thus, manufacturing method 200 of footwear article 10 disclosed herein produces a unique insole having an insole core and an outer shell. Manufacturing method 200 may increase the environmental sustainability of footwear manufacturing by utilizing waste foam as discussed herein.

[0083] The following clauses provide example configurations of the footwear article disclosed herein and methods of manufacturing the footwear article.

[0084] Clause 1. A method of manufacturing a footwear article, the manufacturing method comprising: receiving a waste foam body; cutting the waste foam body into pieces; mixing the pieces with a resin binder to form a mixture; and compression molding the mixture in a mold to form a cushioning component of a sole structure of the footwear article.

[0085] Clause 2. The manufacturing method according to clause 1, further comprising, before compression molding the mixture in the mold: drying the mixture; and pouring the mixture into the mold.

[0086] Clause 3. The manufacturing method according to any one of clauses 1-2, further comprising: adding a dye to the mixture before mixing the pieces with the resin binder.

[0087] Clause 4. The manufacturing method according to any one of clauses 1-3, wherein the cushioning component is an insole core, and the method further comprises: attaching an inner shell body to an inner side surface of the insole core and attaching an outer shell body to an outer side surface of the insole core such that the inner shell body and the outer shell body form an outer shell defining a central cavity, wherein the insole core is disposed in the central cavity.

[0088] Clause 5. The manufacturing method according to Clause 4, wherein attaching the inner shell body to the inner side of the midsole core includes applying an adhesive to the inner shell body and applying an adhesive to the inner side of the midsole core, and pressing the inner shell body against the inner side of the midsole core; wherein attaching the outer shell body to the outer side of the midsole core includes applying an adhesive to the outer shell body and applying an adhesive to the outer side of the midsole core, and pressing the outer shell body against the outer side of the midsole core.

[0089] Clause 6. The manufacturing method according to any one of Clauses 4-5, further comprising: aligning the inner shell body and the outer shell body with the midsole core by mating the alignment features of the inner shell body and the alignment features of the outer shell body with the complementary alignment features of the midsole core before pressing the inner shell body against the inner side of the midsole core and pressing the outer shell body against the outer side of the midsole core.

[0090] Clause 7. The manufacturing method according to any one of Clauses 4-6, further comprising: attaching an outsole to the lower surface of the midsole core, the lower surface of the outer shell body, and the lower surface of the inner shell body.

[0091] Clause 8. The manufacturing method according to any one of Clauses 4-7, further comprising: attaching a heel stabilizer to the upper surface of the outer shell body and the upper surface of the inner shell body in the heel region of the footwear item.

[0092] Clause 9. A footwear item, comprising: a sole structure, the sole structure including an integral cushioning member, the integral cushioning member including a plurality of waste foam blocks configured in a plurality of different polyhedral shapes and a resin binder that fixes the waste foam blocks to each other.

[0093] Clause 10. The footwear item according to Clause 9, wherein the cushioning member is a midsole core, the sole structure further includes an additional cushioning member, the additional cushioning member is configured as an outer shell that defines a central cavity, and the midsole core is disposed in the central cavity.

[0094] Clause 11. The footwear item according to Clause 10, wherein the outer shell includes: an outer shell body extending along the outer side of the midsole core; an inner shell body extending along the inner side of the midsole core; and wherein the outer shell body is joined to the inner shell body in front of and behind the midsole core.

[0095] Clause 12. The footwear article according to Clause 11, wherein the central cavity is a through-hole, and the upper surface and the lower surface of the midsole core are exposed in the central cavity.

[0096] Clause 13. The footwear article according to Clause 12, wherein the upper surface of the midsole core is flush with the outer shell body and the inner shell body, the lower surface of the midsole core is flush with the outer shell body and the inner shell body, or both the upper surface and the lower surface of the midsole core are flush with the outer shell body and the inner shell body.

[0097] Clause 14. The footwear article according to any one of Clauses 11-13, wherein: at least one of the inner shell body or the outer shell body has an inner side and an outer side and defines at least one through-hole extending from the inner side to the outer side; and the midsole core extends across the at least one through-hole at the inner side.

[0098] Clause 15. The footwear article according to any one of Clauses 11-13, wherein: the outer shell body and the inner shell body each have an inner edge extending into the central cavity; and the midsole core cooperates with the outer shell body and the inner shell body at the inner edge such that the inner edge rests on the midsole core.

[0099] Clause 16. The footwear article according to any one of Clauses 11-15, wherein: the outer shell body has a bonding surface in front of the midsole core; and the inner shell body has a bonding surface in front of the midsole core, and the bonding surface of the inner shell body is adjacent to and joined to the bonding surface of the outer shell body.

[0100] Clause 17. The footwear article according to any one of Clauses 11-16, wherein: the outer shell body has a bonding surface behind the midsole core; and the inner shell body has a bonding surface behind the midsole core, and the bonding surface of the inner shell body is adjacent to and joined to the bonding surface of the outer shell body.

[0101] Clause 18. The footwear article according to Clause 17, wherein the bonding surface of the outer shell body and the bonding surface of the inner shell body extend in the longitudinal direction of the footwear article.

[0102] Clause 19. The footwear item according to any one of Clauses 11-18 further includes: an outsole that extends across and is fixed to the lower surface of the midsole core, the lower surface of the outer shell body, and the lower surface of the inner shell body.

[0103] Clause 20. The footwear item according to any one of Clauses 11-19 further includes: a heel stabilizer that is fixed to the upper surface of the outer shell body and the upper surface of the inner shell body in the heel region of the footwear item.

[0104] Clause 21. The footwear item according to any one of Clauses 10-20, wherein the midsole core is a first foam material and the outer shell is a second foam material different from the first foam material.

[0105] Clause 22. The footwear item according to any one of Clauses 9-21, wherein the cushioning member further includes a dye mixed in a resin binder.

[0106] Clause 23. The footwear item according to any one of Clauses 9-22, wherein the waste foam block includes Pebax foam, and the resin binder includes polyurethane.

[0107] Clause 24. A footwear item includes: a midsole that includes: a first cushioning member configured as a midsole core; and a second cushioning member configured as an outer shell that defines a central cavity; wherein the midsole core is disposed within the central cavity, wherein the outer shell abuts the outer and inner sides of the midsole core and defines a plurality of through-holes that expose the outer and inner sides of the midsole core.

[0108] Clause 25. The footwear item according to Clause 24, wherein the central cavity is a through-hole and the upper and lower surfaces of the midsole core are exposed within the central cavity.

[0109] Clause 26. The footwear item according to any one of Clauses 24-25, wherein the outer shell includes: an outer shell body that extends along the outer side of the midsole core; an inner shell body that extends along the inner side of the midsole core; and wherein the outer shell body is joined to the inner shell body in front of and behind the midsole core.

[0110] Clause 27. The footwear article according to Clause 26, wherein an upper surface of the midsole core is flush with the outer shell body and the inner shell body, a lower surface of the midsole core is flush with the outer shell body and the inner shell body, or both the upper surface and the lower surface of the midsole core are flush with the outer shell body and the inner shell body.

[0111] Clause 28. The footwear article according to any one of Clauses 26-27, wherein at least one of the inner shell body or the outer shell body has an inner side and an outer side, and at least one of the plurality of through holes extends from the inner side to the outer side, and the midsole core extends across the through hole at the inner side.

[0112] Clause 29. The footwear article according to any one of Clauses 26-28, wherein: the outer shell body and the inner shell body each have an inner edge extending inwardly into the central cavity; and the midsole core mates with the outer shell body and the inner shell body at the inner edge such that the inner edge rests on the midsole core.

[0113] Clause 30. The footwear article according to any one of Clauses 26-29, wherein: the outer shell body has a bonding surface in front of the midsole core; and the inner shell body has a bonding surface in front of the midsole core, and the bonding surface of the inner shell body is adjacent to and joined to the bonding surface of the outer shell body.

[0114] Clause 31. The footwear article according to any one of Clauses 26-30, wherein: the outer shell body has a bonding surface behind the midsole core; and the inner shell body has a bonding surface behind the midsole core, and the bonding surface of the inner shell body is adjacent to and joined to the bonding surface of the outer shell body.

[0115] Clause 32. The footwear article according to any one of Clauses 26-31, wherein the bonding surface of the outer shell body and the bonding surface of the inner shell body extend in a longitudinal direction of the footwear article.

[0116] Clause 33. The footwear article according to any one of Clauses 26-32, further comprising: an outsole that extends across and is fixed to a lower surface of the midsole core, a lower surface of the outer shell body, and a lower surface of the inner shell body.

[0117] Clause 34. The footwear item according to any one of Clauses 26 - 33 further includes: a heel stabilizer, which is fixed to the upper surface of the outer shell body and the upper surface of the inner shell body in the heel region of the footwear item.

[0118] Clause 35. The footwear item according to any one of Clauses 26 - 34, wherein the midsole core includes recycled foam blocks and a resin binder coating the recycled foam blocks.

[0119] Clause 36. The footwear item according to Clause 35, wherein the midsole core further includes a dye mixed in the resin binder.

[0120] Clause 37. The footwear item according to any one of Clauses 35 - 36, wherein the recycled foam blocks include Pebax foam, and the resin binder includes polyurethane.

[0121] To assist in and clarify the description of the various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Additionally, all references mentioned are incorporated herein in their entirety.

[0122] "Footwear item", "footwear product", and "footwear" can be considered both a machine and a manufactured article. An assembled and ready - to - wear footwear item (such as a shoe, sandal, boot, etc.) and discrete components of a footwear item (such as a midsole, outsole, upper components, etc.) are considered herein and optionally referred to in the singular or plural as "footwear item" before being finally assembled into a ready - to - wear footwear item.

[0123] "A", "an", "the", "at least one", and "one or more" are used interchangeably to indicate the presence of at least one item among the items. Unless the context clearly indicates otherwise, there can be multiple such items. Unless the context clearly or explicitly indicates otherwise, all numerical values of parameters (e.g., quantities or conditions) in this specification (including the appended claims) should be understood to be modified in all cases by the term "about", whether or not "about" actually appears before the value. "About" indicates that the stated value allows some slight imprecision (somewhat close to the accuracy of the value; approximately or moderately close to the value; nearly). If the imprecision provided by "about" is not otherwise understood in the art in this ordinary meaning, then as used herein, "about" at least indicates the variations that may be caused by the ordinary methods of measuring and using these parameters. Additionally, the disclosure of a range should be understood to specifically disclose all values within the range and further divided ranges.

[0124] The terms "comprising", "including", and "having" are inclusive and thus specify the presence of the stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed when possible, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the associated listed items. The term "any" is understood to include any possible combination of the recited items, including "any one" of the recited items. The term "any" is understood to include any possible combination of the recited claims of the appended claims, including "any one" of the recited claims.

[0125] For consistency and convenience, directional adjectives may be employed throughout this detailed description corresponding to the illustrated embodiments. Those of ordinary skill in the art will recognize that terms such as "above", "below", "upward", "downward", "top", "bottom", etc. may be used descriptively with respect to the drawings and do not represent a limitation on the scope of the invention as defined by the claims.

[0126] The term "longitudinal" refers to the direction extending along the length of a component. For example, the longitudinal direction of a shoe extends between the toe region and the heel region of the shoe. The terms "forward" or "anterior" are used to refer to the general direction from the heel region toward the toe region of the shoe, and the terms "rearward" or "posterior" are used to refer to the opposite direction, i.e., from the toe region toward the heel region of the shoe. In some cases, a component may be identified with a longitudinal axis and a forward longitudinal direction and a rearward longitudinal direction along that axis. The longitudinal direction or longitudinal axis may also be referred to as the anterior-posterior direction or anterior-posterior axis.

[0127] The term "transverse" refers to the direction extending along the width of a component. For example, the transverse direction of a shoe extends between the outer side and the inner side of the shoe. The transverse direction or transverse axis may also be referred to as the lateral direction or lateral axis or the mediolateral direction or mediolateral axis.

[0128] The term "vertical" refers to a direction that is substantially perpendicular to both the lateral direction and the longitudinal direction. For example, in a case where the sole is placed flat on a ground surface, the vertical direction can extend upward from the ground surface. It should be understood that each of these directional adjectives can be applied to the respective components of the sole. The terms "upward" or "upwards" refer to the vertical direction pointing towards the top of a component, which may include the back, fastening area, and / or throat of the upper. The terms "downward" or "downwards" refer to the vertical direction opposite to the upward direction, pointing towards the bottom of a component and may generally point towards the bottom of the sole structure of the footwear item.

[0129] The "interior" of a footwear item (such as a shoe) refers to the portion at the space occupied by the wearer's foot when the shoe is being worn. The "inner side" of a component refers to the side or surface of the component that is oriented towards (or will be oriented towards) the interior of the component or the footwear item when assembled. The "outer side" or "exterior" of a component refers to the side or surface of the component that is oriented away from (or will be oriented away from) the interior of the shoe when assembled. In some cases, other components may be located between the inner side of a component and the interior within the assembled footwear item. Similarly, other components may be located between the outer side of a component and the space outside the assembled footwear item. Additionally, the terms "inward" and "inwardly" refer to the direction towards the interior of a component or a footwear item (such as a shoe), and the terms "outward" and "outwardly" refer to the direction towards the exterior of a component or a footwear item (such as a shoe). Further, the term "proximal" refers to the direction that is closer to the center of the footwear component or closer to the foot when the footwear item is worn by a user and the foot is inserted into the footwear item. Similarly, the term "distal" refers to the relative position that is further away from the center of the footwear component or further away from the foot when the footwear item is worn by a user and the foot is inserted into the footwear item. Thus, the terms proximal and distal can be understood as providing generally opposite terms to describe relative spatial positions.

[0130] Although multiple embodiments have been described, this description is intended to be exemplary and not restrictive, and it will be apparent to those of ordinary skill in the art that more embodiments and implementations within the scope of the embodiments are possible. Any feature of any embodiment can be used in combination with or replace any other feature or element in any other embodiment, unless specifically restricted. Thus, the embodiments are not limited except as defined by the appended claims and their equivalents. Moreover, various modifications and variations can be made within the scope of the appended claims.

[0131] Although numerous modes for implementing many aspects of the present teachings have been described in detail, those skilled in the art to which these teachings pertain will recognize various alternative aspects of implementing the present teachings within the scope of the appended claims. It is intended that all content included in the foregoing description or shown in the accompanying drawings be construed as illustrative and exemplary of the overall scope of alternative embodiments that would be recognized by one of ordinary skill in the art, such alternative embodiments being implied by the content included, structurally and / or functionally equivalent to the content included, or otherwise made apparent based on the content included, and not limited solely to those embodiments explicitly depicted and / or described.

Claims

1. An article of footwear, comprising: a midsole, the midsole comprising: a first cushioning member configured as a midsole core; and a second cushioning member configured as an outer shell defining a central cavity; wherein the midsole core is disposed within the central cavity; wherein the outer shell comprises: an outer shell body extending along an outer side surface of the midsole core; and an inner shell body extending along an inner side surface of the midsole core; wherein the outer shell body is coupled to the inner shell body, wherein the midsole core has a front notch and a rear notch, the front notch defining a front outer boss extending only in a forefoot region of the article of footwear, and the rear notch defining a rear outer boss extending only in a heel region of the article of footwear; wherein inner side surfaces of the midsole core in a midfoot region of the article of footwear and outer side surfaces of the midsole core in the midfoot region of the article of footwear extend from an upper surface of the midsole core to a lower surface of the midsole core without any bosses extending between the upper surface and the lower surface in the midfoot region; and wherein the outer shell body and the inner shell body each have an inner edge extending into the central cavity and resting on the front outer boss and an inner edge extending into the central cavity and resting on the rear outer boss.

2. The article of footwear according to claim 1, wherein the central cavity is a through hole, and upper and lower surfaces of the midsole core are exposed within the central cavity.

3. The article of footwear according to claim 2, wherein the upper surface of the midsole core is flush with the outer shell body and the inner shell body, or the lower surface of the midsole core is flush with the outer shell body and the inner shell body, or both the upper surface and the lower surface of the midsole core are flush with the outer shell body and the inner shell body.

4. The article of footwear according to any one of claims 1-3, wherein the outer shell body and the inner shell body define a plurality of through holes exposing the outer and inner side surfaces of the midsole core.

5. The article of footwear according to claim 4, wherein at least one of the inner shell body or the outer shell body has an inner side and an outer side, at least one of the plurality of through holes extends from the inner side to the outer side, and the midsole core extends across at least one of the plurality of through holes at the inner side.

6. The article of footwear according to any one of claims 1-5, wherein: the outer shell body has a front bonding surface in front of the midsole core; the inner shell body has a front bonding surface in front of the midsole core, and the front bonding surface of the inner shell body abuts and is coupled to the front bonding surface of the outer shell body. The outer shell body has a rear joining surface behind the midsole core; and The inner shell body has a rear joining surface behind the midsole core, and the rear joining surface of the inner shell body is adjacent to and joined to the rear joining surface of the outer shell body.

7. The footwear item according to claim 6, wherein the front joining surface of the outer shell body, the front joining surface of the inner shell body, the rear joining surface of the outer shell body, and the rear joining surface of the inner shell body extend in the longitudinal direction of the footwear item.

8. The footwear item according to any one of claims 1-7, further comprising: An outsole that extends across and is fixed to the lower surface of the midsole core, the lower surface of the outer shell body, and the lower surface of the inner shell body.

9. The footwear item according to any one of claims 1-8, further comprising: A heel stabilizer that is fixed to the upper surfaces of the outer shell body and the inner shell body in the heel region of the footwear item.

10. The footwear item according to any one of claims 1-9, wherein the midsole core comprises recycled foam blocks and a resin binder coating the recycled foam blocks.

11. The footwear item according to claim 10, wherein the midsole core further comprises a dye mixed in the resin binder.

12. A manufacturing method for manufacturing the footwear item according to any one of claims 1-11, the manufacturing method comprising: Receiving a waste foam body; Cutting the waste foam body into blocks; Mixing the blocks with a resin binder to form a mixture; and Compression molding the mixture in a mold to form a cushioning member of the sole structure of the footwear item.

13. The manufacturing method according to claim 12, further comprising: Before compression molding the mixture in the mold: Drying the mixture; and Pouring the mixture into the mold.

14. The manufacturing method according to any one of claims 12-13, further comprising: Adding a dye to the mixture before mixing the blocks with the resin binder.

15. The manufacturing method according to any one of claims 12-14, wherein the cushioning member is a midsole core, and the method further comprising: Joining an inner shell body to the inner side surface of the midsole core and joining an outer shell body to the outer side surface of the midsole core, such that the inner shell body and the outer shell body form an outer shell defining a central cavity, wherein the midsole core is disposed in the central cavity.

16. The manufacturing method according to claim 15, wherein joining the inner shell body to the inner side surface of the midsole core includes applying an adhesive to the inner shell body, applying an adhesive to the inner side surface of the midsole core, and pressing the inner shell body against the inner side surface of the midsole core; The step of joining the outer shell body to the outer side of the midsole core includes applying an adhesive to the outer shell body, applying an adhesive to the outer side of the midsole core, and pressing the outer shell body against the outer side of the midsole core.

17. The manufacturing method according to any one of claims 15-16, further comprises: Before pressing the inner shell body against the inner side of the midsole core and pressing the outer shell body against the outer side of the midsole core, aligning the inner shell body and the outer shell body with the midsole core by mating the alignment features of the inner shell body and the alignment features of the outer shell body with the complementary alignment features of the midsole core.

18. The manufacturing method according to any one of claims 15-17, further comprises: Attaching an outsole to the lower surfaces of the midsole core, the outer shell body, and the inner shell body.

19. The manufacturing method according to any one of claims 15-18, further comprises: In the heel region of the footwear article, attaching a heel stabilizer to the upper surfaces of the outer shell body and the inner shell body.

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