(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2013/0126075 A1
`
`
` Jiang (43) Pub. Date: May 23, 2013
`
`US 20130126075A1
`
`(54) CO-MOLDED SOLE
`
`Publication Classification
`
`(71) Applicant: Columbia Sportswear North America,
`Inc., Portland, OR (US)
`
`(72)
`
`Inventor: Wei Yi Jiang, Zhuhai City (CN)
`
`(73) Assignee: COLUMBIA SPORTSWEAR
`NORTH AMERICA, INC., Portland,
`OR (US)
`
`.
`(21) Appl. NO" 13/679,880
`(22)
`Filed:
`Nov. 16, 2012
`
`Related US. Application Data
`
`(60) Provisional application No. 61/561,740, filed on Nov.
`18, 2011.
`
`(51)
`
`Int. Cl.
`329C 65/02
`(52) U.S. Cl.
`CPC ...................................... B29C 65/02 (2013.01)
`USPC ........................................... 156/219; 156/581
`
`(2006.01)
`
`(57)
`
`ABSTRACT
`
`Embodiments herein provide a eo-molded sole for footwear,
`such as athletic shoes. Embodiments also provide a mold for
`manufacturing the eo-molded sole. In various embodiments,
`the eo-molded sole may include an outsole and a midsole. The
`outsole may be composed of an outsole material, and the
`midsole may be composed of a midsole material. The outsole
`and midsole may be eo-molded together to form a unitary
`piece by the mold. The mold may include a lower plate, a
`middle plate, and an upper plate.
`
`
`
`, 126‘
`
`
`
`Skechers U.S.A., Inc. v. Nike, Inc.
`Skeehers USA, Inc. v. Nike, Inc.
`IPR2021-00159
`IPR2021-00159
`Patent No. 10,098,412
`Patent No. 10,098,412
`Ex. 2010
`
`Ex. 2010
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`mesa #”
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`13:3 4
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`Figure 1A
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`218»
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`Piece me or more partisans 0i euteeie meteriei in
`patterned eeriien 0i iewer pieie ei maid
`
`Lower middie piete and upper pieie ei meld on to
`iee e'i iewei’ pieie
`
`Piece maid in first eempreeeien even ie eppiy
`heat endler pressure ie meid end/er eeiseie
`meieriei
`
`Remove meid frem first eeriipreseien everi and
`eiiew to ceei
`
`
`
`Liii upper pieie and middie piaie and dean
`excess outseie maieriei from meid
`
`Lewei' middie piete, and insert bieci: 0i midseie
`maieriei into epening 0i middie piate on top of
`the eeiseie
`
`Lewer upper pia‘ie and piece meici in eeeend
`eempressien even ie eppiy heet end/er pressure
`is meid end/er mideeie meieriei
`
`Remeve seie irem meid and trim excess maieriai
`
`Remove meici from second compressien ever:
`and eiiew ie (2005
`
`
`around edges ef seie
`EX. 2010 - Page 4
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`Figure 3A
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`-_ f 332::
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`fi 3306
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`mew
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`“NE“.
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`US 2013/0126075 A1
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`May 23, 2013
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`CO-MOLDED SOLE
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`[0001] The present application claims priority to U.S. Pro-
`visional Patent Application No. 61/561,740, filed Nov. 18,
`2011, entitled “CO-MOLDED SOLE,” the entire disclosure
`of which is hereby incorporated by reference.
`
`TECHNICAL FIELD
`
`[0002] Embodiments herein relate to the field of footwear,
`and, more specifically, to footwear with molded soles.
`
`BACKGROUND
`
`[0003] Many types of footwear, such as athletic shoes,
`include soles having an outsole and a midsole. The outsole is
`typically made of a relatively harder material than the midsole
`to provide durability and traction. The midsole is typically
`softer to provide cushioning and support to the user.
`[0004]
`In a shoe manufacturing plant, the outsole and mid-
`sole are formed using separate molds. The outsole is then
`attached to the midsole by an adhesive. The various steps
`involved in manufacturing the shoe increase the time and
`complexity of the process. Additionally, the manufacturing
`process requires precise alignment of the outsole with the
`midsole. This can be even more complex with soles including
`a non-continuous outsole that includes multiple pieces. Fur-
`thermore, the adhesive between the outsole and midsole is
`often an area of structural weakness for the sole.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0005] Embodiments will be readily understood by the fol-
`lowing detailed description in conjunction with the accom-
`panying drawings and the appended claims. Embodiments
`are illustrated by way of example and not by way of limitation
`in the figures of the accompanying drawings.
`[0006]
`FIG. 1A illustrates an exploded view of a mold for
`manufacturing a co-molded sole, including a lower plate, a
`middle plate, and an upper plate in accordance with various
`embodiments;
`[0007]
`FIG. 1B illustrates a perspective view ofthe mold of
`FIG. 1A with the plates ofthe mold closed in accordance with
`various embodiments;
`[0008]
`FIG. 2 illustrates a flow diagram of a method of
`manufacturing a co-molded sole in accordance with various
`embodiments;
`[0009]
`FIG. 3A illustrates a partial top view of a lower plate
`of a mold with outsole pieces placed in respective outsole
`locations on a patterned portion of the lower plate in accor-
`dance with various embodiments;
`[0010]
`FIG. 3B illustrates a partial top view of the lower
`plate of FIG. 3A with the middle plate in a lowered (closed)
`position, and with a midsole block placed in a right opening of
`the middle plate, in accordance with various embodiments;
`[0011]
`FIG. 4A illustrates a bottom view of a co-molded
`sole in accordance with various embodiments; and
`[0012]
`FIG. 4B illustrates a top perspective view of the
`co-molded sole of FIG. 4A in accordance with various
`embodiments.
`
`DETAILED DESCRIPTION OF DISCLOSED
`EMBODIMENTS
`
`In the following detailed description, reference is
`[0013]
`made to the accompanying drawings which form a part
`hereof, and in which are shown by way ofillustration embodi-
`ments that may be practiced. It is to be understood that other
`embodiments may be utilized and structural or logical
`changes may be made without departing from the scope.
`Therefore, the following detailed description is not to be
`taken in a limiting sense, and the scope of embodiments is
`defined by the appended claims and their equivalents.
`[0014] Various operations may be described as multiple
`discrete operations in tum, in a manner that may be helpful in
`understanding embodiments; however, the order of descrip-
`tion should not be construed to imply that these operations are
`order dependent.
`[0015] The description may use perspective-based descrip-
`tions such as up/down, back/front, and top/bottom. Such
`descriptions are merely used to facilitate the discussion and
`are not
`intended to restrict
`the application of disclosed
`embodiments.
`
`[0016] The terms “coupled” and “connected,” along with
`their derivatives, may be used. It should be understood that
`these terms are not intended as synonyms for each other.
`Rather, in particular embodiments, “connected” may be used
`to indicate that two or more elements are in direct physical or
`electrical contact with each other. “Coupled” may mean that
`two or more elements are in direct physical or electrical
`contact. However, “coupled” may also mean that two or more
`elements are not in direct contact with each other, but yet still
`cooperate or interact with each other.
`[0017]
`For the purposes of the description, a phrase in the
`form “NB” or in the form “A and/or B” means (A), (B), or (A
`and B). For the purposes of the description, a phrase in the
`form “at least one ofA, B, and C” means (A), (B), (C), (A and
`B), (A and C), (B and C), or (A, B and C). For the purposes of
`the description, a phrase in the form “(A)B” means (B) or
`(AB) that is, A is an optional element.
`[0018] The description may use the terms “cmbodimcnt” or
`“embodiments,” which may each refer to one or more of the
`same or different embodiments. Furthermore,
`the terms
`“comprising,” “including,” “having,” and the like, as used
`with respect to embodiments, are synonymous, and are gen-
`erally intended as “open” terms (e.g., the term “including”
`should be interpreted as “including but not limited to,” the
`term “having” should be interpreted as “having at least,” the
`term “includes” should be interpreted as “includes but is not
`limited to,” etc.).
`[0019] With respect to the use of any plural and/or singular
`terms herein, those having skill in the art can translate from
`the plural to the singular and/or from the singular to the plural
`as is appropriate to the context and/or application. The vari-
`ous singular/plural permutations may be expressly set forth
`herein for sake of clarity.
`[0020]
`In various embodiments, methods, apparatuses, and
`systems for a co-molded sole and a mold for making a co-
`molded sole are provided.
`[0021] Embodiments herein provide a co-molded sole for
`footwear, such as athletic shoes. Embodiments also provide a
`mold for manufacturing the co-molded sole and a method of
`using the mold to manufacture the co-molded sole. In various
`embodiments, the co-molded sole may include an outsole and
`a midsole. The outsole may be composed of an outsole mate-
`rial, and the midsole may be composed of a midsole material.
`
`EX. 2010 - Page 9
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`In some embodiments, the outsole material may be different
`from the midsole material. For example, in some embodi-
`ments, the midsole material may include a thermoplastic,
`such as ethylene Vinyl acetate (EVA), modified EVA, and/or
`polyolefin. The outsole material may include a thermoplastic,
`thermoplastic rubber, synthetic rubber, natural rubber and/or
`a thermoplastic/rubber compound.
`[0022]
`In various embodiments, the outsole and midsole
`may be co-molded together to form a unitary piece. The
`co-molding may permanently couple the midsole with the
`outsole while at the same time molding the midsole and/or
`outsole into the desired shape. In some embodiments, the
`co-molding may bond and/or fuse the outsole material with
`the midsole material to form a unitary piece without the use of
`an adhesive between the outsole and midsole.
`In other
`
`embodiments, an adhesive (e.g., an adhesive film or other
`adhesive) may be disposed between the midsole and outsole
`as a bonding interface.
`[0023] The term “co-molded” as used herein may generally
`refer to one or more applications of molding, sculpting, cut-
`ting, carving, casting, and/or injecting of adjoining multiple
`layers, thereby combining the layers to form a unitary piece.
`The co-molding may also shape one or more of the adjoining
`multiple layers. The term unitary piece refers to a self-con-
`tained single object, which may include multiple layers per-
`manently bonded and/or fused together.
`[0024]
`In some embodiments, the outsole may be non-
`continuous and may include multiple outsole portions
`arranged on a bottom surface of the midsole and separated
`from one another. In these embodiments, the multiple outsole
`portions may be of the same material or different materials.
`Similarly, the multiple outsole portions may have the same or
`different material properties, such as hardness and/or density.
`In other embodiments, the outsole may be a single continuous
`piece of material. The material properties of the continuous
`piece of material may be the same or may vary over different
`portions of the continuous piece of material.
`[0025]
`In various embodiments, the mold may include a
`lower plate, a middle plate, and an upper plate. In some
`embodiments, the lower plate, middle plate, and/or upper
`plate may be coupled to each other by one or more hinges,
`thereby allowing the middle plate and’or upper plate to rotate
`with respect to the lower plate (e.g., a “clamshell” arrange-
`ment). In some embodiments, the middle plate and upper
`plate may be coupled to the lower plate by the same hinge. In
`other embodiments, one hinge may be used to couple the
`middle plate to the lower plate, and a separate hinge may be
`used to couple the upper plate to the middle plate.
`[0026] When the mold is in a closed position, the lower
`plate, middle plate and upper plate may be substantially par-
`allel to and adjacent to one another. In various embodiments,
`the middle plate may be said to be in a closed position when
`the middle plate is disposed on top ofthe lower plate, whether
`or not the upper plate is open or closed. The mold may be
`opened by lifting the upper plate and/or the middle plate,
`thereby rotating the upper plate and/or middle plate about the
`hinge or other coupling with respect to the lower plate. In
`various embodiments, the mold may include one or more
`handles or other structures to facilitate opening, closing, and/
`or transporting the mold.
`[0027]
`In various embodiments, the lower plate ofthe mold
`may include a first pattemedportion in an upper surface ofthe
`lower plate. The first patterned portion may have a surface
`that is used to shape a bottom surface ofthe sole formed by the
`
`mold (i.e., the first patterned portion may correspond to the
`shape of the bottom surface of the sole).
`[0028] The middle plate may include a body portion and an
`opening having a cross-sectional shape that corresponds to a
`cross-sectional shape ofthe sole. The opening may be defined
`by a side wall. In some embodiments, at least a portion of the
`side wall may be patterned to mold a side surface of the sole
`with a desired shape.
`[0029] The upper plate may include a protruding portion
`that extends at least partially into the opening in the middle
`plate when the mold is closed. The protruding portion may
`include a cross-sectional shape that is similar to the cross-
`sectional shape in the opening in the middle plate, but slightly
`smaller than the cross-sectional shape ofthe opening to allow
`the protruding portion to enter the opening when the mold is
`closed. In some embodiments, a lower surface of the upper
`plate may be shaped to mold an upper surface of the sole into
`a desired shape.
`[0030] The mold may include any suitable materials, such
`as aluminum and/or steel. In some embodiments, aluminum
`may be used to provide increased thermal conductivity com-
`pared with steel. In some such embodiments, the mold may be
`casted with an aluminum alloy, such as Aluminum-Magne-
`sium (Alng) alloy and/or Aluminum-Copper (Al%u)
`alloy, which may allow the mold to withstand high pressure
`and/or high temperature. This may increase the durability o
`the mold compared with a mold made only of aluminum. In
`other embodiments, the mold may be made of steel, which
`may provide increased stiffness and/or durability comparec
`with aluminum, but with reduced heat-conductivity.
`[0031]
`In some embodiments, the mold may be configurec
`to form both left and right soles (e.g., for left and right feet).
`In these embodiments, the lower plate may include left anc
`right patterned portions, the middle plate may include left anc
`right openings, and the upper plate may include left and righ
`protruding portions. In other embodiments, separate molds
`may be used to form the left and right soles.
`[0032]
`In various embodiments, the same mold may be
`used to shape the outsole, shape the midsole, and to co-molc
`the outsole to the midsole to form a unitary piece. Using the
`single mold simplifies the process of manufacturing the soles
`compared with using separate molds to form the outsole anc
`the midsole and then adhering the outsole to the midsole, such
`as using an adhesive. Furthermore,
`the mold may lower
`manufacturing costs, facilitate alignment between the outsole
`and the midsole, and/or create a stronger bond between the
`outsole and the midsole. In some embodiments, the mold may
`co-mold the outsole directly to the midsole (e. g., without an
`adhesive layer between the outsole and the midsole). In other
`embodiments, an adhesive layer may be placed between the
`outsole and the midsole to facilitate co-molding ofthe outsole
`to the midsole.
`
`
`
`FIGS. 1A and 1B show a mold 100 in accordance
`[0033]
`with various embodiments. FIG. 1A shows an exploded view
`of mold 100, and FIG. 1B shows mold 100 in a closed posi-
`tion. Mold 100 includes a lower plate 102, a middle plate 104,
`and an upper plate 106. Mold 100 is configured to make both
`left and right soles (e.g., for left- and right-footed shoes). In
`other embodiments, mold 100 may be configured to make
`only a left or right sole.
`[0034] Lower plate 102 includes a left patterned portion
`108a and a right patterned portion 1081). Middle plate 104
`includes a left opening 110a having a side wall 112a and a
`right opening 110!) having a side wall 11219. The cross-sec-
`
`EX. 2010 - Page 10
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`tional shape of the openings 110a-b is substantially similar to
`the shape of the border of the respective patterned portion
`108a-b. Upper plate 106 includes a left protruding portion
`114a and a right protruding portion 114b extending from a
`lower surface 116 ofupperplate 106. The protruding portions
`114a-b may include bottom surfaces 118a-b.
`[0035]
`Protruding portions 114a-b may have a cross-sec-
`tional shape that corresponds to the cross-sectional shape of
`the respective opening 110a-b in middle plate 104. For
`example, the cross-sectional shape of the protruding portions
`114a-b may be similar, but slightly smaller than, the cross-
`sectional shape of the respective opening 110a-b in middle
`plate 104. This may allow the protruding portions 114a-b to
`extend through at least a portion of the respective opening
`110a-b when the mold 100 is closed to exert pressure on a
`material disposed on the patterned portions 108a-b of the
`lower plate 102. In some embodiments, the upper plate 106
`may further include protruding portions 120a-b that extend
`from an upper surface 122 ofupper plate 106. The protruding
`portions 120a-b may facilitate pressure to be exerted on mate-
`rial placed in the mold (e. g., on patterned portions 108a-b).
`[0036] Middle plate 104 and upper plate 106 are coupled to
`lower plate 102 by a hinge 124, allowing middle plate 104
`and/or upper plate 106 to be rotated with respect to lower
`plate 102 about hinge 124. When the mold 100 is in a closed
`position (as shown in FIG. 1B), the lower plate 102, middle
`plate 104, and upperplate 106 are substantially parallel to one
`another, with the middle plate 104 in contact with the lower
`plate 102, and the upper plate 106 in contact with the middle
`plate 104. The mold 102 may be opened by lifting the upper
`plate 106 and/or the middle plate 104, thereby rotating the
`upper plate 106 and/or middle plate 104 with respect to the
`lower plate 102. The middle plate 104 includes handles 126,
`and the upper plate 106 includes handles 128, to facilitate
`opening and/or closing of the mold 100.
`[0037]
`FIG. 2 illustrates a method 200 of using the mold
`described herein (e.g., mold 100) to form a sole in accordance
`with various embodiments. At 202, with the upper plate ofthe
`mold open, one or more portions of outsole material (referred
`to as outsole portions) are placed in designated locations of
`the patterned portions on the lower plate. For example, FIG.
`3A shows a portion of a lower plate 302 while in the process
`of operation 202 of method 200. Lower plate 302 includes a
`left patterned portion 308a with outsole locations 330a-i.
`FIG. 3A shows outsole portions 332a-e in respective outsole
`locations 330a-e and outsole locations 330fli empty. Other
`outsole portions are placed in outsole locations 330f-i as part
`of operation 202 of method 200.
`[0038] The outsole locations 3300-1’ may be defined by
`ridges 334. Ridges 334 may also form a dam between the
`outsole and the midsole, as further discussed below. The
`outsole material may be any suitable material, such as rubber.
`Additionally, the outsole portions 332a-e may be of any suit-
`able color or colors. In some embodiments, one or more ofthe
`outsole portions 332a-e may be substantially clear in color
`(transparent, translucent, etc.). The outsole portions 332a-e
`may be preformed into a suitable shape to be placed in des-
`ignated locations 330a-e of patterned portion 308a.
`[0039]
`In some embodiments, a contrasting material may
`be inserted in one or more designated locations of the pat-
`terned portion. The designated locations for the contrasting
`material may mold the contrasting material into any desirable
`shape, such as a word, logo, and/or other design. The con-
`trasting material may generally be a different color than a
`
`surrounding material on the sole. Pressure may be applied to
`press the contrasting material into the designated location,
`and excess contrasting material may be wiped away. An out-
`sole portion may then be placed on top of the contrasting
`material (e.g., if the contrasting material is in an outsole
`location 330a-i).
`[0040]
`In other embodiments, the sole may not include a
`contrasting material, and these aspects of method 200 may
`not be included.
`
`[0041] At 204 of method 200, the mold is closed (e.g., the
`upper plate is lowered on to top of the middle plate and lower
`plate as shown in FIG. 1B). At 206, the mold is placed in a
`compression oven. The compression oven may apply heat
`and/or pressure to the outsole portions. For example, the
`compression oven may apply a first set of curing conditions,
`e.g., pressure, temperature, and/or duration to the outsole
`portions. The heat and/or pressure may cause the outsole
`portions to conform to the shape of patterned portions of the
`mold and/or may cause the outsole material to cure.
`[0042] The first set of curing conditions may be selected
`based on the outsole material used, characteristics of the
`mold, and/or other considerations. For example,
`in one
`embodiment, the curing duration for the outsole may be about
`4 minutes. In some embodiments, the pressure applied by
`compression oven 124 may be about 60 to about 150 kg/cmz,
`such as about 110 to about 120 kg/cmz. In some embodi-
`ments, a lower pressure may be used (e. g., about 110 to about
`120 kg/cm2 or lower) than a normal curing pressure for rubber
`(e.g., about 140 to about 150 kg/cmZ). The lower pressure
`may increase the usable life- span ofthe mold and/or allow use
`of an aluminum mold. In some embodiments, the outsole
`material (e.g., the type of rubber) may be selected to account
`for the lower pressure. Additionally,
`the mold may be
`designed to release air to facilitate flow ofthe outsole material
`during molding. The temperature subjected to the mold by the
`compression oven may be about 150 to about 180 degrees
`Celsius, such as about 160 to about 170 degrees Celsius. A
`higher temperature may facilitate molding of the outsole
`material by the mold.
`[0043] After the outsole material and/or mold is/are sub-
`jected to the first curing conditions, the mold is removed, at
`208, from the compression oven and the outsole material is
`allowed to cool. In some embodiments, excess outsole mate-
`rial may have spread beyond the designated outsole locations
`of the lower plate and/or onto the middle plate and/or upper
`plate. Accordingly, at 210, excess outsole material may be
`cleaned from the mold. For example, the excess material may
`be wiped off, such as with a cloth and/or a scraping tool.
`[0044] Thereafter, at 212, with the middle plate in the
`closed position (e.g., lowered on top of the lower plate) and
`the upper plate open, a block of midsole material is placed in
`the openings in the middle plate. For example, FIG. 3B illus-
`trates a portion of lower plate 302 and middle plate 304 while
`in the process of operation 212 of method 200. Middle plate
`304 includes openings 310a and 310b. A midsole block 336 is
`disposed in opening 310b of middle plate 306, while opening
`310a of middle plate 306 does not yet have a midsole block
`placed therein. FIG. 3B further shows outsole portions 332a-i
`after being molded as described above. A midsole block is
`also placed in the opening 310a ofmiddle plate 304 as part of
`operation 212.
`[0045] The blocks of midsole material (e.g., block 336)
`may be roughly shaped to fit in one or both of openings
`310a-b. The midsole material may be any suitable material,
`
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`such as EVA. In some embodiments, the block of midsole
`material may be formed by fluid posting and/or another suit-
`able method.
`
`In some embodiments, the midsole block may be
`[0046]
`placed directly on top of the outsole portions on the lower
`plate. In other embodiments, an adhesive, such as an adhesive
`film, may be placed between the outsole material and the
`block of midsole material.
`
`[0047] At 214, after midsole blocks are placed in the open-
`ings ofthe middle plate, the upper plate is lowered to close the
`mold. The mold is then placed in a compression oven. The
`compression oven may be the same machine and/or a differ-
`ent machine from the compression oven used in operation
`206. The compression oven may apply a second set of curing
`conditions (e.g., pressure, temperature, and/or duration) to
`the midsole block and/or outsole pieces as part of operation
`214. In some embodiments, the second set of curing condi-
`tions may be different from the first set of curing conditions.
`In other embodiments, the second set of curing conditions
`may be the same as the first set of curing conditions. In one
`embodiment, the temperature and pressure of the second set
`of curing conditions may be the same as the temperature and
`pressure of the first set of curing conditions, and the curing
`duration of the second set of curing conditions may be longer
`than the curing duration of the first set of curing conditions.
`For example, the curing duration of the second set of curing
`conditions may be about 5 minutes to about 8 minutes, such as
`about 6 minutes.
`
`[0048] The heat and/or pressure of the second set of curing
`conditions causes the midsole block to conform to the shape
`ofthe side walls of middle plate (e.g., side walls 112a-b of
`middle plate 104 shown in FIG. 1A) and/or the bottom sur-
`faces of the protruding portions of upper plate (e.g., the bot-
`tom portions 118a-b of protruding portions 114a-b shown in
`FIG. 1A). Also, if there are exposed portions of the patterned
`portions of the lower plate (e.g., if the outsole does not cover
`the all of the patterned portions), the midsole block may
`conform to the shape of the exposed portions of the patterned
`portions on the lower plate. Additionally, the heat and/or
`pressure may co-mold the midsole block to the outsole por-
`tions. The co-molding may cause the midsole block to
`become permanently coupled (e.g., bonded and/or fused)
`with the outsole portions.
`[0049] After the midsole material, outsole material, and/or
`mold is subjected to the second curing conditions, the mold is
`removed from the compression oven, at 216, and allowed to
`cool. In some embodiments, the mold may be placed in a
`cooling chamber to cool. Additionally, or alternatively, the
`mold may be cooled by circulating fluid (e.g., water) through
`a cooling structure built into the mold. In yet other embodi-
`ments, fluid (e.g., water) may be sprayed on the mold until the
`mold, midsole material, and/or outsole material reaches a
`desired temperature. For example, the mold may be placed in
`a cooling station and water may be sprayed on the mold for
`about 7 to about 10 minutes.
`
`[0050] After cooling, at 218, the mold may be opened and
`the sole may be removed. There may be excess portions ofthe
`midsole material and/or outsole material around the edges of
`sole. In that case, the excess portions may be trimmed.
`[0051]
`In other embodiments, the outsole pieces and mid-
`sole block may be shaped and co-molded together in a single
`molding/curing step. That is, the one or more outsole portions
`may be placed in the patterned portion of lower plate, and the
`midsole block may be placed on top of the outsole portions.
`
`The mold may then be closed and placed in a compression
`oven to apply heat and/or pressure to the mold, outsole por-
`tions, and/or midsole block. The outsole portions and/or mid-
`sole block may be shaped by the patterned portions of the
`lower plate, the side walls of the middle plate, and/or the
`protruding portions of the upper plate. Additionally, the mid-
`sole block may bond and/or fuse with the outsole portions to
`form a unitary piece.
`[0052]
`In some embodiments in which the midsole is co-
`molded to the outsole without an adhesive layer between the
`midsole and the outsole, the outsole material and/or midsole
`material may have material properties selected to facilitate
`the co-molding without an adhesive. For example, the outsole
`material may be a rubber having a hardness of about 50 Shore
`A (50A) to about 75A, or more specifically about 60A to
`about 70A. The midsole material may be EVA having a hard-
`ness of about 45 Asker C to about 75 Asker C, such as about
`60 Asker C. The hardness of the midsole material may facili-
`tate applying pressure from the midsole material to the out-
`sole material to facilitate bonding between the midsole mate-
`rial and the outsole material.
`
`FIGS. 4A and 4B show a co-molded sole 400 in
`[0053]
`accordance with various embodiments. Sole 400 may be
`formed by method 200. The co-molded sole 400 is for a
`left-footed shoe. Co-molded sole 400 includes a discontinu-
`ous outsole 440 including a plurality of outsole portions
`442a-i. Sole 400 further includes a midsole 444 that is
`
`coupled to the outsole portions 442a-I by co-molding, as
`described herein.
`
`[0054] As shown in FIG. 4A, the separate outsole portions
`442a-i do not collectively cover a bottom surface 446 of the
`sole 400 entirely. Accordingly, the midsole 444 makes up a
`portion of the bottom surface 446. In other embodiments, the
`outsole 440 may be continuous and/or may substantially
`cover the entire bottom surface 446 of the sole 400.
`
`[0055] The sole 400 further includes a dam 450 that borders
`the outsole portions 442a-i and is recessed from the surface of
`midsole 444. In some embodiments, the dam 450 may have a
`depth (the distance from the surface of midsole 444 to the
`bottom of dam 450) and a width (the distance the dam 450
`extends from the edges of outsole 440). In some embodi-
`ments, the depth of the dam 450 may be about 1 to about 3
`millimeters (m), such as about 1.5 mm. The width of the
`dam 450 may be about 1 to about 2 m, such as about 1.5 mm.
`Dam 450 may prevent/reduce the color of outsole 440 from
`bleeding onto the surface of the midsole 444 beyond the dam
`450. Dam 450 may be formed by ridges (e.g., ridges 334
`shown in FIG. 3A) in the patterned portions ofthe lower plate
`around the designated outsole locations. Other embodiments
`may not include a dam or may include a dam ofreduced width
`and/or depth.
`[0056] The outsole 440 and/or midsole 444 may also
`include a sidewall parting line 452 at the edges of sole 400.
`The sidewall parting line 452 of the outsole 440 and/or mid-
`sole 444 may be substantially smooth and/or straight to facili-
`tate trimming of excess material around the edges of sole 400.
`[0057] As shown in FIG. 4B, the midsole 444 includes sides
`454 that are shaped by the middle plate of the mold (e.g., side
`wall 112a of middle plate 104 shown in FIG. 1A). Midsole
`444 further includes an upper surface 456 that is shaped by the
`protruding portion of the upper plate of the mold (e.g., pro-
`truding portion 11411 of upper plate 106 shown in FIG. 1A).
`[0058] Although embodiments herein have been described
`using a mold to co-mold a midsole and an outsole, the meth-
`
`EX. 2010 - Page 12
`
`EX. 2010 - Page 12
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`

`

`US 2013/0126075 A1
`
`May 23, 2013
`
`ods and apparatuses described herein may be used to co-mold
`any two or more layers of material. In some embodiments, a
`third element, such as a hard plastic shank, may be co-molded
`together with the midsole and the outsole.
`[0059] Although certain embodiments have been illus-
`trated and described herein, it will be appreciated by those of
`ordinary skill in the art that a wide variety of alternate and/or
`equivalent embodiments or implementations calculated to
`achieve the same purposes may be substituted for the embodi-
`ments shown and described without departing from the scope.
`Those with skill in the art will readily appreciate that embodi-
`ments may be implemented in a very wide variety of ways.
`This application is intended to cover any adaptations or varia-
`tions of the embodiments discussed herein. Therefore, it is
`manifestly intended that embodiments be limited only by the
`claims and the equivalents thereof.
`What is claimed i