Patent ID: 8747711
Filing Date: 2014-06-10
Classification: B29C,B29D,B29K,B29L

Abstract:
1. A method of forming a sole assembly with a mold assembly comprising the steps of: using a top plate having a bottom surface; a middle plate positioned beneath the top plate and having a top surface and a bottom surface, the bottom surface of the top plate and the top surface of the middle plate cooperating to define an upper recess therebetween; and a bottom plate positioned beneath the middle plate and having a top surface, the top surface of the bottom plate and the bottom surface of the middle plate cooperating to define a lower recess therebetween; wherein the bottom surface of the top plate and the top surface of the bottom plate are configured such that when the top plate and bottom plate are in contact with one another they cooperate to define a sole recess, the sole recess having a volume that is larger than a volume of the upper recess and a volume of the lower recess combined: preheating the bottom plate, middle plate, and top plate; placing a quantity of rubber in a first portion of the lower recess; placing the lower surface of the middle plate in contact with the upper surface of the bottom plate, and the lower surface of the upper plate in contact with the upper surface of the middle plate; subjecting the top plate, middle plate, and bottom plate to heat to semi-cure the rubber in the lower recess to form an outsole member; separating the top plate, the middle plate, and the bottom plate; placing the lower surface of the top plate in contact with the upper surface of the bottom plate, wherein a quantity of a polyolefin forming a midsole member is in the sole recess above the semi-cured rubber; and subjecting the top plate and bottom plate to heat such that the polyolefin expands within the sole recess and the polyolefin and rubber in the sole recess fully cure, cross-link, and bond to one another to form a sole assembly for an article of footwear; cooling the top plate and the bottom plate; and removing the top plate from the bottom plate and removing the sole assembly from the sole recess.