Method of manufacturing an article of footwear having a direct attach sole component

A method of manufacturing an article of footwear having a direct attach sole component includes providing an upper and a receptacle shell that defines a receptacle adapted to receive a cushion insert. A molding insert is placed into the receptacle, and the upper is joined with the receptacle shell. A mold is closed about the receptacle shell and at least a portion of the upper to form a mold cavity corresponding to the direct attach sole component. Material is introduced into the mold cavity to form the direct attach sole component. The mold insert protects the shell from deformation during the molding process. The mold insert is removed and replaced with a cushioning insert after the molding process. The footwear can optionally include a partially transparent shell that supports a sole component that receives a cushion insert, such that the cushion insert and/or sole component are visible through the shell.

BACKGROUND OF THE INVENTION

The present invention relates to footwear and, more particularly, to an adjustable footwear sole construction and method for making the same.

The design and manufacture of footwear is complicated by the fact that different people have different footwear needs. For example, some individuals prefer a firmer, more unyielding sole, while others prefer a softer, more cushioning sole. With some people this is simply an aesthetic desire, but for others it can result from physical factors, such as those associated with foot shape, skeletal alignment and other anatomical issues. Anatomical issues cause some individuals to suffer from a tendency to pronate (roll their feet inward when striding) and others to have the opposite tendency to supinate (roll their feet outward when striding). One method for addressing these issues is to stiffen the sole in select regions to provide increased resistance against the undesired motion. For example, pronation can be addressed by providing a dual-density midsole with a higher density region along the medial side of the sole. Similarly, supination can be addressed by providing a dual-density midsole with a higher density region along the lateral side of the sole.

In an effort to address the needs of different consumers, a variety of footwear products have been developed with a customizable sole construction. For example, in some products, the sole defines a void or receptacle adapted to receive one of a variety of different cushioning inserts, or a single insert having differing cushioning characteristics depending on the position of the insert in the receptacle. The wearer customizes the sole based on the wearer's individual cushioning and support needs by either inserting the appropriate cushioning insert into the receptacle or rotating the single insert to the desired position. A type of cushioning insert configuration is described in U.S. Patent Publication 2008/0289219, which is hereby incorporated herein by reference in its entirety.

There is also an ongoing effort in the footwear industry to produce footwear that provides both durability and flexibility. Many conventional footwear constructions, however, focus on either durability or flexibility—but usually not both—because the features providing these characteristics typically compete against one another. One construction that is known for flexibility is a direct attach construction, which can include a flexible polyurethane midsole that is direct attached to an upper. The direct attach construction also provides a secure connection between the midsole and the upper and eliminates the need for cement or a welt. One typical method for manufacturing a direct attach construction includes arranging the upper over a last and adding a sole board adjacent a bottom surface of the last to provide a molding surface. The assembly is then placed in a mold so that the midsole material can be molded in place directly onto the sole board and upper.

While the customizable sole and the direct attach constructions are both desirable, it is difficult to combine the two constructions in one piece of footwear.

SUMMARY OF THE INVENTION

One aspect of the present invention provides a method of manufacturing an article of footwear including the steps of joining a receptacle shell with an upper, filling the shell with a molding insert and molding a sole component directly to the shell.

According to one embodiment, a method of manufacturing an article of footwear having a direct attach sole component includes: (a) providing an upper and a receptacle shell that forms a receptacle adapted to receive an insert; (b) placing a molding insert into the receptacle; (c) arranging the upper about a last adapted to engage the receptacle shell and joining the upper with the receptacle shell; (d) closing a mold about the receptacle shell and at least a portion of the upper to form a mold cavity corresponding to the direct attach sole component; and (e) introducing a material into the mold cavity to form the direct attach sole component.

Optionally, the receptacle shell can have a contoured interface surface that directly corresponds with an interface surface on the molding insert. The molding insert can be formed from a relatively hard material that maintains the shape of the receptacle shell when the material is introduced into the mold cavity. After the direct attach sole component is formed, the molding insert can be removed and replaced with a cushion insert, which can be formed from a softer material than that used to form the molding insert.

According to another embodiment, the method includes arranging an upper about a last that has at least one projection that corresponds to the shape of the receptacle in the receptacle shell. The projection can be adapted to interfit with the receptacle, such that a separate molding insert is not required.

According to yet another embodiment, the mold can include at least one protrusion, and the method can include engaging the receptacle shell with the protrusion while the material is introduced into the mold cavity to prevent the material from engaging the receptacle shell in select locations. When the protrusions are separated from the direct attach sole component, windows or openings are left in the sole component.

Another aspect of the invention provides a shell that includes a transparent portion, such that portions of an edge of a cushion insert and/or a sole component adapted to support the cushion insert are viewable from an exterior of the footwear article.

According to one embodiment, a footwear article includes a shell adapted to receive a sole component adapted receive a cushion insert. The cushion insert has a contoured interface surface that engages at least a portion of a contoured interface surface on the sole component. The interface surfaces of both the cushion insert and the sole component have an edge, at least one of which is viewable through a transparent portion of the shell. The footwear construction also includes an outsole joined with at least a portion of the shell, such that the transparent portion of the shell is viewable from the exterior of the footwear construction. An upper is attached to the shell, the sole component and/or the outsole.

Optionally, the outsole can define at least one window. Portions of the edge of the cushion insert interface surface and/or the sole component interface surface can be viewable through the window. The shell can include a floor adapted to support the sole component and at least one sidewall. The sidewall can optionally be the transparent portion of the shell and can be aligned with the window in the outsole.

Thus, one aspect of the invention provides a method of manufacturing a footwear article that allows a sole component to be directly attached to the article and formed in a shape that is adapted to receive an insert. In an embodiment in which the direct attach sole component attaches to a receptacle shell, a molding insert maintains the general contour of the shell and, therefore, the contour of the direct attach sole component. The molding insert can prevent the shell from being deformed by the high temperature and pressure encountered during molding of the sole component. Another aspect of the present invention provides a shell having a transparent portion that allows a sole component and/or cushion insert to be covered and viewable from an exterior of a footwear article. The transparent shell can prevent dirt or other debris from entering the footwear article through a window or other opening.

DESCRIPTION OF THE CURRENT EMBODIMENT

A footwear construction or article in accordance with an embodiment of the present invention is shown inFIGS. 1-7Cand is generally designated10. In the illustrated embodiment, the footwear article10generally includes an upper12, a receptacle shell18, a cushion insert20and a direct attach sole component22. A receptacle24adapted to receive the cushion insert20is formed in the top surface27of the receptacle shell18. The footwear article10can be manufactured by arranging the upper12over a last114and placing a molding insert112into the receptacle24(FIG. 7B). The upper12is joined with the receptacle shell18, with a first or top surface27of the receptacle shell18facing the last and the upper. A mold100is closed about at least a portion of the upper12and the receptacle shell18to form a mold cavity110that corresponds to the direct attach sole component22. A material is introduced into the mold cavity110to form the direct attach sole component22, such that the material forms a direct attach bond with at least a portion of the upper and with the bottom surface26of the receptacle shell18. The mold100and last114can then be separated from the upper12, receptacle shell18and direct attach sole component22, thus forming the footwear article10. The molding insert112can then be removed and replaced by the cushion insert20.

For purposes of this disclosure, the embodiments are described in connection with a shoe; however, the method is well-suited for manufacturing other types of soled footwear. Further, as used herein, the term “arch region” (or arch portion) refers generally to the portion of the shoe corresponding to the arch of the wearer's foot; the term “forefoot region” refers generally to the portion of the shoe forward of the arch region corresponding to the forefoot (e.g., the ball and the toes) of a wearer's foot; and the term “heel region” refers generally to that portion of the shoe rearward of the arch region corresponding to the heel of the wearer's foot. The forefoot region34, arch region36and heel region38are generally identified inFIG. 2; however, it is to be understood that delineation of these regions may vary depending upon the configuration of the footwear.

The upper12is generally conventional and will not be described in detail. As shown inFIGS. 1 and 2, the upper12is adapted to be secured to at least one other component to cooperatively define a foot-containing envelope. The upper20may be manufactured from leather, canvas, nylon, or other suitable materials and may include a liner (not shown) or other conventional accessories. Although not shown, the upper12can include multiple elements, such as a vamp, quarters and a back stay. If included, these pieces of the upper may be fitted and sewn together using conventional techniques and apparatus. The construction of the upper12can vary depending on the type of footwear article10.

In the illustrated embodiment, the sole board16extends through the forefoot and arch regions36and38of the article10and is adapted to overlap and/or be joined with the receptacle shell18(discussed below), so that the direct attach sole component22has a full-length surface to which it can attach. The sole board16can be constructed from a variety of conventional materials and can be generally flat and flexible. The sole board16can be cemented, stitched, stapled or otherwise fastened to the upper12and the receptacle shell18.

The receptacle shell18can be formed in any size and shape suitable to join with the sole board16to provide a full-length surface to which the sole component22can attach. In the illustrated embodiment, the receptacle shell18is a partial-length shell that is positioned in the heel region38of the footwear article10(FIGS. 1-4). However, in other embodiments, the receptacle shell18can be a full-length shell that follows the general shape of a footwear article10, such that a sole board16is not required. As shown inFIG. 2, the edge19of the receptacle shell18is adapted to overlap and be joined with an adjacent edge15of the sole board16. In the illustrated embodiment shown inFIG. 1, the edge19of the receptacle shell18and the edge15of the sole board16are both relatively thinner than the remaining portions of the respective receptacle shell18and sole board16, such that the thickness of these components remains relatively the same across the length of the footwear article10, despite the region of overlap. The edge19of the receptacle shell18can optionally be adhered or sewn to the sole board16.

The receptacle shell18can be formed as a thin layer of a relatively hard material that is somewhat flexible under loads encountered during use, such as TPU or a harder EVA, and can have a generally uniform thickness across the length and width of the receptacle shell. The hardness of the receptacle shell18may vary from application to application as desired. For example, the receptacle shell18can have a durometer in the range of approximately 80-90 on the Asker A scale. In the illustrated embodiment, the receptacle24is formed as a cup-shaped cavity that extends below the top surface40of the shell18. As shown inFIG. 3, the portion of the shell18is defining the cup-shaped cavity extends from the bottom surface26of the receptacle shell18.

The receptacle24can be formed to receive a cushion insert20of any suitable size and shape. In the illustrated embodiment, an interface surface40on the receptacle24includes a plurality of projections or lobes42, which correspond to a plurality of lobes46on an interface surface or bottom surface44of the cushion insert20. The lobes42and46are adapted to be substantially interfitted when the cushion insert20is installed in the receptacle24, although a gap may exist between a portion of the respective lobes42and46(FIG. 5). The lobes42on the receptacle24can be positioned around the interface surface40in a pattern of regular waves coinciding with angular sections of the receptacle24. For example, in the illustrated embodiment, the receptacle24includes eight lobes42arranged in a regular repeating pattern about the center of the interface surface40. Although the lobes42of the illustrated embodiment are formed by smooth and continuous curved contours, the term “lobes” is used broadly to refer to essentially any contours, whether or not such contours are curved, smooth or run continuously together. Optionally, the lobes42on the receptacle24and the lobes46on the cushion insert20can be of different shapes to provide different support/cushioning characteristics.

Although this embodiment shows a receptacle shell18having a single receptacle24in the heel region38, a receptacle24and cushion insert20can alternatively be positioned in other regions of the article10, such as in the forefoot portion34or other locations where the type of adjustability provided by this construction may be desirable. Alternatively, the receptacle shell18can define a plurality of receptacles24configured to receive a plurality of cushion inserts20positioned in more than one location on the article10.

The cushion insert20can be shaped and sized to fit substantially within the receptacle24. In the illustrated embodiment, the cushion insert20is generally disc-shaped and is configured to be seated within the generally round receptacle24(SeeFIGS. 1,2and4). Optionally, the cushion insert20is configured to be removably fitted into the receptacle24in a variety of different orientations to provide differing cushioning characteristics. To differ the cushioning characteristics, one or more of the lobes46can vary in size, shape or other characteristics from the remainder of the lobes46so that repositioning of the cushion insert20results in repositioning of the lobes46and therefore causes changes to the support/cushioning characteristics of the article10. Although the illustrated embodiment discloses differing lobes46, adjustability may also be provided by varying essentially any characteristic of the cushion insert20or the lobes46, such as size, shape, configuration and materials to provide the desired support/cushioning throughout the range of adjustability of the cushion insert20. For example, the lobes may be manufactured from materials of different degrees of hardness. In an embodiment of this type, the cushion insert may be formed of lobes manufactured from different materials. Although the manufacturing process may vary, the different materials of the cushion insert may be cemented together, integrally molded using multiple shots or compression molded.

In the illustrated embodiment, the insert20defines a central hole48adapted to be fitted over a central post50formed by the receptacle shell18. The central hole48and central post50may assist in aligning and/or retaining the insert20in the receptacle24. The central hole48and central post50can optionally be configured to be snap-fitted together. Although not shown, the central post50may include a head (not shown) and the central hole48may define an enlarged space (not shown) to receive the head of the central post50when the cushion insert20is installed in the receptacle24. As another example, the central post50and the central hole48may be shaped so that the insert20fits into the receptacle24only in select orientations.

Optionally, to assist a user in grasping the cushion insert20from the receptacle24, the receptacle shell18and/or the post50can include an indentation21positioned at the periphery of the receptacle24. The indentation21allows access to a side portion of the cushion insert20, such that the cushion insert20can be more easily lifted from or rotated in the receptacle24. The receptacle shell18can also optionally include markings23, including but not limited to arrows, showing the user how the cushion insert can be adjusted.

Optionally, a support layer30can be included between the cushion insert20and the receptacle24(FIG. 2). The support layer30can be positioned over one or more of the lobes42or46to provide the lobes with the desired characteristics. For example, a firmer support layer (e.g., a relatively thin layer of TPU or other plastic material) may be provided over select lobes to provide enhanced firmness, while a thinner support layer (or the absence of a support layer) over select lobes may provide reduced firmness in select regions. Variations in the thickness of the support layer30may be used to provide the desired variations in lobe characteristics. The support layer30may be secured to the undersurface of the cushion insert20or the upper surface of the receptacle24, if desired.

The direct attach sole component22can be a midsole or any other sole component that is adapted to be molded directly onto the receptacle shell18and sole board16. The sole component22of the illustrated embodiment is a single unitary construction that extends from the heel portion38, through the arch portion36, to the forefoot portion34. However, the sole component22can alternatively be a collection of separate components or may be a partial sole component configured to extend through only one or more select portions of the article10.

The sole component22may be formed from essentially any moldable material or combination of materials capable of providing the desired cushioning/support characteristics. For example, the sole component22can be manufactured from polyurethane or EVA having the desired hardness/resiliency. The hardness of the sole component22may vary from application to application as desired.

The material from which the sole component22is constructed bonds directly to the lower portion13of the upper12, to the bottom surface26of the receptacle shell18, and to the bottom surface52of the sole board16and therefore forms a supporting surface that directly corresponds to the respective surfaces of the upper, receptacle shell and sole board. Immediately adjacent the upper12, the sole component22can form a bead or a shoulder54, which can be generally rounded and can circumferentiate the entire upper. As desired, the shoulder54can be interrupted to provide a desired appearance in certain regions of the footwear. Optionally, the direct attach sole component22can define windows or openings so that the cushion insert20and/or receptacle shell18are visible from outside of the article18.

Optionally, a window or opening may be formed in the direct attach sole component22, such that the cushion insert and/or the receptacle shell are visible through the window from outside of the article10. For example, as shown inFIG. 6, both the cushion insert20and the support layer30are visible through the window126, which is formed in a side wall or portion of the direct attach sole component22.

The footwear article10can also include an outsole28that can be joined with the sole component22. The outsole28is generally conventional and will not be described in detail. The outsole28can be manufactured from a relatively hard rubber or other sufficiently durable and wear-resistant material. The bottom or outer surface of the outsole28forms the wearing surface of the outsole28and can be contoured to the desired heel and tread pattern. The outer surface can be textured to improve the traction and aesthetic appeal of the shoe. Optionally, an upper surface of the outsole can be textured as well.

II. Manufacture and Assembly

Manufacture of the footwear article10will now be described with reference toFIG. 7B. The upper12can be manufactured using generally conventional techniques and apparatus. For example, the desired upper material can be cut to form the upper. Optionally, a liner can be secured within the upper via adhesives or stitching (not shown). The optional liner can be fitted to the upper so that in the finished footwear, it extends downward a sufficient distance so that the later-added sole component22terminates above the lowermost portion of the liner.

The upper12can be fitted on a conventional last114as shown inFIG. 7B. Optionally, to assist in securing the last114in place on the upper12, a portion of the upper12can be temporarily tacked or stapled to the last114. The lower portion13of the upper12can then be board-lasted with cement, adhesive or other attachment means to both the receptacle shell18in the heel region of the article10and to the sole board16in the forefoot and arch regions34and36.

In one embodiment, prior to lasting the upper12to the receptacle shell18, a molding insert112is inserted into the receptacle24of the receptacle shell18to prevent the receptacle shell18from becoming distorted during the molding process. For example, without the molding insert112, the thin layer of material forming the receptacle24could be softened by the high temperature of the injected material and forced upward toward the upper12. As shown inFIG. 7B, the molding insert112can be directly and completely interfitted with the receptacle24, such that there are no voids or gaps or spaces between the insert112and the receptacle24. In the illustrated embodiment, the insert112is adjusted so that the plurality of lobes116on the insert112are interfitted with the lobes42of the receptacle24.

Optionally, the upper12can be fitted on two separate lasts. For example, in one embodiment, the upper12can be stretched over a first last and joined with the receptacle shell18and sole board16. The first last can then be removed from the upper12, receptacle shell18and sole board16. The molding insert112can then be placed in the receptacle shell18. A second, molding last could then be inserted between the upper12and the receptacle shell18and sole board16.

The molding insert112maintains the shape and contour of the receptacle shell18during the molding process. As discussed above, the material used to form the molding insert112can be substantially harder than the material used to form the cushion insert20. If the cushion insert20is formed from a relatively soft and flexible material adapted to provide cushioning characteristics, the cushion insert20is typically unsatisfactory for maintaining the shape and contour of the receptacle shell18during the molding process.

Alternatively, a last214can be used that includes at least one projection216extending from a bottom surface thereof, the projection216being adapted to be fitted within the receptacle24during the molding process (FIG. 7C). In this embodiment, the projection216on the last214eliminates any voids or gaps or spaces between the projection216and the receptacle24and maintains the shape of the receptacle24and receptacle shell18during molding. Thus, in this embodiment, the projection216on the last114performs the function of the mold insert112described above, such that a separate mold insert112is not required.

Once either the molding insert112or the projection216is placed in the receptacle24, a lower portion13of the upper12can then be board lasted with cement, adhesive or other attachment means to the upper surface27of the receptacle shell18. As shown inFIGS. 7B and 7C, the molding insert112(or the projection216) faces the upper12. Before or after lasting the upper12to the receptacle shell18, the upper12can also be lasted to the upper surface17of the sole board16. With the upper12lasted to the receptacle shell18and the sole board16, these components are ready for a direct attach molding operation as illustrated inFIGS. 7B and 7C.

The board lasted upper12, with the receptacle shell18and the sole board16attached, is lowered against the mold100, which includes side molds118and bottom molds120. Each side mold118wraps around the sides of the lasted upper20, and the side molds118mate with one another at the front and rear of the article10. In the illustrated embodiment, the upper12, receptacle shell18and sole board16form an upper wall in the midsole cavity110. The side molds118generally define the sidewalls in the cavity110, and the bottom molds120form the bottom walls in the cavity110. A lower portion13of the upper12is included in the mold cavity110and is positioned to be direct attached to the sole component22.

With the cavity110properly formed by the components, the appropriate volume of material to form the sole component22is injected or poured into the cavity110, such as through ports or the like. The mold100holds the upper12firmly enough to prevent material from exiting the mold100from the top of the cavity110. The material introduced into the cavity substantially fills the cavity110, so that the material direct attaches to the upper12, the receptacle shell18and the sole board16. As the material fills the midsole cavity, it forms the sole component22. The sole component material is then allowed to sufficiently cure and direct attach to the upper12, the receptacle shell18and the sole board16.

Optionally, the side molds118or the bottom mold120can include protrusions or inserts122and124adapted to form windows126and128in the sole component22. As shown inFIGS. 7B and 7C, the protrusions122and124extend into the mold cavity from the inner surface of each of the side molds118. For purposes of illustration, one of the side molds118and protrusion124are shown in place in the mold cavity, while the opposite side mold118and protrusion122are shown after they have been separated from the mold cavity, leaving behind the window126in the sole component22. The protrusions122and124are both adapted to engage an outside surface of the receptacle shell18during molding to prevent the material that forms the sole component22from engaging those portions of the receptacle shell18. Once the material in the mold cavity110has cured to form the sole component22, the side molds118and protrusions122and124are moved away from or out of the mold cavity, leaving behind the windows126and128in the sole component22. Optionally, the receptacle shell18can be formed from a clear, transparent or translucent or otherwise “see-through” material, such that the cushion insert20will be visible or viewable through the windows126and128from outside of the article10.

The last114can then be separated from the upper12, receptacle shell18and sole component22, leaving behind the article10.

A number of other conventional finishing operations can then be performed on the shoe10. For example, any excess flashing resulting from the direct attach process may be trimmed from the sole component22. Additionally, the upper12can be cleaned, polished and treated as desired.

III. Transparent Shell Construction

According to another embodiment of the invention, a footwear construction or footwear article310includes a shell367having a transparent portion369. As shown inFIGS. 8 and 9, the shell367is adapted to support or receive a sole component358, which is adapted to support or receive an adjustable cushion insert320. Both the sole component358and the cushion insert320have a contoured interface surface361and345, respectively, each of which has a respective edge363and347. Portions of at least one of the edges347and363of the respective interface surfaces are visible through the transparent portion369of the shell367. In the illustrated embodiment, the footwear construction310also includes an outsole372molded onto at least a portion of the shell367, such that portions of at least one of the edges347and363is viewable from the exterior of the footwear construction310. An upper312is attached to at least one of the shell367, the sole component358and the outsole372.

The cushion insert320can be identical or substantially similar to the cushion insert20described above in detail with respect to footwear construction10. The cushion insert320can be shaped and sized to fit over a portion of the sole component358. In the illustrated embodiment, the cushion insert interface surface345includes a plurality of projections or lobes346extending therefrom. As discussed above with respect to cushion insert20and receptacle shell18, the projections346can be aligned to at least partially interfit with corresponding lobes or projections362on the sole component interface surface361.

Optionally, the cushion insert320is configured to be removably fitted over the sole component interface surface361in a variety of different orientations to provide differing cushioning characteristics. To differ the cushioning characteristics, one or more of the projections346can vary in size, shape or other characteristics from the remainder of the projections346so that repositioning of the cushion insert320results in repositioning of the projections346and, therefore, causes changes to the support/cushioning characteristics of the article310.

The sole component358can be formed in any suitable shape and size, such that portions of at least one of the edges347and363is visible or viewable when the cushion insert320is in place over the sole component358. This permits a user to visually determine the position of the insert without removing the article of footwear. In the illustrated embodiment, the sole component interface surface361is formed in an upper or top surface of the sole component358and is partially surrounded by a sidewall360. The remaining edge portion of the sole component interface surface361is exposed, such that a portion of both the edge347of the cushion insert interface surface345and the edge363of the sole component interface surface361are visible when the cushion insert320is fitted over the sole component358.

Optionally, to assist a user in grasping the cushion insert320from the interface surface361of the sole component358, the sole component358can include an indentation364positioned at the periphery of the sole component interface surface361. Like the indentation21discussed above with respect to footwear article10, the indentation364can allow access to a side portion of the cushion insert320, such that the cushion insert320can be more easily lifted from or rotated about the sole component358. The sole component358can also optionally include markings366, including but not limited to arrows, showing the user how the cushion insert can be adjusted.

To retain the cushion insert320on the sole component358, the cushion insert can optionally define an aperture348adapted to be fitted over a post350on the sole component358. The hole348and post350may assist in aligning and/or retaining the insert320over the sole component358and may be substantially similar or identical to the central hole48and central post50discussed above with respect to the footwear article10.

The shell367can be formed in any suitable shape adapted to receive or support the sole component358. In the illustrated embodiment, the shell367includes a floor370adapted to support a bottom surface of the sole component358and at least one sidewall368extending from the floor370. The shell367and sole component358can optionally be sized so that the sole component358and cushion insert320fit substantially or completely within the shell367. The shell367can include an open upper surface, such that the sole component358and cushion insert320can be accessed while the sole component358is positioned in the shell367.

Any or all portions of the shell367can be transparent. In the illustrated embodiment, the sidewall portion368of the shell367is transparent. However, in other embodiments, select portions of the shell367that are viewable from the exterior of the footwear construction310may be transparent. As used herein, the term “transparent” can mean transparent, clear, translucent or “see-through.” The transparent portion369can also optionally be tinted any desired color.

As shown inFIG. 9, when the sole component358is fitted into the shell367, both the edge347of the cushion insert interface surface345and the edge363of the sole component interface surface361are aligned with the transparent sidewall368of the shell367. Thus, in the illustrated embodiment, the exposed edges347and363are viewable through the shell367.

The outsole372can be a generally conventional outsole and can be joined with at least one of the shell367, the sole component358and the upper312in any suitable manner, such as by cement. The outsole372includes a generally flat upper surface376adapted to support a bottom surface of the shell367. Optionally, the outsole372can be molded directly onto the shell367. For example, the outsole372can be direct attached to the shell367in the manner that direct attach sole component22is attached to the receptacle shell18, as described above with respect to footwear article10.

The outsole372can be manufactured from a relatively hard rubber or other sufficiently durable and wear-resistant material. As discussed above with respect to outsole28, the bottom or outer surface of the outsole372forms the wearing surface of the outsole372and can be contoured to the desired heel and tread pattern. The outer surface can be textured to improve the traction and aesthetic appeal of the shoe.

Optionally, the outsole372can define at least one window374, such that the transparent portion369and at least a portion of the edge347of the cushion insert interface surface345and/or the edge363of the sole component interface surface361are viewable through the window. This embodiment may be substantially similar to the footwear article shown inFIG. 6, having a window126. In the illustrated embodiment inFIG. 9, the transparent sidewall368of the shell367is adapted to be aligned with the window374in the outsole, such that portions of both of the edges347and363are viewable through the window374from the exterior of the footwear construction310. As shown inFIG. 9, the outsole372can optionally define multiple windows, which can be located on opposite sides of the outsole. The windows374can alternatively or additionally be positioned on the rear or bottom or any other portion of the outsole. The location of the windows374can depend on the arrangement of the cushion insert320and sole component358in the shell367.

Alternatively, to allow the transparent portion369and portions of the edges347and363to be viewed without a window374in the outsole, the peripheral edge of the outsole372can optionally be formed to angle downward along the shell367to reveal part of the transparent portion369of the shell367(not shown).

The upper312can be generally conventional and can be substantially similar or identical to the upper12described above with respect to footwear article10.