Injection molded article of footwear and method of manufacturing

Abstract

An article of footwear including an upper having an opening for receiving a wearer's foot, a insole for supporting the wearer's foot, and an outsole. The upper, the insole and the outsole are comprised of at least two different forms of injection molded polymer materials permanently bonded at interfaces between the different forms of polymer materials to provide an integrally formed and unitary article of footwear. For example, the upper is formed of a limb silicone material, the insole is formed of a silicone gel material, and the outsole is formed of a silicone foam material. The method for manufacturing the integrally formed injection molded article of footwear includes providing a mold having at least one cavity for forming the article of footwear and providing the at least two different forms of polymer materials. A controlled amount of each of said tat lest two different forms of polymer materials are injected into the mold cavity at a predetermined temperature and a predetermined pressure for each of the different forms of polymer materials. The different forms of polymer materials bond to each other at interfaces between the different forms of polymer materials. The polymer materials are cured to provide the integrally formed article of footwear and the article of footwear is removed from the mold.

What is claimed is:  
     
         1 . A method for manufacturing an integrally formed injection molded article of footwear, comprising: 
 providing a mold having at least one cavity for forming the article of footwear;    providing at least two different forms of polymer materials; and    injecting into the mold cavity a controlled amount of each of said at least two different forms of polymer materials at a predetermined temperature and a predetermined pressure for each of the different forms of polymer materials;    bonding each of the different forms of polymer materials to the other at an interface between the different forms of polymer materials;    curing said different forms of polymer materials to provide the integrally formed article of footwear; and    removing the article of footwear from the mold.    
     
     
         2 . A method, as recited in  claim 1 , wherein the step of injecting into the mold cavity a controlled amount of each of said at least two different forms of polymer materials, further comprises 
 coupling at least one distributor valve to a supply of each of said at least two different forms of polymer materials;    coupling a plurality of sprues to the mold leading to the mold cavity and to the distributor valves wherein each of said at least two different forms of polymer materials arc distributed in said controlled amounts from the distributor valves and are injected into the mold cavity through the plurality of sprues.    
     
     
         3 . A method, as recited in  claim 2 , further comprising: 
 connecting a control device including microprocessor to each distributor valve and to each of said supply of the at least two different forms of polymer materials wherein the control device controls the distribution of said at least two different forms of polymer materials; and    controlling the temperature and pressure of said supply of the at least two different forms of polymer materials.    
     
     
         4 . A method, as recited in  claim 3 , wherein the control devise controls the temperature and pressure of said supply of the at least two different forms of polymer materials.  
     
     
         5 . A method, as recited in  claim 1 , wherein the at least two different forms of polymer materials are different forms of silicone.  
     
     
         6 . A method, as recited in  claim 1 , further comprising: 
 embedding a functional element into the article of footwear.    
     
     
         7 . A method, as recited in  claim 1 , further comprising: 
 embedding an ornamental element into the article of footwear.    
     
     
         8 . Ar article of footwear comprising: 
 an upper having an opening for receiving a wearer's foot;    a insole for supporting the wearer's foot: and    an outsole; and    wherein the upper, the insole and the outsole are comprised of at least two different forms of injection molded polymer materials permanently bonded at interfaces between said different forms of polymer materials to provide an integrally formed and unitary article of footwear having said upper, said insole and said outsole.    
     
     
         9 . An article of footwear, as recited in  claim 8 , further comprising: 
 a plurality of injection molded points on a bottom of said outsole.    
     
     
         10 . An article of footwear, as recited in  claim 8 , further comprising: 
 an injection molded three-dimensional ornamental design.    
     
     
         11 . An article of footwear, as recited in  claim 8 , wherein the at least two different forms of polymer materials are different forms of silicone.  
     
     
         12 . An article of footwear, as recited in  claim 8 , wherein said upper is formed of a limb silicone material.  
     
     
         13 . An article of footwear. as recited in  claim 8 , wherein said insole is formed of a silicone gel material.  
     
     
         14 . An article of footwear, as recited in  claim 8 , wherein said outsole is formed of a silicone foam material.  
     
     
         15 . An article of footwear, as recited in  claim 9 , wherein the injection molded points are formed of a silicone gel material.  
     
     
         16 . An article of footwear, as recited in  claim 8 , further comprising: 
 an embedded functional element.    
     
     
         17 . An article of footwear, as recited in  claim 8 , further comprising: 
 an embedded ornamental element.