Multiple response property footwear

Abstract

Embodiments herein relate generally to the field of footwear, and more particularly to components of performance footwear, such as midsoles, as well as methods of making midsoles. In various embodiments, multiple response property midsoles and/or portions of footwear are provided that may include strategically arranged multiple response property areas having blended transition zones disposed there between. Such blended transition zones may help facilitate a more fluid foot movement, improve manufacturing and production techniques, and prevent injury to the foot, ankle, and/or legs during exercise, such as running, hiking, walking, and other impact-generating activities.

1 . A multiple response property midsole comprising:
 a first foam material having a first material response property;   a second foam material having a second material response property, wherein the second foam material is coupled to the first foam material at a first junction zone; wherein the first junction zone comprises a blended transition between the first foam material and the second foam material.   
     
     
         2 . The multiple response property midsole of  claim 1 , further comprising a third foam material having a third material response property, wherein the third foam material is coupled to the second foam material at a second junction zone, wherein the second junction zone comprises a blended transition between the third foam material and the second foam material. 
     
     
         3 . The multiple response property midsole of  claim 2 , further comprising a fourth foam material having a fourth material response property, wherein the fourth foam material is coupled to the third foam material at a third junction zone, wherein the third junction zone comprises a blended transition between the fourth foam material and the third foam material 
     
     
         4 . The multiple response property midsole of  claim 1 , wherein the first and second material response properties are density or durometer. 
     
     
         5 . The multiple response property midsole of  claim 1 , wherein the midsole lacks a linear or planar seam between the first foam material and the second foam material. 
     
     
         6 . The multiple response property midsole of  claim 1 , where the first foam material is positioned in an arch region of the midsole, and wherein the first foam material comprises a higher density or durometer foam than the second foam material. 
     
     
         7 . The multiple response property midsole of  claim 6 , further comprising a third foam material, wherein the second foam material comprises a higher density or durometer foam than the third foam material, and wherein the second foam material is positioned between the first and the third foam materials. 
     
     
         8 . The multiple response property midsole of  claim 7 , wherein the third foam material is coupled to the second foam material at a second junction zone; and wherein the second junction zone comprises a blended transition between the second foam material and the third foam material. 
     
     
         9 . The multiple response property midsole of  claim 1 , where the first foam material is positioned in both a medial midfoot region and a lateral midfoot region of the midsole, and wherein the first foam material comprises a higher density or durometer foam than the second foam material. 
     
     
         10 . The multiple response property midsole of  claim 8 , further comprising a third foam material, wherein the second foam material comprises a higher density or durometer foam than the third foam material, and wherein the second foam material is positioned between the first and the third foam materials in both the medial and lateral midfoot regions. 
     
     
         11 . The multiple response property midsole of  claim 10 , wherein the third foam material is coupled to the second foam material at a second junction zone; and wherein the second junction zone comprises a blended transition between the second foam material and the third foam material. 
     
     
         12 . The multiple response property midsole of  claim 1 , where the first foam material is positioned in a heel region, a medial midfoot region, and a lateral midfoot region of the midsole, and wherein the first foam material comprises a higher density or durometer foam than the second foam material. 
     
     
         13 . The multiple response property midsole of  claim 12 , further comprising a third foam material, wherein the second foam material comprises a higher density or durometer foam than the third foam material, and wherein the second foam material is positioned between the first and the third foam materials in the heel region, in the medial midfoot region, and in the lateral midfoot region. 
     
     
         14 . The multiple response property midsole of  claim 13 , wherein the third foam material is coupled to the second foam material at a second junction zone; and wherein the second junction zone comprises a blended transition between the second foam material and the third foam material. 
     
     
         15 . The multiple response property midsole of  claim 1 , wherein at least one of the first and second foam material comprise ethylene vinyl acetate foam. 
     
     
         16 . The multiple response property midsole of  claim 1 , wherein the midsole does not comprise any glue. 
     
     
         17 . The multiple response property midsole of  claim 1 , where the midsole is free of volatile organic compounds. 
     
     
         18 . A method of making a multiple response property midsole, comprising:
 positioning a first foam material having a first density or durometer in a midsole mold;   positioning a second foam material having a second density or durometer adjacent the first foam material in the midsole mold, wherein the first foam material forms a first interface with the second foam material; and   heating the first and second foam materials sufficiently to cause blending of the first and second foam materials at the first interface.   
     
     
         19 . The method of  claim 18 , wherein the method further comprises positioning a third foam material having a third density or durometer adjacent the first or second foam material, wherein the third foam material forms a second interface with the first and/or second foam material, and wherein heating the first, second, and third foam materials causes blending of the first, second, and/or third foam materials at the first and second interfaces. 
     
     
         20 . The method of  claim 19 , wherein the method further comprises positioning a fourth foam material having a fourth density or durometer adjacent the first, second, and/or third foam material, wherein the fourth foam material forms a third interface with the first, second, and/or third foam material, and wherein heating the first, second, third, and fourth foam materials causes blending of the first, second, third, and/or fourth foam materials at the first, second, and third interfaces. 
     
     
         21 . The method of  claim 18 , wherein the method further comprises:
 forming a first pre-molded portion of a midsole from first foam pellets to form the first foam material.   
     
     
         22 . The method of  claim 21 , wherein the method further comprises:
 forming a second pre-molded portion of a midsole from second foam pellets to form the second foam material.   
     
     
         23 . The method of  claim 21 , wherein forming a first pre-molded portion of the midsole comprises:
 positioning the first foam pellets in a pre-mold;   heating the first foam pellets to a temperature of about 130° C.; and   cooling the first pre-molded portion before positioning the first pre-molded portion in the midsole mold.   
     
     
         24 . The method of  claim 18 , wherein the first density or durometer is greater than the second density or durometer. 
     
     
         25 . The method of  claim 18 , wherein the method further comprises:
 pre-cutting the first foam material in a first desired shape.   
     
     
         26 . The method of  claim 25 , wherein the method further comprises:
 pre-cutting the second foam material in a second desired shape.   
     
     
         27 . The method of  claim 18 , further comprising positioning the first and/or second foam material in the midsole mold using a jig or cage. 
     
     
         28 . The method of  claim 27 , wherein the cage is configured to melt or dissolve when heated to a temperature of about 130° C. 
     
     
         29 . The method of  claim 18 , wherein at least one of the first and second foam materials comprise ethylene vinyl acetate.