Sole Assembly Formed of Multiple Preforms

Abstract

A sole assembly may be formed by a method that includes positioning a plurality of preforms having different colors together to form a sole assembly preform and placing the sole assembly preform in a recess in a first portion of a mold assembly. The sole assembly preform is subjected to heat for a predetermined amount of time such that the plurality of preforms bond to one another to form a sole assembly.

What is claimed is: 
     
         1 . A sole assembly, comprising:
 a core portion including a lower surface and ribs extending downward from the lower surface, wherein the ribs define a shoulder extending about at least a portion of the core portion;   a first insert contained within and bonded to the core portion; and   a perimeter portion bonded to the core portion, wherein the perimeter portion forms at least a portion of an outer periphery of the sole assembly, wherein the perimeter portion includes an aperture that defines an interior lip, and wherein the interior lip is seated on the shoulder of the core portion.   
     
     
         2 . The sole assembly according to  claim 1 , wherein an outer peripheral edge of the first insert is completely surrounded by the core portion and contained within a first interior recess defined by the ribs of the core portion. 
     
     
         3 . The sole assembly according to  claim 1 , wherein the perimeter portion completely surrounds an outer periphery of the core portion. 
     
     
         4 . The sole assembly according to  claim 1 , wherein a surface of the aperture abuts an exterior perimeter of the ribs. 
     
     
         5 . The sole assembly according to  claim 1 , wherein lower surfaces of the core portion, the first insert, and the perimeter portion include a plurality of grooves and lugs or projections. 
     
     
         6 . The sole assembly according to  claim 1 , wherein the core portion has a first color, the first insert has a second color different from the first color, and the perimeter portion has a third color different from the first color and the second color. 
     
     
         7 . The sole assembly according to  claim 1 , wherein each of the core portion, the first insert, and the perimeter portion is an ethyl vinyl acetate material. 
     
     
         8 . The sole assembly according to  claim 1 , wherein the perimeter portion forms an entire outer periphery of the sole assembly. 
     
     
         9 . The sole assembly according to  claim 1 , wherein the core portion, the first insert, and the perimeter portion have different hardnesses from one another. 
     
     
         10 . The sole assembly according to  claim 1 , wherein the first insert is located in a forefoot region or in a heel region of the sole assembly. 
     
     
         11 . The sole assembly according to  claim 1 , wherein the first insert extends from a midfoot region to a forefoot region of the sole assembly. 
     
     
         12 . The sole assembly according to  claim 1 , further comprising:
 a second insert contained within and bonded to the core portion.   
     
     
         13 . The sole assembly according to  claim 12 , wherein an outer peripheral edge of the second insert is completely surrounded by the core portion. 
     
     
         14 . The sole assembly according to  claim 12 , further comprising:
 a third insert contained within and bonded to the core portion.   
     
     
         15 . The sole assembly according to  claim 14 , wherein an outer peripheral edge of each of the second insert and the third insert is completely surrounded by the core portion. 
     
     
         16 . The sole assembly according to  claim 1 , wherein lower surfaces of the core portion, the first insert, and the perimeter portion form a grid of hexagonal projections. 
     
     
         17 . A sole assembly, comprising:
 a core portion including a lower surface and ribs extending downward from the lower surface, wherein the ribs define a shoulder extending about at least a portion of the core portion;   a first insert contained within and bonded to the core portion, wherein an outer peripheral edge of the first insert is completely surrounded by the core portion and contained within a first interior recess defined by the ribs of the core portion; and   a second insert contained within and bonded to the core portion, wherein an outer peripheral edge of the second insert is completely surrounded by the core portion and contained within a second interior recess defined by the ribs of the core portion.   
     
     
         18 . The sole assembly according to  claim 17 , wherein: (a) the first insert is located in a forefoot region of the sole assembly and the second insert is located in a heel region of the sole assembly; or (b) the first insert is located in a forefoot region of the sole assembly and the second insert extends from a midfoot region to a forefoot region of the sole assembly; or (c) the first insert is located in a heel region of the sole assembly and the second insert extends from a midfoot region to a forefoot region of the sole assembly. 
     
     
         19 . The sole assembly according to  17 , further comprising:
 a third insert contained within and bonded to the core portion, wherein an outer peripheral edge of the third insert is completely surrounded by the core portion and contained within a third interior recess defined by the ribs of the core portion.   
     
     
         20 . The sole assembly according to  claim 19 , wherein the first insert is located in a forefoot region of the sole assembly, the second insert extends from a midfoot region to a forefoot region of the sole assembly, and the third insert is located in a heel region of the sole assembly.