Method of making footwear using molds
Injection molded footwear having a flared sole is made using an injection molding method with two different molds. Both molds share the same shell and the same last, but have different plates. The first mold has a void for an upper and the second mold has a void for the flared sole in the shell.
1 . A method of making footwear having an upper and a sole by injection molding, the method comprising:
closing a first mold having a shell, a first plate and a last;
injection molding the upper in the first mold;
closing a second mold having the shell, a second plate and the last; and
injection molding at least a portion of the sole in the shell in the second mold, the portion of the sole flaring outwardly of where the upper and the portion of the sole are in contact.
2 . The method of claim 1 further comprising:
covering the last with a sock liner of the footwear before injection molding the upper;
opening the second mold; and
removing the footwear from the second mold.
3 . The method of claim 2 further comprising inserting an insole into the molded footwear.
4 . The method of claim 1 further comprising inserting a steel toe into the first mold.
5 . The method of claim 1 wherein injection molding at least a portion of the sole comprises injection molding at least a portion of the sole onto the upper.
6 . The method of claim 1 wherein the first plate extends into the shell to provide a lower boundary to the upper.
7 . The method of claim 1 wherein injection molding at least a portion of the sole comprises pushing air with midsole material out of the mold through a passage in the shell.
8 . The method of claim 7 wherein the first plate extends into the shell to provide a lower boundary to the upper and covers the passage when the first mold is closed.