Article of footwear with tubular sole assembly and method of manufacture
An article of footwear includes an upper and a sole assembly secured to the upper. The sole assembly includes a mat formed of at least one randomly dispersed extruded tubular member, each tubular member being hollow in an in-use condition in which the mat provides support for a user's foot.
1. A method of manufacturing a portion of a sole assembly comprising the steps of:
providing a first mold portion having a recess formed therein;
extruding a mat formed of at least one randomly dispersed extruded hollow tubular member into the recess; and
curing the mat.
2. The method of claim 1 , wherein a wall thickness of the tubular member varies along its length.
3. The method of claim 1 , wherein a diameter of the tubular member varies along its length.
4. The method of claim 1 , wherein the recess is substantially foot shaped.
5. The method of claim 1 , further comprising the steps of:
providing a second mold portion having a projection formed thereon; and
the projection being inserted into the recess after the mat is extruded into the recess and before the mat is cured.
6. The method of claim 1 , wherein the mat is extruded from a plurality of extrusion heads simultaneously.
7. A method of manufacturing a portion of a sole assembly comprising the steps of:
extruding a mat preform formed of a randomly dispersed extruded tubular member;
cutting the mat preform to provide a mat of tubular members shaped to form a portion of a sole assembly for an article of footwear, each tubular member being hollow in an in-use condition in which the mat provides support for a user's foot; and
curing the mat.
8. The method of claim 7 , wherein the mat is extruded onto a moving belt and the tubular member is extruded longitudinally and transversely along the belt.
9. The method of claim 7 , wherein a wall thickness of the tubular member varies along its length.
10. The method of claim 7 , wherein a diameter of the tubular member varies along its length.