System and method for forming a molded part having an insert

Abstract

A method for forming a molded article having an insert includes temporarily protecting features of the insert using a malleable plug material during the molding process. In one step, the method includes positioning a plug comprising the plug material within a receptacle of the insert, wherein each receptacle comprises an engagement feature. The insert and the plug material are placed in a mold, and a liquid molding material is applied to an outer surface of the insert. The liquid molding material is solidified, thereby forming a molded article comprising the insert embedded in the solidified molding material. The molded article is removed from the mold, and the plug material is removed from the receptacle of the insert embedded in the molded article to expose the engagement feature.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This PCT international application claims priority to U.S. non-provisional patent application No. 17 / 111,945, filed on December 4, 2020, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 62 / 943,975, filed on December 5, 2019, the contents of which are incorporated by reference in their entirety.

[0003] field

[0004] The present disclosure generally relates to methods and systems for forming a molded part having an insert.

[0005] background

[0006] This section provides background information related to the present disclosure which is not necessarily prior art.

[0007] Articles of footwear conventionally include an upper and a sole structure. The upper can be formed from any suitable material to receive, secure, and support the foot on the sole structure. The sole structure typically includes a layered arrangement extending between a ground surface and the upper. One or more components of an article of footwear, and in particular the sole structure, can be formed using various molding systems and processes, such as injection molding and compression molding systems.

[0008] In some cases, a molded component may include a molding material that is initially provided to a molding system in a fluid state and then solidifies to form the molded component. Here, it may be desirable to provide the molded component with one or more pre-formed inserts that are bonded to the molded component. For example, an insert configured to attach a peripheral component, such as a cleat or stud, may be embedded within the molding material of the molded component.

[0009] Attached photos

[0010] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0011] Figure 1 is a bottom perspective view of an article of footwear including a sole structure formed according to the principles of the present disclosure;

[0012] Figure 2 is forming Figure 1 An exploded perspective view of an example of an insert and traction element used in a sole structure of a shoe;

[0013] Figure 3 is a partial environmental view of a system and method according to the principles of the present disclosure, showing the forming of plugging material into a plurality of blanks;

[0014] Figure 4 is a partial environment diagram of the system and method of the present disclosure, showing the Figure 3 Trimming of blanks;

[0015] Figure 5 is a partial environment diagram of the system and method of the present disclosure, showing the Figure 4 One of the blanks is formed into a plug;

[0016] Figure 6A is a partial environment diagram of the system and method of the present disclosure, showing the Figure 5 One of the plugs is inserted into the insert;

[0017] Figure 6B yes Figure 6A a cross-sectional view of an insert and a plug;

[0018] Figure 7 is a partial environment diagram of the system and method of the present disclosure, showing Figure 6A Placement of inserts and plugs within the mold;

[0019] Figure 8 is a partial environmental view of the system and method of the present disclosure showing the removal of flashing from an insert and a plug;

[0020] Figure 9 is a partial environmental view of the systems and methods of the present disclosure showing the attachment of the insert and plug to the substrate;

[0021] Figure 10 is a partial environment diagram of the system and method of the present disclosure, showing Figure 9 The formation of the sole plate of the base, inserts and plugs;

[0022] Figures 11A-11C is a cross-sectional view of a mold according to the principles of the present disclosure, showing a mold for forming Figure 10 the step of forming the sole plate; and

[0023] Figure 12 is a partial environmental view of the systems and methods of the present disclosure showing the removal of plug material from a shoe sole plate.

[0024] Corresponding reference numerals indicate corresponding parts throughout the drawings.

[0025] Detailed description

[0026] The present disclosure relates to a method for manufacturing a molded article, a system for use in the method, a molded article made using the method and / or system, and a footwear article incorporating a molded article. In some examples, the molded article is formed with an insert to provide more durable or more precise features to the key elements of the molded article. For example, in the case of using a composite material to form a molded article, a metal or polymer insert can be provided in the molded article to provide a rigid and durable attachment point for surrounding items (such as a detachable adhesion friction element). The method and system of the present disclosure are intended to provide an effective way for molding a molded article including an insert during a single molding process, whereby, during the molding process, the key features of the insert (e.g., threads) are protected by a removable plug material provided in the key features of the insert. Specifically, during the molding process, the key features of the insert are temporarily protected by the presence of the removable plug material, whereby once the molding process is completed, the plug material can be withdrawn from the insert to expose the key features of the insert in the molded article. The use of the systems and methods described herein has been found to improve the quality of molded articles by significantly reducing the level of unwanted molding material that enters critical features of inserts during the molding process. Use of these systems and methods also increases the speed of production of molded articles because the removable plug material can be quickly extracted from the insert after molding, and the improved quality of the molded articles results in less time required to clean the unwanted molding material from critical features of the molded articles.

[0027] In one aspect, the present disclosure relates to a method for forming a molded article, wherein the molded article includes an insert having an engagement feature. During molding of the molded article, a plug comprising a plug material is temporarily disposed in a receptacle, thereby protecting the engagement feature during the molding process by preventing the material forming the molded article from contacting the engagement feature. In one example, the molded article is a sole structure for an article of footwear, such as a sole plate. The method includes the following steps: disposing a plug comprising a plug material within a receptacle of an insert, wherein the receptacle includes the engagement feature; placing the insert comprising the plug material into a mold; while in the mold, contacting an outer surface of the insert with a liquid material; solidifying the liquid material in the mold into a solid material to form a molded article comprising an insert partially embedded in the solid material, wherein a surface of the insert remains exposed in the molded article; removing the molded article from the mold and removing the plug material from the receptacle of the exposed surface of the partially embedded insert, exposing the engagement feature. Optionally, the method may further include the step of disposing the plug material in the insert. Providing the plug material may include inserting a preformed (e.g., premolded) plug of the plug material into the receiving portion of the insert before the insert is placed in the mold. Alternatively, the plug material may be provided in the receiving portion of the insert by subjecting the plug material and the insert to a plug molding operation. In the plug molding operation, the plug material is molded when in contact with the engagement feature to cover, fill, or otherwise protect the engagement feature of the insert. In some cases, the plug molding operation may include softening or melting the plug material before or while the plug material is provided in the receiving portion of the insert, or solidifying the plug material while the plug material is provided in the receiving portion of the insert, or both. For example, the step of providing the plug material may include solidifying or partially solidifying the plug material, thereby increasing its hardness. In some examples, the receiving portion is a hole formed through the insert, and the engagement feature is a female helical thread. Here, the plug of malleable plug material can be formed to have a diameter larger than the minor diameter of the female screw thread, so that the plug is pressed into the thread to seal the receiving portion. Optionally, during the molding process, a substrate such as a textile can be included in the mold and can be contacted by the liquid material. When the substrate is present, the substrate can be attached to the insert.

[0028] Another aspect of the present disclosure provides a system for forming a molded article including an insert. The system includes a plate mold having a plate mold cavity. A carcass is disposed within the plate mold cavity of the plate mold and includes a flexible substrate, an insert attached to the flexible substrate and including a receiving portion, and a plug material disposed within the receiving portion of the insert. Here, the plug material has a hardness of less than 100 Shore A, and more specifically, has a hardness ranging from 10 Shore A to 60 Shore A. In some examples, the receiving portion includes a hole formed through at least one end of the insert and including an engagement feature. Here, the engagement feature may include a female helical thread. In some examples, the plug material is formed as a plug disposed within the hole, flush with at least one end of the insert. Here, the plug may include an alignment feature configured to interference fit with a fixture of the plate mold.

[0029] Example configurations will now be described more fully with reference to the accompanying drawings. The example configurations are provided so that this disclosure will be thorough and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that the specific details need not be employed, that the example configurations can be implemented in many different forms, and that the specific details and example configurations should not be construed as limiting the scope of the present disclosure.

[0030] The terms used herein are merely for the purpose of describing specific exemplary configurations and are not intended to be restrictive. As used herein, unless the context clearly indicates otherwise, the singular articles "a," "an," and "the" may also be intended to include the plural form. The terms "comprises," "comprising," "including," and "having" are inclusive and therefore specify the presence of features, steps, operations, elements, and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts, and / or groups thereof. Unless specifically identified as an order of execution, the method steps, processes, and operations described herein should not be interpreted as necessarily requiring them to be performed in the particular order discussed or shown. Additional or alternative steps may be adopted.

[0031] When an element or layer is referred to as being "on," "engaged to," "connected to," "attached to," or "coupled to" another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or there may be intervening elements or layers. Conversely, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0032] The terms first, second, third, etc. can be used in this article to describe a variety of elements, components, regions, layers and / or sections. These elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first", "second" and other numerical terms do not imply a sequence or order unless the context clearly indicates. Therefore, the first element, first component, first region, first layer or first section discussed below can be referred to as the second element, second component, second region, second layer or second section without departing from the teaching of the example configuration.

[0033] Reference Figure 1-11C A method and system for forming an article of footwear 10 having a sole structure 14 including a threaded insert or bushing 18 is provided. Generally, the method includes pressing a moldable plug material 102 into a threaded receptacle 22 of the insert 18 to effectively plug the receptacle 22. The insert 18 is then molded into the sole structure 14 in a separate molding step, wherein the plug material 102 disposed within the receptacle 22 prevents the molding material (e.g., liquid) of the sole structure 14 from flowing into the receptacle 22. After molding the sole structure 14, the plug material 102 can be removed from each of the inserts 18 to expose the interior of the receptacle 22. By providing the system and method described below, a molded part having an insert with critical features (e.g., threads or mating surfaces) can be more easily formed using a conventional molding process because the liquid molding material provided during the molding process is prevented from penetrating the critical features of the insert 18.

[0034] refer to Figure 1, article of footwear 10 includes an upper 12 and a sole structure 14. Upper 12 may be a conventional upper 12 including an interior surface defining an interior cavity configured to receive and secure a foot for support on sole structure 14. Upper 12 may be formed from one or more materials stitched or adhesively bonded together to form an interior cavity. Suitable materials for upper 12 may include, but are not limited to, textiles including mesh or synthetic leather, foam, and natural leather. These materials may be selected and positioned to provide durability, breathability, wear resistance, flexibility, and comfort.

[0035] Sole structure 14 is attached to the bottom of upper 12 and defines the ground-engaging surface of article of footwear 10. In the illustrated example, sole structure 14 includes a sole plate 16 having a plurality of inserts 18. As described in more detail below, inserts 18 can be embedded or molded into sole plate 16 using various molding methods, such as compression molding or injection molding. As shown, sole plate 16 and inserts 18 cooperate to define the ground-engaging surface of article of footwear 10. Sole structure 14 may also include one or more traction elements 20 attached to sole plate 16. One or more traction elements 20 may be permanently attached to sole plate 16 or may be removably attached to sole plate 16. In the illustrated example, traction elements 20 are formed as removable traction elements 20 that can be selectively attached to and detached from sole plate 16. In particular, traction elements 20 may be posts 20 that are configured to interface with insert 18 of sole structure 14, as described in greater detail below.

[0036] Reference Figure 2 , an example of insert 18 and traction element 20 of sole structure 14 is shown in greater detail. As shown, insert 18 includes a receptacle 22 having a hole extending through at least one end of insert 18. In the illustrated example, the hole of receptacle 22 extends completely through the length of insert 18. Here, receptacle 22 is configured to interface with a corresponding component to secure the component to insert 18. For example, in the current example, receptacle 22 is configured to interface with traction element 20.

[0037] As shown, the first portion of the insert 18 includes a bushing 24 forming the receiving portion 22, and a flange 26 projecting laterally outward from the periphery of the bushing 24. The bushing 24 is disposed along the longitudinal axis A of the insert 18. 18 The distance from the first end 28 to the second end 30 defines the length L of the bushing 24. 24, and in this example is the length of the insert 18. The bushing 24 also includes a peripheral side surface 32 that extends between the first end 28 and the second end 30 and defines the outer periphery of the bushing 24. In the illustrated example, the bushing 24 is formed into a cylindrical shape such that the peripheral side surface 32 of the bushing 24 has a circular (i.e., constant radius) cross-section having a first width W 24 In other examples, bushing 24 may have a polygonal or irregular cross-section.

[0038] like Figure 2 As shown in FIG, the receiving portion 22 is formed to include a length L passing through the bushing 24. 24 The hole extends from the first end 28 to the second end 30. Alternatively, the hole of the receiving portion 22 may be formed in only one of the first end 28 or the second end 30 and extend partially through the length L of the bushing 24. 24 Such that the receiving portion 22 is a blind hole. As provided above, the receiving portion 22 is configured to interface with the traction friction element 20 to secure the traction friction element 20 to the sole structure 14. For example, the receiving portion 22 may include a first engagement feature 25a that is configured to interface with a second engagement feature 25b formed on the traction friction element 20. In the illustrated example, the receiving portion 22 includes a first engagement feature 25a in the form of a female helical thread, and the traction friction element 20 includes a corresponding male helical thread 25b formed on the shaft 44 of the traction friction element 20. In other examples, the first engagement feature 25a may include a stop or keyway that is configured to interface with a corresponding feature of the traction friction element 20. As shown, the minor diameter of the female helical thread 25a of the receiving portion 22 defines the inner diameter or width W of the receiving portion 22. 22 .

[0039] As provided above, the flange 26 extends laterally outward (ie, perpendicular to the longitudinal axis A). 18 ) protrudes from the peripheral side surface 32 of the bushing 24 to provide the insert 18 with a significant width W 26 As shown, the flange 26 includes a top surface 34 and a bottom surface 36 formed on a side of the flange 26 opposite the top surface 34. The distance between the top surface 34 and the bottom surface 36 defines the thickness or length L of the flange 26. 26 , which thickness or length is less than the length L of the bushing 24 24 In the illustrated example, each of the top surface 34 and the bottom surface 36 is along the longitudinal axis A. 18, 30 of the bushing 24. In some cases, as shown, each of the surfaces 34, 36 may be equally offset from the respective end 28, 30 of the bushing 24. However, in other examples, the surfaces 34, 36 may be offset by different distances, or one of the surfaces 34, 36 may be flush with the respective end 28, 30 of the bushing 24. The peripheral side surface 38 of the flange 26 extends from the top surface 34 to the bottom surface 36 and defines an outer peripheral profile of the flange 26. In the illustrated example, the flange 26 is formed as a cylindrical flange such that the peripheral side surface 38 of the flange 26 has a defined width W 26 A circular (i.e., constant radius) cross-section.

[0040] In some examples, flange 26 includes one or more attachment features 40, 42 configured to secure insert 18 relative to components of sole plate 16. For example, the illustrated flange 26 includes a series of recesses 40 radially spaced about the circumference of peripheral side surface 38 and a series of holes 42 extending through the thickness of flange 26 from top surface 34 to bottom surface 36. As described in more detail below, when sole structure 14 is formed, the material of sole plate 16 can interface with attachment features 40, 42 to prevent relative movement between insert 18 and components of sole plate 16. For example, recesses 40 are configured to engage with the resin or molding material of sole plate 16 when sole structure 14 is molded to secure the position of insert 18 relative to sole plate 16. Holes 42 are configured to receive stitching for attaching insert 18 to a substrate, such as textile, prior to molding sole plate 16. In other examples, the attachment features may be implemented as protrusions extending from any of the surfaces 34 , 36 , 38 .

[0041] Still refer to Figure 2 , traction element 20 generally includes a shaft 44 having a second engagement feature 25b, and a post or cleat 45 attached to shaft 44. As provided above, shaft 44 including second engagement feature 25b is configured to interface with receptacle 22 including first engagement feature 25a to selectively secure traction element 20 to sole structure 14. Therefore, it is important that first engagement feature 25a of receptacle 22 be free of debris that could impede full engagement between first engagement feature 25a and second engagement feature 25b.

[0042] Now turn Figure 3-11C, illustrates a method and system 100 for forming the above-described sole structure 14. Generally, the system 100 and method provide a way to temporarily plug the receptacle 22 of the insert 18 with material 102 during molding of the sole structure 14 to prevent contamination of the engagement features 25a of the receptacle 22 with material used in forming the sole plate 16. After the sole structure 14 is formed, the material 102 can be removed from the receptacle 22 to expose the first engagement features 25a.

[0043] Reference Figure 3 , the system 100 is provided with a plug material 102 that is operable to be shaped and molded to temporarily plug the receptacle 22 of the insert 18. The plug material 102 may include an elastomer having a relatively low hardness. For example, a material having a hardness of less than 100 Shore A can be used, and more specifically, a material having a hardness ranging from 10 Shore A to 60 Shore A can be used. The plug material 102 may include a thermosetting material, a thermosetting material (i.e., a material that is initially thermoplastic but becomes thermosetting after curing), or a thermoplastic material that has a desired hardness when cured. In one example, the plug material 102 is a thermosetting material that can be cured under the application of heat. The plug material 102 may include natural rubber or a synthetic rubber (e.g., gum or green rubber), such as styrene-butadiene rubber, isoprene rubber, silicone rubber, or a combination thereof.

[0044] Still refer to Figure 3 The sheet 102a of plug material 102 is provided to the system 100 in a forgeable state and has a substantially constant thickness T 102a As shown, the system 100 also includes a mold 104 configured to form the sheet 102a into a preform 102b having a plurality of blanks 102c of the plug material 102. Here, the mold 104 includes a plurality of mold cavities 106 corresponding to the desired shapes of the plug material blanks 102c. For example, the mold cavities 106 of the illustrated example have a rectangular profile for forming rectangular blanks 102c. In one step, the mold 104 at least partially presses through the thickness T of the sheet 102a. 102a (as indicated by arrow D1 ) such that the contour of the mold cavity 106 is imparted to the sheet 102a to form a preform 102b having a plurality of blanks 102c.

[0045] In the illustrated example, the die 104 presses only partially through the thickness T of the sheet 102a. 102a , so that a web region 108 is formed between adjacent ones of the blanks 102c. The web region 108 has a thickness that is less than the initial thickness T of the blank 102c and the sheet 102a. 102a, to provide the preform 102b with a series of tear seams along which individual ones of the blanks 102c can be removed from the preform 102b. Optionally, the web region 108 can be perforated to facilitate tearing or removal of the blank 102c.

[0046] Now refer to Figure 4 , the blanks 102c can be trimmed so that the first material 102 is appropriately sized for insertion into the receiving portion 22. In particular, the volume of each blank 102c can be trimmed to be larger than the volume of the receiving portion 22 so that when the plug material 102 is inserted into the receiving portion 22, the receiving portion 22 will be filled with the plug material 102 to cover the engagement feature 25a, as described in more detail below. In the illustrated example, the size of the blank 102c is set by trimming the blank 102c of the preform 102b using a cutting tool (e.g., scissors). However, in other examples, the blanks 102c can initially be formed by the mold 104 with a desired volume, whereby the individual blanks in the blanks 102c can be removed from the preform 102b without additional trimming.

[0047] exist Figure 5 , a blank 102c of plug material 102 is formed into plugs 102d that are configured to be inserted into the receptacles 22 of the insert 18. Typically, each of the plugs 102d is sized to fill the receptacles 22 such that each of the first engagement features 25a is obscured or covered by the plug material 102. As shown, each plug 102d may be formed to have a length L 102d and diameter or width W 102d Here, the length L of the plug 102d is 102d and width W 102d Both are larger than the length L of the accommodation portion 22 24 and width W 22 In particular, the width W of the plug 102d is formed by the outer diameter of the plug 102d. 102d is larger than the minor diameter of the female helical threads forming the first engagement feature 25a, such that when the plug 102d is disposed within the receptacle 22, the plug material 102 will at least partially extend into the female helical threads. For example, the width W of the plug 102d is 102d (ie, the outer diameter) may be greater than the width W of the receiving portion 22. 22 (ie, small diameter) 10% to 25% larger (eg, a 5 mm diameter plug inserted into a 4.5 mm diameter receptacle).

[0048] Optionally, the plug 102d may be formed with a first guide hole 110 configured to align the insert 18 during the molding step, as described in more detail below. In the illustrated example, the first guide hole 110 is formed along the length L of the plug 102d. 102d Here, the hole 110 is defined by the blank 102c being rolled into the shape of the plug 102d, whereby the inner surface of the blank 102c forms the hole 110. However, the hole 110 can be formed by a separate operation, such as by piercing the plug 102d with a punch. As described below, the size (e.g., diameter) of the cross section of the hole 110 is selected to provide a slight interference fit between the plug 102d and corresponding features of the insert die 112.

[0049] Although the previous steps provide a method for forming the plug 102d from the sheet 102a of plug material 102, in other examples, the plug 102d can be formed from other types of material stock. For example, the plug material 102 can be provided as a sheet of the desired diameter W of the plug 102d. 102d The rod stock is provided, from which the desired length L of the plug 102d can be cut 102d Thus, the illustrated example of plug 102d shows the seam and hole 110 resulting from forming plug 102d from one of blanks 102c, in other examples, plug 102d may be a solid body having a shape corresponding to receptacle 22. In such an example, hole 110 may be provided along the length of the bar stock, or may be provided after the bar stock is cut to the desired length L. 102d It is then subsequently formed in the plug 102d.

[0050] Now refer to Figure 6A and Figure 6B , the plug 102d is shown inserted into the receiving portion 22 of the insert 18. In the illustrated example, the plug material 102 is provided in a forgeable state and can be pressed into the receiving portion 22 through the threads 25a. Here, the larger diameter W of the plug 102d is 102d The plug material 102 will be made to conform to the profile of the female threads 25a, thereby partially filling the threads 25a. Figure 6B As provided above, the length L of the plug 102d 102d and width W 102d Greater than the length L of the accommodation portion 22 24 and width W 22 , such that a portion of the plug 102 d protrudes from each end 28 , 30 of the bushing 24 .

[0051] Reference Figure 7, the system 100 also includes an insert mold 112 that is configured to form and cure the plug material 102 within the receptacle 22. For example, with the plug 102d inserted into the receptacle 22 of the insert 18, the insert 18 is positioned within the insert mold 112. As shown, the insert mold 112 includes a mold cavity 114 having one or more sockets 116 for receiving the insert 18 and the plug 102d. Each socket 116 includes a recess 118 for receiving and aligning the position of the insert 18 within the mold cavity 114. The recess 118 has a cross-sectional shape that corresponds to the profile of the peripheral side surface 32 of the bushing 24, whereby the bushing 24 can be at least partially inserted into the recess 118 to position the insert 18 and the plug 102d in the mold cavity 114.

[0052] Each seat 116 may include a pin 120 extending from the recess 118 and configured to be inserted at least partially through the plug 102d to form a length L extending at least partially through the plug 102d. 102d The guide hole ( Figure 8 In the illustrated example, the pin 120 has a width W of 120 Greater than the width W of the hole 110 110 ( Figure 6B ), so that when the insert 18 and the plug 102d are placed at the seat 116, the pin 120 is press-fit into the hole 110 to fix the position of the insert 18 and the plug 102d. However, in other examples where the plug 102d is provided without the hole 110, the pin 120 can be configured to pierce the plug 102d.

[0053] With the insert 18 and the plug 102d positioned in the mold cavity 114, the insert mold 112 is closed and the insert 18 and the plug 102d are subjected to heat and pressure to mold the plug 102d within the receptacle 22. Optionally, the molding process may fully or partially cure the plug material 102. In one example, when the plug material 102 is a silicone material, the insert 18 and the plug 102d may be pressed at a temperature of approximately 170 degrees Celsius for approximately five minutes to mold and at least partially cure the silicone material, thereby increasing its hardness. During the pressing operation, the plug material 102 is pressed into the female threads 25a of the receptacle 22 to completely seal the threads. In addition, the size and shape of the pin 120 will be imparted to the cured plug 102d such that when the insert 18 is removed from the insert mold 112, the plug 102d will remain at least partially formed through the plug and have a width W of the same as the pin 120. 120 Similar width W 122 The shape of the alignment feature 122 is as follows Figure 8 shown.

[0054] Now refer to Figure 8 During the molding process, excess plug material 102 may form a flash 102e around the bushing 24 of the insert 18. Figure 8 Another step is illustrated in which the flash 102e is separated from the molded plug 102d, leaving only the molded plug 102d and the insert 18. As shown, once the flash 102e is removed, the molded plug 102d is flush with each of the first end 28 and the second end 30 of the bushing 24, so that all of the threads 25a of the receiving portion 22 are covered by the plug material 102. Alternatively, when the plug material 102 is a thermosettable material and has not yet been cured in the previous step, the plug material 102 can be cured once all of the threads 25a of the receiving portion 22 are covered by the plug material 102.

[0055] exist Figure 9 In the embodiment of the present invention, one or more of the inserts 18 are attached to a base 46 to form the sole plate 16. Collectively, the base 46, the attached inserts 18, and the plug 102d can be referred to as the carcass 47 of the sole plate 16, which comprises the physical components of the sole plate 16 before providing the molding material 54 (e.g., resin). The base 46 can be a fabric or fiber material configured for use in forming a composite material. For example, the base 46 can be a unidirectional tape or a multiaxial fabric having a series of fibers 48 impregnated with resin. The base 46 can include at least one of carbon fibers, aramid fibers, boron fibers, glass fibers, and other polymer fibers that form a unidirectional sheet or multiaxial fabric. Fibers 48 (such as carbon fibers, aramid fibers, and boron fibers) can provide a high Young's modulus, while glass fibers (e.g., fiberglass) and other polymer fibers (e.g., synthetic fibers such as polyamides, polyesters, and polyolefins other than aramid) provide a medium modulus. Additionally or alternatively, the base 46 can include a unidirectional tape. Furthermore, the substrate may include multiple sheets, wherein one or more of the sheets include fibers formed from the same material, or alternatively, one or more of the sheets include fibers 48 formed from a different material than the fibers 48 of the other sheets.

[0056] As shown, the base 46 includes one or more openings 50 for receiving a portion of a corresponding one of the inserts 18. The openings 50 can be formed in the base 46 by a stamping or cutting process. In some examples, the openings 50 can be sized to receive one end 28, 30 of the bushing 24 therethrough so that the surfaces 34, 36 of the flange 26 of the insert 18 face and abut the face of the base 46 surrounding the opening 50. Thus, the width of each opening 50 can be greater than the width W of the bushing 24. 24 , but less than the width W of the flange 26 26 .like Figure 9As shown, the insert 18 may be attached to the substrate by stitching 52. For example, the insert 18 may be attached by stitching through holes 42 formed in the flange 26.

[0057] Now refer to Figure 10-11C , the system 100 may include a plate mold 124 for forming the sole plate 16. Figure 11A As shown, plate mold 124 includes a mold cavity 126 defined by an upper mold surface 128 and a lower mold surface 130. Mold cavity 126 is configured to receive and enclose carcass 47 therein. One or both of mold surfaces 128, 130 may include contours or features configured to receive base 46 and insert 18 and impart a desired contour to molded sole plate 16.

[0058] As shown, the plate mold 124 may include one or more fixtures 132 positioned within the mold cavity 126, the fixtures 132 being configured to position each of the inserts 18 in a desired arrangement. In the illustrated example, the fixtures 132 are embodied as pins 132 extending from the lower mold surface 130. Here, the pins 132 are provided having a diameter or width W defined by an outer peripheral sidewall. 132 The cylindrical body. Figure 11B As shown, the width W of the cross section of each pin 132 is 132 is selected to be greater than the width W of the cross section of the alignment feature 122 formed in the plug 102d. 122 , so that when the insert 18 and the plug 102d are pressed onto the pin 132, the pin 132 will provide an interference fit with the alignment feature 122. For example, the width W of the pin 132 132 (ie, outer diameter) may be greater than the width W of the alignment feature 122 122 By providing an interference fit between the pin 132 and the plug 102 d, the position of the insert 18 within the mold cavity 126 is maintained during the molding process, thereby providing consistent positioning of the insert 18 within the finished sole plate 16.

[0059] like Figure 11BAs best shown in FIG, when the base 46 and inserts 18 are positioned within the plate mold 124 and engaged with the jig 132, at least one of the ends 28, 30 of one or more of the inserts 18 can be protected from the molding material 54 covering the ends 28, 30. For example, in the illustrated example, the second end 30 of each of the inserts 18 rests against the lower mold surface 130 to form a seal around the second end 30 of the inserts 18. Thus, when the molding material 54 is provided to the mold cavity 126, the second end 30 of the inserts 18 will be obscured by the lower mold surface 130 so that when the molded sole structure 14 is removed from the mold 124 ( Figure 12 ), the second ends 30 of the inserts 18 will be exposed through the bottom surface of the sole structure 14. In other examples, the first end 28 of each insert 18 may additionally or alternatively be obscured by the upper mold surface 128 during the molding process.

[0060] Reference Figure 11C With the substrate 46 and insert 18 positioned and secured within the mold cavity 126, the mold 124 is moved to a closed position to seal the mold cavity 126, and a molding material 54 is provided to the mold cavity 126. In some examples, the molding material 54 is a liquid molding material 54 that can be cured by applying heat and / or pressure. The molding material 54 can include a molten thermoplastic material and / or a liquid material, a curable thermosetting material. For example, the molding material 54 can include at least one of an epoxy resin, a polyurethane, a polymerizable composition, a prepolymer, or a combination thereof.

[0061] When the molding material 54 is injected into the mold cavity 126, the high pressure of the molding material 54 causes the molding material 54 to fill the mold cavity 126 and impregnate the fibers 48 of the base 46. However, by providing the insert 18 with the plug 102d that is in sealing contact with the engagement feature 25a of the receiving portion 22, the molding material 54 is prevented from flowing into the receiving portion 22. In addition, the sealed interface between the pin 132 of the plate mold 124 and the alignment feature 122 prevents the molding material 54 from flowing into the alignment feature 122. The molding material 54 is then cured in the mold cavity 126 at a predetermined temperature and pressure to form the sole structure 14 including the sole plate 16 and the insert 18.

[0062] Now turn Figure 12Once the molding material 54 of the sole plate 16 is cured, the sole structure 14 is removed from the mold cavity 126 for a series of finishing steps. As shown, after the sole structure 14 is removed from the mold cavity 126, the plug 102d remains within the receptacle 22 and must therefore be removed. In the illustrated example, the system 100 can be provided with a punch 134 that is sized to remove the plug 102d from the receptacle 22. Specifically, the punch 134 can include a punch having a width W 136 The plunger 136 has a width W 136 Smaller than the width of the receiving portion 22 and larger than the width W of the alignment feature 122 122 Thus, the plunger 136 is configured to press against the end of the plug 102d and through the receptacle 22 to remove the plug 102d from the receptacle 22. Optionally, the punch 134 may include a protrusion 138 configured to engage the alignment feature 122 of the plug 102d. For example, the protrusion 138 may have a width W 138 , operable to be inserted into the alignment feature 122 to maintain the relative position between the plug 102d and the punch 134. In some examples, the punch 134 can be provided in conjunction with a mechanical press. However, the punch 134 can also be manually operated.

[0063] As the plug 102d is removed from the receiving portion 22, the first engagement feature 25a (i.e., thread) of the receiving portion 22 can be cleaned to ensure that all of the plug material 102 is removed from the receiving portion 22. As shown, in the case where the first engagement feature 25a is formed as a helical thread, the tapping step can include advancing a tap 140 having a corresponding male helical thread through the receiving portion 22 to remove any remaining fragments of the plug material 102. In other examples, in the case where the first engagement feature 25a is provided as a keyway or other attachment geometry, different tools can be used to clean the first engagement feature 25a. For example, a fluid such as compressed air or vacuum can be used to clean the first engagement feature 25a. Once the sole structure 14 is completed, the sole structure can be attached to the upper 12 of the article of footwear 10 using conventional methods.

[0064] The system 100 and method provided above provide an efficient way to form a molded part including a threaded insert embedded therein. Specifically, the system 100 and method allow the insert to be attached to the base material of the molded part before the molding process, and then the insert is accurately placed in a predetermined position within the mold. In addition to providing fixation for the insert during the molding process, the aforementioned system 100 and method improve the quality of the molded part by preventing contamination of the key features of the insert during the molding process. Specifically, the molded plug 102d is configured to cover and / or seal key features (e.g., threads), making it possible to easily protect the key features. Although the present disclosure is provided with respect to forming a sole structure for an article of footwear, it will be understood that the methods discussed herein can be applied to forming other types of molded parts, including any insert having key features that must be unobstructed during the use of the part.

[0065] The following clauses provide exemplary configurations for the methods, systems, sole structures, and articles of footwear described above.

[0066] Item 1. A method of forming a molded article, the method comprising the steps of: positioning a plug comprising a first material within a receptacle of an insert, the receptacle comprising an engagement feature; placing the insert comprising the first material into a mold; applying a liquid second material to an outer surface of the insert; curing the liquid second material to a solid to form the molded article comprising the insert embedded in a solid second material, wherein a surface of the insert is exposed in the molded article; removing the molded article from the mold; and removing the first material from the receptacle of the insert embedded in the molded article to expose the engagement feature.

[0067] Clause 2. The method of Clause 1, further comprising forming an alignment feature in the plug, the alignment feature configured to engage a corresponding fixture of the mold.

[0068] Clause 3. The method of Clause 2, wherein forming the alignment feature comprises forming the alignment feature to have an interference fit with the fixture.

[0069] Clause 4. The method of any preceding clause, further comprising molding the plug comprising the first material within the receptacle to cover the engagement feature.

[0070] Clause 5. The method of Clause 4, wherein molding the plug comprises pressing the plug into the receptacle under the action of heat and pressure.

[0071] Clause 6. The method of any preceding clause, further comprising attaching the insert to a flexible substrate to form a carcass.

[0072] Clause 7. The method of Clause 6, wherein the flexible substrate comprises a plurality of fibers selected from carbon fibers, aramid fibers, boron fibers, polymer fibers, glass fibers, or any combination thereof.

[0073] Clause 8. The method of any preceding clause, wherein the first material is an elastomer.

[0074] Clause 9. The method of any preceding clause, wherein applying the liquid second material comprises an injection molding process.

[0075] Clause 10. The method of any preceding clause, wherein the insert comprises a sleeve and a flange extending laterally outward from the sleeve.

[0076] Clause 11. The method of Clause 10, wherein the receptacle comprises a hole formed at least partially through the bushing.

[0077] Clause 12. The method of any preceding clause, further comprising forming the first material into the plug before placing the first material into the insert.

[0078] Clause 13. The method of Clause 12, wherein the plug has a first width that is greater than a second width of the receptacle.

[0079] Clause 14. The method of any preceding clause, wherein removing the first material from the receptacle comprises pulling the first material from the receptacle.

[0080] Clause 15. The method of any preceding clause, wherein removing the first material from the receptacle comprises applying a vacuum to the receptacle.

[0081] Clause 16. The method of any preceding clause, wherein the molded article is a component of an article of footwear.

[0082] Clause 17. The method of Clause 16, wherein the component of the article of footwear is a sole structure.

[0083] Clause 18. The method of Clause 17, wherein the sole structure includes a sole plate configured to engage the ground.

[0084] Clause 19. A molded article made by the method of any preceding method clause.

[0085] Clause 20. An article of footwear comprising the molded article of Clause 19.

[0086] Item 21. A system for forming a sole structure for an article of footwear, the system comprising: a plate mold, the plate mold including a plate mold cavity; an insert, the insert being disposed within the plate mold cavity and including a receiving portion; a plug, the plug comprising a first material disposed within the receiving portion of the insert, the first material having a hardness less than 100 Shore 00; and a second material, the second material being disposed within the plate mold cavity and contacting an outer surface of the insert.

[0087] Clause 22. The system of Clause 21, wherein the receptacle comprises a hole formed through at least one end of the insert and comprising an engagement feature.

[0088] Clause 23. The system of Clause 22, wherein the first material covers the engagement feature and is flush with the at least one end of the insert.

[0089] Clause 24. The system of clause 23, wherein the first material is an elastomer.

[0090] Clause 25. The system of any preceding clause, wherein the insert is attached to the substrate by suturing.

[0091] Clause 26. The system of Clause 25, wherein the second material is disposed within the plate mold cavity and impregnates the substrate.

[0092] Clause 27. The system of Clause 26, wherein the first diameter of the plug is greater than the second diameter of the receptacle.

[0093] Clause 28. The system of Clause 27, wherein the plug comprises an alignment feature.

[0094] Clause 29. The system of Clause 28, wherein the plate mold cavity includes a fixture configured to interference fit with the alignment feature.

[0095] Clause 30. The system of any preceding clause, wherein the first material extends through the entire length of the insert.

[0096] Clause 31. A molded article made using the system of any preceding system clause.

[0097] Clause 32. An article of footwear comprising the molded article of Clause 31.

[0098] The foregoing description has been provided for the purpose of illustration and description. This foregoing description is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in a selected configuration, even if not explicitly shown or described. Individual elements or features of a particular configuration can also be varied in many ways. Such variations are not considered to depart from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A method of forming a molded article, the method comprising the steps of: placing a plug comprising a first material that is an elastomer within a receiving portion of the insert, the receiving portion comprising an engagement feature; forming a guide hole in the plug, the guide hole being configured to engage a corresponding pin of the mold; removing a portion of the first material formed outside the receiving portion of the insert so that the first material covers the engagement feature while being arranged flush with both ends of the insert; placing the insert comprising the first material into the mold; applying a liquid second material to an outer surface of the insert; solidifying the liquid second material into a solid, thereby forming the molded article comprising the insert embedded in the solid second material, wherein a surface of the insert is exposed in the molded article; removing the molded article from the mold; as well as The first material is removed from the receiving portion of the insert embedded in the molded article to expose the engagement feature. 2 . The method of claim 1 , further comprising forming an alignment feature in the plug, the alignment feature configured to engage a corresponding fixture of the mold. 3 . The method of claim 2 , wherein forming the alignment feature comprises forming the alignment feature to have an interference fit with the fixture.

4. The method of any one of claims 1-3, further comprising molding the plug comprising the first material within the receptacle to cover the engagement feature.

5. The method of claim 4, wherein molding the plug comprises pressing the plug into the receptacle under the action of heat and pressure.

6. The method of any one of claims 1-5, further comprising attaching the insert to a flexible substrate to form a carcass.

7. The method of claim 6, wherein the flexible substrate comprises a plurality of fibers selected from carbon fibers, aramid fibers, boron fibers, polymer fibers, glass fibers, or any combination thereof.

8. The method of any one of claims 1-7, wherein applying the liquid second material comprises an injection molding process.

9. The method of any one of claims 1-8, wherein the insert comprises a sleeve and a flange extending laterally outward from the sleeve.

10. The method of claim 9, wherein the receptacle comprises a hole formed at least partially through the bushing.

11. The method of any one of claims 1-10, further comprising forming the first material into the plug before placing the first material into the insert. 12 . The method of claim 11 , wherein the plug has a first width greater than a second width of the receiving portion.

13. The method of any one of claims 1-12, wherein removing the first material from the receptacle comprises pulling the first material from the receptacle.

14. The method of any one of claims 1-13, wherein removing the first material from the receptacle comprises applying a vacuum to the receptacle.

15. The method of any one of claims 1-14, wherein the molded article is a component of an article of footwear.

16. The method of claim 15, wherein the component of the article of footwear is a sole structure.

17. The method of claim 16, wherein the sole structure includes a sole plate configured to engage the ground.

18. A molded article made by the method according to any one of claims 1 to 17.

19. An article of footwear comprising the molded article of claim 18.

20. A system for forming a sole structure for an article of footwear, the system comprising: a plate mold comprising a plate mold cavity and a pin extending into the plate mold cavity; an insert disposed within the panel mold cavity and comprising a receiving portion; a plug including a guide hole corresponding to and disposed on the pin of the plate mold, and comprising a first material disposed within the receiving portion of the insert, the first material being an elastomer having a hardness less than 100 Shore 00, the first material covering the engagement features of the receiving portion and being flush with both ends of the insert; as well as A second material is disposed within the plate mold cavity and contacts an outer surface of the insert.

21. The system of claim 20, wherein the receptacle comprises a hole formed through at least one end of the insert and comprising the engagement feature.

22. The system of claim 21, wherein the first material covers the engagement feature and is flush with the at least one end of the insert.

23. The system of any one of claims 20-22, wherein the insert is attached to the substrate by suturing.

24. The system of claim 23, wherein the second material is disposed within the plate mold cavity and impregnates the substrate.

25. The system of claim 24, wherein the first diameter of the plug is greater than the second diameter of the receptacle.

26. The system of claim 25, wherein the plug includes an alignment feature.

27. The system of claim 26, wherein the plate mold cavity includes a fixture configured to provide an interference fit with the alignment feature.

28. The system of any one of claims 20-27, wherein the first material extends through the entire length of the insert.

29. A moulded article made using the system of any one of claims 20-28.

30. An article of footwear comprising the molded article of claim 29.

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