Method for manufacturing a footwear component

Abstract

A method for physically foaming a footwear component using a single-phase solution of a polymer composition and a supercritical fluid is provided. The method includes conditioning the temperature of a mold and then engaging the mold with a robot that transports the mold to a press. At the press, a gas backpressure is applied to the cavity of the mold before injecting the single-phase solution of the polymer composition and the supercritical fluid into the cavity of the mold. The process continues where the gas backpressure is released from the cavity of the mold and then the footwear component is removed from the cavity of the mold. The parameters of the method are configured to form the footwear component in an automated manner.

Description

Technical Field

[0001] Aspects of the present disclosure relate to systems and methods for forming physically foamed footwear or other apparel or equipment components. Background Art

[0002] Injection molding is used to manufacture various components of footwear products, such as footwear soles, footwear uppers, and parts of footwear soles or footwear uppers (e.g., cushioning elements, trimming edges, etc.). For example, in some cases, an injection molding system is used to distribute a polymer melt into the cavities of a mold, after which the polymer melt solidifies into a polymer product having the shape of the mold cavities. In some cases, such as when manufacturing a footwear sole (e.g., all or part of a footwear midsole), it may be advantageous for the polymer product to include a foamed material. Systems configured to mold foamed polymer products may include some components different from those of systems configured to mold non-foamed polymer products. For example, some injection molding systems both foam and mold polymer compositions. Summary of the Invention

[0003] This Summary of the Invention is provided to introduce a selection of concepts that are further described below in the Detailed Description in a simplified form. This Summary of the Invention is not intended to identify key features or essential elements of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. The invention is defined by the claims. At a high level, the present disclosure relates to systems and methods for physically foaming using an injection molding system configured to mold various articles.

[0004] The present disclosure provides the following items:

[0005] 1. A method for physically foaming a footwear component, the method comprising: adjusting the temperature of a mold to a temperature between 15 degrees Celsius and 90 degrees Celsius; engaging the mold with an end effector of a robot transfer adapted to reversibly engage with the mold; transferring the mold to a press using the end effector; applying a gas backpressure to the cavity of the mold; injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold; releasing the gas backpressure from the cavity of the mold; and removing the footwear component from the cavity of the mold.

[0006] 2. The method according to item 1, further comprising selecting the mold from a plurality of molds housed at a temperature adjustment bracket before engaging the mold with the end effector of the robot transfer.

[0007] 3. The method according to item 1, further comprising reading an RFID tag of the mold using an RFID reader.

[0008] 4. The method according to item 1, wherein joining the mold comprises: positioning the end effector at the mold, wherein a first side of the end effector is on a first side of the mold and a second side of the end effector is on a second side of the mold; and positioning the first side of the end effector to the first side of the mold such that a first protrusion of the first side of the end effector is inserted into a first plate-manipulator keyway of the first side.

[0009] 5. The method according to item 1, wherein joining the mold further comprises reading an RFID tag of the mold with an RFID reader of the end effector.

[0010] 6. The method according to item 1, further comprising selecting the mold with the end effector at least partially based on the mold reaching a defined temperature within a temperature-regulated temperature range.

[0011] 7. The method according to item 6, further comprising: positioning the mold on a platen of the press with the end effector; raising the platen supporting the mold within the press; joining the mold with a common runner plate; aligning a runner outlet of the common runner plate with a runner of the mold; and aligning a gas port of the common runner plate with a gas port of the mold.

[0012] 8. The method according to item 7, wherein the common runner plate is a hot runner plate, and the method further comprises circulating a temperature-regulating fluid through channels of the common runner plate.

[0013] 9. The method according to item 8, wherein the temperature-regulating fluid circulating through the channels of the common runner plate is in a range from about 20 degrees Celsius to about 250 degrees Celsius.

[0014] 10. The method according to item 1, wherein the polymer composition is a thermoplastic polyester composition.

[0015] 11. The method according to item 1, wherein the footwear component has a relative density of 0.1 to 0.6.

[0016] 12. The method according to item 1, wherein after injecting the single-phase solution, a gas backpressure is maintained in the cavity of the mold at a pressure effective to maintain the single-phase solution as a single-phase solution in the cavity of the mold for about 0.5 seconds to about 10.0 seconds.

[0017] 13. The method according to item 1, further comprising: joining the mold with the end effector at the press; and transferring the mold to a temperature-regulating bracket with the end effector.

[0018] 14. The method according to item 1 further includes: reading the RFID tag of the mold with the RFID reader of the end effector; and reading the RFID tag of the mold with the RFID reader of the temperature adjustment bracket.

[0019] 15. The method according to item 1 further includes adjusting the temperature of the mold at the temperature adjustment bracket after injecting the single-phase solution and before removing the footwear component from the cavity of the mold.

[0020] 16. The method according to item 1 further includes positioning the mold having the footwear component in the cavity of the mold at a position other than the press for about 1 minute to about 90 minutes before removing the footwear component from the cavity of the mold.

[0021] 17. The method according to item 1 further includes reducing the temperature of the single-phase solution in the cavity of the mold after injecting the single-phase solution and before reducing the gas backpressure to a pressure below the pressure effectively maintaining the supercritical fluid in the supercritical fluid state.

[0022] 18. The method according to item 1 further includes transferring the mold to the temperature adjustment bracket using the end effector after removing the footwear component from the cavity of the mold.

[0023] 19. A method for physically foaming a footwear component, the method including: adjusting the mold temperature to a temperature of about 15 degrees Celsius to about 90 degrees Celsius; applying a gas backpressure to the cavity of the mold; injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold; releasing the gas backpressure from the cavity of the mold; and removing the footwear component from the cavity of the mold.

[0024] 20. The method according to item 19 further includes adjusting the temperature of the mold at the temperature adjustment bracket after injecting the single-phase solution and before removing the footwear component from the cavity of the mold. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Some of the subject matter described in this disclosure includes systems, tools, and methods for an injection molding system for molding physically foamed components. The subject matter is described in detail below with reference to the accompanying drawings, which are submitted with this specification and incorporated herein by reference:

[0026] Figure 1 A footwear article component according to aspects herein is depicted;

[0027] Figure 2Depicts a schematic plan view of a footwear component manufacturing system in a first configuration in accordance with various aspects of the present disclosure;

[0028] Figure 3 Depicts a schematic plan view of a footwear component manufacturing system in a second configuration in accordance with various aspects of the present disclosure;

[0029] Figure 4 Depicts a perspective view of a temperature regulating bracket and a temperature control unit in accordance with various aspects of the present disclosure;

[0030] Figure 5 Depicts a Figure 4 temperature regulating bracket and a temperature control unit having a plurality of molds in accordance with various aspects of the present disclosure;

[0031] Figure 6 Depicts a Figure 5 rear perspective view of the temperature regulating bracket in accordance with various aspects of the present disclosure;

[0032] Figure 7 Depicts an end effector in a first configuration in accordance with various aspects of the present disclosure;

[0033] Figure 8 Depicts an Figure 7 end effector in a second configuration in accordance with various aspects of the present disclosure;

[0034] Fig. 9 Depicts a perspective view of a mold in accordance with various aspects of the present disclosure;

[0035] Fig.10 Depicts a Fig. 9 side view of the mold in accordance with various aspects of the present disclosure;

[0036] Fig.11 Depicts a perspective view of a press in accordance with various aspects of the present disclosure;

[0037] Fig.12 Depicts a front view of a press from Fig.11 in a first configuration in accordance with various aspects of the present disclosure;

[0038] Fig.13 Depicts a front view of a press with a mold from Fig.11 in a second configuration in accordance with various aspects of the present disclosure;

[0039] Fig.14A Depicts a perspective view of a mold that is connected to a hot runner plate to form a tool assembly in accordance with various aspects of the present disclosure;

[0040] Fig. 14B Depicts a Fig.14A partial exploded view of the tool assembly, showing a second mold plate separated from a mold annular plate, in accordance with various aspects of the present disclosure;

[0041] Fig.15A depicts a front view of a mold and a hot runner plate according to various aspects of the present disclosure; Fig.14A

[0042] Fig. 15B depicts internal components of a hot runner plate according to various aspects of the present disclosure; Fig.15A

[0043] Fig. 15C depicts a cross-sectional view taken along line 15C-15C in Fig. 15B according to various aspects of the present disclosure;

[0044] Fig.16 depicts a side view of a mold and a hot runner plate according to various aspects of the present disclosure; Fig.14A

[0045] Fig.17 depicts a bottom plan view of a mold and a hot runner plate according to various aspects of the present disclosure; Fig.14A

[0046] Fig.18A depicts a press aligned with a syringe according to various aspects of the present disclosure; Fig.11

[0047] Fig.18B depicts an injection manifold according to various aspects of the present disclosure;

[0048] Fig.19 depicts a paired press and syringe of FIG. 18a according to various aspects of the present disclosure;

[0049] Fig. 20 depicts a perspective view of a syringe of FIG. 18 according to various aspects of the present disclosure;

[0050] Fig.21 depicts a side view of a syringe according to various aspects of the present disclosure; Fig. 20

[0051] Fig. 22 depicts a cross-sectional view of a syringe taken along section line 22-22 according to various aspects of the present disclosure; Fig.21

[0052] Fig.23 depicts a perspective view of an unloading machine according to various aspects of the present disclosure;

[0053] Fig.24 depicts a side view of an unloading machine according to various aspects of the present disclosure; Fig.23

[0054] Fig.25 depicts an unloading machine in a first configuration according to various aspects of the present disclosure; Fig.24Cross-sectional view of a unloading machine;

[0055] Fig.26 Depicts a unloading machine with a mold in a second configuration according to various aspects herein Fig.24 Cross-sectional view of a unloading machine;

[0056] Fig. 27 Depicts a flowchart representing a first method of physically foaming a footwear component according to various aspects herein;

[0057] Fig.28 Depicts a flowchart representing a second method of physically foaming a footwear component according to various aspects herein;

[0058] Fig.29 Depicts a flowchart representing a third method of physically foaming a footwear component according to various aspects herein;

[0059] Fig.30 Depicts a flowchart representing a fourth method of physically foaming a footwear component according to various aspects herein; and

[0060] Fig.31 Depicts a flowchart representing a workflow process for manufacturing foamed polymer articles (such as segments of footwear articles) from virgin and recycled thermoplastic polymer elastomer compositions. Detailed Description

[0061] Footwear articles can include various components formed from a foamed polymer composition. For example, a sole that can include an insole, a midsole, and / or an outsole can be formed from a foamed polymer composition. Other components (such as inserts, liners, uppers, etc.) are also contemplated components of footwear articles that can be formed from a foamed polymer composition. Depending on the polymer composition, how the polymer composition is foamed, and other process variables, foam components can pose challenges for recycling or otherwise sustainably disposing of at the end of the useful life or at the end of manufacturing. The systems and methods provided herein can form foamed polymer composition components that are more suitable for recycling, reusing, and / or reforming than conventionally formed foamed polymer compositions.

[0062] However, it is challenging to develop systems and methods for producing foamed polymer composition components suitable for footwear products while still providing improved sustainability. The systems and methods disclosed herein provide a foamed polymer composition that can be recycled into the manufacturing stream and / or other recycling streams (e.g., post-consumer recycling streams) to potentially limit the environmental impact caused by the foamed polymer components. This is achieved by manipulating the components of the system, the parameters of the operation of the system components, the foamed polymer composition, and the foaming process used to foam the polymer composition. As will be illustrated in detail below, the combination of two or more variables provides a solution for forming a foamed polymer composition that provides enhanced environmental sustainability results.

[0063] For example, the systems and methods provided herein contemplate physically foaming a thermoplastic elastomer composition, which includes a thermoplastic polyester composition (i.e., a polymer composition including one or more thermoplastic polyester elastomers), in a temperature-regulated mold. However, the process of physically foaming a thermoplastic elastomer composition is sensitive to manufacturing variables such as time, pressure, and temperature. Accordingly, the identification of various manufacturing processes and specific variables of the components that result in acceptable physically foamed components has been developed through continuous investment in time, experimentation, and resources. The resulting tools, components, processes, and manufacturing controls are provided below.

[0064] Physical foaming is the process of foaming a polymer composition with a physical blowing agent (as opposed to a chemical blowing agent). Inert compositions such as nitrogen or carbon dioxide (CO2) are examples of physical blowing agents contemplated herein. In an example, unlike a chemical blowing agent that effectively foams a polymer composition through a deflation effect (such as raising the temperature of the chemical blowing agent above its degradation temperature), a physical blowing agent effectively foams the polymer composition by inducing a pressure change in the physical blowing agent. In some examples, the physical blowing agent can be in a gaseous state, a liquid state, and / or a supercritical fluid state. For example, the physical blowing agent can be a supercritical fluid that, when exposed to a reduced pressure (e.g., a pressure below the critical pressure of the physical blowing agent), is released from the solution, causing the foaming action to occur.

[0065] A supercritical fluid is a fluid in a supercritical fluid phase, having a temperature and pressure above the critical point of the composition. For example, the critical point of nitrogen is -147 degrees Celsius and 34.0 bar, and the critical point of carbon dioxide is 31.2 degrees Celsius and 73.8 bar. As will be discussed below, a single-phase solution comprising a supercritical fluid (e.g., carbon dioxide or nitrogen) dissolved in a molten polymer composition (e.g., a thermoplastic elastomer composition) can be injected into a mold as a single-phase solution. Once inside the mold, the pressure experienced by the injected material can be reduced, which causes the supercritical fluid to undergo a phase change from the supercritical fluid state to the gas state when the pressure is reduced below the critical pressure. The phase change of the physical blowing agent causes the physical blowing agent to be released from the solution with the polymer composition. This creates a cellular structure in the polymer composition, which results in a foamed polymer part. It is contemplated that other phase changes and / or pressure differentials can also be combined with the physical blowing agent to foam the polymer composition.

[0066] Aspects herein include a physical foaming injection molding system for a footwear component. It is contemplated that a single-phase solution comprising a polymer composition and a supercritical fluid is foamed through the system. The system includes an injector and a press paired with the injector. To achieve the efficiency of the manufacturing process in an automated manner, the system further includes a robot that includes an end effector adapted to reversibly engage with a mold. The mold is configured to engage with the injector and the press in such a way as to allow the robot to be positioned relative to the press to reversibly engage the end effector with the mold.

[0067] Aspects herein also include a physical foaming injection molding system for a footwear component, the system including a temperature control unit and a temperature regulating bracket effectively coupled to the temperature control unit. The temperature regulating bracket is adapted to regulate the temperature of a mold maintained at the temperature regulating bracket. The injector includes a physical blowing agent port and a physical blowing agent source fluidly coupled to the physical blowing agent port of the injector. The system further includes a press paired with the injector. The system further includes an unloader having a frame, an unloader plate, and a pair of unloader arms that move in unison in a first direction and non-unison in a second direction. The system further includes a robot having an end effector adapted to reversibly engage with a mold. The robot is positioned relative to the temperature regulating bracket, the press, and the unloader to manipulate the end effector at the temperature regulating bracket, the press, and the unloader to reversibly engage with the mold. As will be provided below, one or more of the recited components can be omitted, replaced, or added. Additionally, the arrangement of the various components of the system can be adjusted.

[0068] Aspects of the present disclosure also contemplate a method of physically foaming a footwear component, the method comprising adjusting the temperature of a mold to a temperature between 15 degrees Celsius and 90 degrees Celsius and then engaging the mold with a robotically transported end effector adapted to reversibly engage with the mold. The method continues by transporting the mold to a press with the end effector and then applying a gas backpressure to the cavity of the mold to pressurize the mold cavity. In an example, the gas backpressure is at or above the critical pressure of a physical blowing agent of a single-phase solution to be injected into the mold. The method continues by injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold. The method then continues by releasing the gas backpressure from the cavity of the mold and then finally removing the footwear component from the cavity of the mold. Additional or alternative steps may be implemented, as will be provided in more detail hereinafter. Additionally, one or more steps may be omitted in some examples.

[0069] One type of injection molding system for foaming and molding polymer compositions uses a microcellular injection molding process, where one or more supercritical fluids (e.g., supercritical nitrogen, supercritical carbon dioxide, etc.) are used as physical blowing agents. For example, a supercritical fluid can be injected into a polymer melt contained in an injection barrel of an injection molding system, where the supercritical fluid dissolves in the polymer melt to form a molten single-phase solution. The single-phase solution can then be flowed into a mold cavity, at which point conditions are adjusted to cause the supercritical fluid to transform into a gas (e.g., nucleate into a gas) and cause the polymer to solidify. This transformation of the polymer composition in the mold cavity can cause the polymer composition to expand (e.g., due to foaming) to fill the mold cavity and, once solidified, retain the shape of the foamed polymer product.

[0070] These types of injection molding systems that use a microcellular injection molding process are generally configured to control system parameters that can affect the properties of the foamed polymer product. System parameters can be controlled at various stages of the injection molding process. For example, parameters can be controlled at the melting and mixing components that form the single-phase solution and between the components that transport the single-phase solution to the mold. Additionally, parameters can be controlled at the mold. These stages can independently and / or jointly affect the melting, mixing, and molding processes.

[0071] Conventional injection molding systems are configured to perform a microcellular injection molding process. However, the properties of the parts generally molded with these systems are typically limited such that the operating parameters and tools of conventional systems are generally not calibrated to mold parts with different properties. For example, the part thickness or wall thickness of the parts generally molded in conventional systems may be relatively thin such that conventional systems cannot produce thicker parts with desired properties.

[0072] Turning to Figure 1, which depicts a footwear article component 100 in accordance with various aspects herein. The footwear article component 100 is a sole. As previously discussed, any foamed component is contemplated to be manufactured using the disclosed systems and methods provided herein, but in an example, the footwear article component 100 is a footwear sole (e.g., a footwear midsole). The footwear component 100 has an upper surface 102, a lower surface 104, a toe end 106, a heel end 108, a lateral side 110, and a medial side 112. The upper surface 102 is sometimes referred to as the foot-facing surface, and the lower surface 104 is sometimes referred to as the ground-facing surface, where both of these alternative designations are based on the conventional orientation of the footwear article during intended use.

[0073] The footwear component 100 can be of any size, but it includes those shoe sizes having a length between the toe end 106 and the heel end 108 in the range from 127 millimeters to 342 millimeters. The footwear component 100 has a width that can be of any size (such as in the range from 70 millimeters to 135 millimeters), which is measured perpendicular to a line extending between an extreme point at the toe end 106 and an extreme point at the heel end 108 on the widest part of the footwear component between the medial side 112 and the lateral side 110. The footwear component has a thickness that can be of any thickness, but in an example, the thickness between the upper surface 102 and the lower surface 104 at the thickest location is from 1 millimeter to 80 millimeters.

[0074] Accordingly, it is contemplated that the systems and methods provided herein effectively form foamed polymer components that have a relatively significant volume compared to articles formed by conventional physical foaming operations. Additionally, relative to articles formed by conventional physical foaming, the resulting foamed components produced by the systems and methods disclosed herein can have a high foaming ratio (e.g., the volume of the non-polymerized material relative to the volume of the polymerized composite of the resulting foamed article). For example, some foamed components formed by the methods and systems provided herein have a foaming ratio in the range from 90:10 to 65:35, such as 90:10, or 85:15, or 80:20, or 75:25, or 70:30, or 65:35, or ratios therebetween. In other words, it is contemplated that a footwear component having a foam ratio of 80:20 has 20% of the component volume formed by the polymer composite, and the remaining 80% of the foamed component volume is the open volume of the cell structure formed as a result of the foaming process (e.g., non-polymer composite). In yet another way of characterizing the foam composition, the relative density can be expressed. The relative density of a foam article (e.g., a foamed footwear component) is the density of the foamed article divided by the material forming the foamed article (e.g., the polymer composite). Accordingly, it is contemplated that the footwear component has a relative density in the range from 0.1 to 0.35, such as 0.1, or 0.15, or 0.2, or 0.25, or 0.3, or 0.35, or relative densities therebetween. This high foaming ratio results in foamed components suitable for use as footwear components.

[0075] It is contemplated that alternative sizes, shapes, and styles of soles can be formed by the provided systems and methods. It is contemplated that alternative components can be formed by the provided systems and methods. For example but not limited to, it is contemplated that insoles, midsoles, outsoles, inserts, or other foot support structures can be formed by the systems and methods provided herein. Additionally, footwear uppers, components of footwear uppers, or other components of a footwear article can also be formed by the methods and systems provided herein. Footwear component 100 is a non-limiting example of a footwear component that can be formed by the methods and systems provided herein.

[0076] Figure 2Depicts a schematic plan view of a footwear component manufacturing system 200 in a first configuration in accordance with aspects of the present disclosure. The system 200 is configured to move a tool, such as a mold, through various system components, such as a syringe 212. Moving the tool to the syringe, as opposed to moving the syringe to the tool, facilitates achieving greater throughput in manufacturing footwear components. For example, by moving the tool to the syringe, the syringe can inject during the time it would have moved in an alternative configuration where the syringe moves to the tool. Additionally, since various footwear component sizes (e.g., different sole sizes for different shoe sizes) can be manufactured within a common time period, a particular tool moved to the syringe can be adjusted to meet production requirements. In an alternative configuration where the syringe moves to the tool, travel time may increase when the syringe is forced to travel past tools that do not meet current production requirements. As such, moving the tool to the syringe (as provided in system 200) improves efficiency through flexible manufacturing. In alternative instances, it is contemplated that the syringe moves to two or more locations of the system, such as between two or more tool locations.

[0077] The system 200 includes, in a clockwise manner, a temperature conditioning bracket 202, a temperature control unit 228, a temperature conditioning bracket 204, a temperature conditioning bracket 206, a temperature control unit 230, a temperature conditioning bracket 208, a controller 216, a physical blowing agent supply source 218, a press 210, and a syringe 212, a metering feed source 220, a hopper 222, a temperature control unit 224, a gas backpressure source 226, an unloader, a robot 232, and an end effector 234. Each of the components of the system 200 will be discussed individually below.

[0078] A dashed representation of a tool (mold 201) is depicted at various elements of the system 200 (e.g., temperature conditioning bracket 202, press 210, unloader 214). The mold 201 is depicted in dashed lines to highlight that the mold 201 is transient in the system 200 and can thus be positioned or not positioned at one or more elements at a particular time. The mold 201 is configured to receive an injection of a polymer composition from the syringe 212 at the press 210. The injected polymer composition is formed into a foamed article within the mold. Examples of the mold 201, such as Figures 9 and 10 and FIG. 14A to FIG. 17 mold 900 in

[0079] will be described in connection with Figures 4 to 6The temperature conditioning bracket 202, discussed in more detail, is a temperature conditioning bracket that effectively conditions the temperature of the mold. Temperature conditioning affects the temperature of the conditioned article to a target temperature. Temperature conditioning can raise or lower the temperature of the article to the target temperature. For example, prior to injecting a molten polymer composition into the cavity of a mold, temperature conditioning can effectively raise the temperature of the mold (e.g., mold 201) from ambient conditions. Temperature conditioning can also (or alternatively) effectively lower the temperature of the mold 201 from the post-injection temperature resulting from the injection of the molten polymer composition. This post-injection temperature conditioning can reduce the time for the cell structure of the foamed article to achieve sufficient structural stability within the mold to be removed from the cavity of the mold. As such, it is contemplated that the temperature conditioning bracket 202 can be used to condition the temperature of the mold 201 prior to injection and to condition the temperature of the mold 201 after injection. In an example, the ability to condition the temperature of the mold 201 with the temperature conditioning bracket 202 prior to injecting a single-phase solution into the cavity of the mold 201 results in the formation of a consistent physically foamed article within the mold 201.

[0080] The temperature conditioning bracket 202 includes a radio frequency identification (RFID) reader 238. The RFID reader 238 is configured to transmit electromagnetic interrogation pulses that can be received by an RFID tag (such as Fig.17 the RFID tag 1708). In response, the RFID tag responds with information that is received by the RFID reader 238. This information can be static information for a given RFID tag or can be dynamic information stored by and provided as a response by the RFID tag. In either case, it is contemplated that the RFID reader 238 effectively receives information from the RFID tag. In use, a mold or other tool includes an RFID tag that is interrogated by the RFID reader 238 to determine what associated tool is present at the temperature conditioning bracket 202. As will be seen in Figure 4 it is contemplated that the temperature conditioning bracket 202 includes a plurality of compartments and that each of the compartments includes a unique RFID reader (e.g., RFID reader 438). Thus, each RFID reader effectively determines the specific RFID tag present in each of the compartments of the temperature conditioning bracket (and thus determines the associated mold having the specific RFID tag associated therewith). Thus, specific knowledge of the mold and the location of the mold within the temperature conditioning bracket is obtained through the use of the plurality of RFID readers for the temperature conditioning bracket.

[0081] While various elements / components / systems of system 200 are discussed as including RFID readers (e.g., RFID reader 238 of temperature regulation bracket 202), one or more RFID readers of one or more of the components from system 200 may be entirely omitted. For example, due to the automated nature of system 200 that limits or eliminates human intervention, system 200 effectively always maintains knowledge of the tool position within system 200 because the position of the tool is controlled by components of system 200 (e.g., robot 232). In an example, system 200 can determine the position of the tool (even without relying on RFID confirmation) through a record of the tool position changed by system 200. However, it is also contemplated to use confirmation systems such as RFID, vision codes (e.g., QR codes, barcodes), or other tracking technologies capable of using radio frequencies to ensure confirmation of the tool position, thereby further limiting potential manufacturing challenges.

[0082] The temperature regulation bracket 202 further includes a thermocouple 240 configured to measure temperature. In an example, the thermocouple 240 can be an electrical device that generates a temperature-related voltage or resistance (e.g., resistance temperature detector (RTD)) that is interpreted as measuring temperature. The thermocouple 240 effectively measures the temperature of the mold within the temperature regulation bracket 202. Alternatively, and as will be discussed in more detail in Figures 4 to 6 the thermocouple can effectively measure the temperature of the temperature regulation plate on which the mold is placed. The temperature regulation plate 203 is a support structure of the temperature regulation bracket 202 that is configured to regulate the temperature of a tool (e.g., mold 201) supported by the temperature regulation plate 203. The temperature regulation plate 203 will be discussed in more detail below at Figure 4 as the temperature regulation plate 416 as an example of the temperature regulation plate 203. As will be provided herein, it is contemplated that system 200 includes multiple temperature regulation plates 203. For example, each compartment of the temperature regulation brackets 202, 204, 206, and 208 can include a temperature regulation plate such as the temperature regulation plate 203.

[0083] In an example, the temperature regulation plate 203 is configured to regulate the temperature of the tool using heat conduction. Conduction allows the transfer of thermal energy between the tool (e.g., mold 201) and the temperature regulation plate (e.g., temperature regulation plate 203). Over time, the temperature of the tool converges to the temperature of the temperature regulation plate through conduction. Thus, the temperature measurement of the temperature regulation plate 203 serves as an approximation or representative value of the temperature of the mold 201 maintained at the temperature regulation plate 203. Therefore, the thermocouple 240 effectively measures or estimates the temperature of the mold 201 (or any tool) within the temperature regulation bracket 202 maintained on the temperature regulation plate 203. Based on the temperature measured by the thermocouple 240, system 200 can determine whether the temperature of the mold 201 is suitable for receiving an injection or for removing a foamed component therefrom.

[0084] The descriptions of temperature adjustment brackets 204, 206, and 208 are similar to that of temperature adjustment bracket 202. However, it is contemplated that each of temperature adjustment brackets 202, 204, 206, 208 may vary in size, location, configuration, and components. In an example, each of temperature adjustment brackets 202, 204, 206, 208 may adjust the temperature of a tool (such as die 201) to a different temperature or a similar temperature. Additionally, temperature adjustment bracket 204 includes RFID reader 242 and thermocouple 244, temperature adjustment bracket 206 includes RFID reader 246 and thermocouple 248, and temperature adjustment bracket 208 includes RFID reader 250 and thermocouple 252.

[0085] Temperature control unit 228 effectively manipulates the temperature of the temperature adjustment fluid to a target temperature. A temperature control unit (such as temperature control unit 228) effectively heats and / or cools the fluid circulating therethrough. Temperature control unit 228 may include a heat exchanger that effectively extracts or introduces thermal energy from / to the temperature adjustment fluid. In some cases, temperature control unit 228 includes a refrigerant that effectively cools the temperature adjustment fluid. In some cases, temperature control unit 228 includes a heating element (e.g., a resistance heater, a combustion chamber, an electric induction coil) (not shown) that effectively heats the temperature adjustment fluid. It is also contemplated that temperature control unit 228 includes a circulation pump (not shown) that effectively circulates the temperature adjustment fluid (e.g., pumps the temperature adjustment fluid).

[0086] Temperature control unit 228 is fluidly coupled to temperature adjustment bracket 202. Fluidly coupled (or fluid connection) means a connection that effectively circulates or transfers fluid between at least two components. A fluid connection may include a hose, a pipe, a channel, a conduit, or other vasculature effective for fluid transfer between components for fluid connection. As will be discussed in more detail in Figures 4 to 6 Temperature control unit 228 may be fluidly coupled to temperature adjustment bracket 202 through at least one manifold that effectively distributes the circulated temperature adjustment fluid between multiple compartments (or temperature adjustment plates 203 in each compartment) to achieve the desired temperature at each of the targets (e.g., compartments, temperature adjustment plates).

[0087] The description of temperature control unit 230 and temperature control unit 224 is similar to that of temperature control unit 228. However, it is contemplated that each of the temperature control units may have different configurations, settings, capacities, etc. For example, it is contemplated that temperature control units 228 and 230 circulate temperature regulating fluid at a first temperature (e.g., in the range from 15 degrees Celsius to 90 degrees Celsius), and temperature control unit 224 fluidly coupled to press 210 operates at a second temperature. If temperature control unit 224 is fluidly coupled to the hot runner plates of press 210 (e.g., Fig.11 the hot runner plates 1116, 1212), the second temperature may be higher than the first temperature, as will be discussed in more detail below. For example, while temperature control units 228, 230 are configured to regulate the temperature regulating fluid to a temperature in the range from 15 degrees Celsius to 90 degrees Celsius, in an example, temperature control unit 224 is configured to regulate the temperature regulating fluid to a temperature in the range from 20 degrees Celsius to 250 degrees Celsius. In other words, depending on the components whose temperature is regulated by temperature control units 224, 228, 230, temperature control units 224, 228, 230 may supply temperature-regulated fluid at different temperatures to the correspondingly connected components.

[0088] Each of temperature control units 224, 228, 230 may serve one or more components. For example, it is contemplated that temperature control unit 228 is fluidly coupled to temperature regulating brackets 202 and 204. It is contemplated that temperature control unit 230 is fluidly coupled to temperature regulating brackets 206 and 208. Temperature control unit 224 is fluidly coupled to press 210. As will be discussed in Figure 11 to Figure 1 more detail in 8, in an example, temperature control unit 224 may serve the platen of press 210 (e.g., Fig.11 the platen 1110) and / or the hot runner plates of press 210 (e.g., Fig.12 the hot runner plates 1116, 1212).

[0089] Although system 200 is discussed as having fluid connections between temperature control units (e.g., temperature control units 224, 228, 230) and components of system 200 (e.g., temperature regulating brackets 202, 204, 206, 208 and press 210), it is also contemplated that temperature control units 224, 228, 230 may be integrated with or otherwise coupled to the components. For example, induction heating, piezoelectric and thermoelectric effect devices, resistance heaters, etc. may alternatively be used to regulate the temperature of one or more components of the system.

[0090] As will be in Figures 12 to 19As discussed in more detail herein, press 210 secures mold 201 for receiving the injected polymer composition from syringe 212. Additionally, press 210 effectively serves as a conduit for gas backpressure from gas backpressure source 226 to mold 201. Press 210 also supports a manifold (e.g., Fig.13 injection manifold 1120) that is configured to distribute the polymer composition from syringe 212 to the mold. Further, press 210 supports one or more common runners (e.g., Fig.14A hot runner plate 1116 and second hot runner 1212) that serve as conduits through which a manifold (e.g., Fig.13 injection manifold 1120) having the polymer composition extends, and that in the case of the hot runner is configured to effect temperature regulation during fluid communication from syringe 212 to the mold. Press 210 also includes RFID reader 254. RFID reader 254 effectively identifies an RFID tag associated with mold 201 at press 210. As with other components of system 200, identification of mold 201 allows controller 216 to monitor production, tools, and components for effectively manufacturing a physically foamed footwear component.

[0091] will be discussed in more detail in Figures 19 to 22 Syringe 212 is configured to form a single-phase solution including a molten polymer composition and a physical blowing agent. As discussed herein, the physical blowing agent can be a supercritical fluid supplied from metering source 220 and introduced into the polymer composition at syringe 212. Additionally or alternatively, the physical blowing agent can be impregnated into the polymer composition supplied to syringe 212. Hopper 222 is a device for supplying the polymer composition to syringe 212. The polymer composition can be supplied from hopper 222 in various media such as pellets, beads, chips, regrind waste, and / or granules. Example compositions for the polymer material are discussed below.

[0092] Syringe 212 (which can also be referred to as an injection barrel, an injection molding system, and / or an injection molding machine) melts and / or shears the polymer composition supplied by hopper 222 by applying heat and / or pressure to produce a molten polymer composition. In the envisioned example, syringe 212 is also responsible for introducing a physical blowing agent (e.g., a supercritical fluid supplied from metering source 220) into the polymer composition to form a single-phase solution of the polymer composition and the physical blowing agent. In this example, the conditions within syringe 212 must be capable of supporting the supercritical fluid in a supercritical fluid state. In other words, when the supercritical fluid is introduced, the conditions within syringe 212 are at a temperature and pressure above the critical temperature and critical pressure of the introduced supercritical fluid. Syringe 212 then is responsible for metering (e.g., feeding) the single-phase solution to press 210. As previously introduced, it is envisioned that syringe 212 will effect such metering via an injection manifold (e.g., Fig.11 The injection manifold 1120) is paired with a hot runner plate (e.g., Fig.14A the hot runner plates 1116, 1212) to ultimately form a fluid connection with the mold 201 held at the press 210, and the metered single-phase solution is injected into the press 210.

[0093] The metering source 220 effectively prepares and meters a physical blowing agent for introduction into the syringe 212 and impregnation with the polymer composition. For example, the metering source 220 is fluidly connected to the physical blowing agent supply source 218 and prepares the physical blowing agent supplied by the physical blowing agent supply source 218 for introduction into the syringe 212 through the fluid connection between the physical blowing agent supply source 218 and the syringe 212. In an example, the metering source 220 effectively converts an inert substance (such as nitrogen or carbon dioxide) from a first state (e.g., gas or liquid) supplied by the physical blowing agent supply source 218 into a different state, such as a supercritical fluid. In an example, this phase transition is achieved by a pressure differential with a pressure above the critical pressure of the inert substance. Additionally, the metering source 220 effectively meters (e.g., measures) a determined amount of the physical blowing agent for the polymer composition to be prepared by the syringe 212 for injection.

[0094] Specifically, for the manufacture of physically foamed footwear components, various sizes, volumes, and / or shapes will be formed by a series of injections from the syringe 212. For example, the mold 201 into which the syringe will inject the single-phase solution can be of a first size of a first style during a first injection, and then the next and immediate injections will be for a mold of a second size and a second style of footwear component. Thus, different volumes of the single-phase solution will be metered by the syringe 212 based on the footwear component to be formed at the press 210 for a given mold. With each change in the injection volume, different metered amounts of the physical blowing agent are provided by the metering source 220 to the syringe 212. This is different from traditional physically foamed injection operations in which a consistent injection volume is injected into a common mold during successive injections. Since footwear components are formed in various sizes corresponding to various shoe sizes, a dynamic metering solution, as opposed to a set and maintained static metering solution, is included as the metering source 220 in the system 200.

[0095] The physical blowing agent supply source 218 can be a tank, cylinder, container, generator, or other component that effectively stores or generates a physical blowing agent effectively for the system 200. The physical blowing agent supply source 218 is fluidly connected to the metering source 220; thus, the physical blowing agent supply source 218 can be a supply line or other remote solution for storing, maintaining, and / or generating the physical blowing agent.

[0096] The gas backpressure source 226 is fluidly coupled to the press 210 and effectively supplies backpressure to the mold positioned at the press 210 before and / or during injection of the polymer composition into the mold. The gas backpressure source 226 is configured to supply a gas backpressure in the range from 500 pounds per square inch (psi) to 1,500 psi. However, it is envisioned that pressures above and below this range can be utilized to achieve foamed articles in the system 200. In a first example, the gas backpressure source 226 is a compressor or other pressure generating device that effectively converts the gas from a first pressure to a second higher pressure. For example, the second pressure can be at or above the critical pressure of the supercritical fluid of the single-phase solution to be injected into the mold 201. The gas backpressure source 226 effectively delivers backpressure via the press 210 that pressurizes a cavity (e.g., Fig. 14B cavity 1420) within the mold 201 positioned at the press 210. Pressurizing the mold cavity with backpressure as the single-phase solution transitions from the syringe through the manifold to the mold allows the single-phase solution injected into the volume of the cavity to remain a single-phase solution (e.g., prevents foaming from occurring). In this way, the initiation of foaming can be controlled based on the release of the backpressure rather than being initiated immediately upon injection. This control of the initiation time of foaming (e.g., dropping the pressure below the critical pressure of the physical blowing agent) also allows the system 200 to compensate for the molten polymer to achieve an appropriate temperature prior to foaming. Accordingly, using gas backpressure allows the system 200 to achieve a desired foaming time, achieve a desired dispersion of the polymer material within the mold cavity prior to foaming, and achieve a desired polymer temperature prior to foaming. In other words, the gas backpressure source 226 allows the mold 201 to maintain the single-phase solution as a single phase until the system 200 is ready to initiate foaming of the polymer material.

[0097] The gas backpressure source 226 includes a regulator 225 that effectively implements and maintains a defined pressure within the mold cavity of the mold 201. The regulator 225 is effective in at least two stages. In a first stage, the gas backpressure is introduced into the mold cavity before (or during) injection of the single-phase solution. The regulator 225 effectively ensures that the pressure experienced within the mold cavity is the set pressure regardless of whether the gas pressure at the gas backpressure source 226 is at or above the set pressure. The second stage is during the injection phase. As the syringe 212 injects the polymer composition into the mold cavity, the polymer composition consumes at least a portion (e.g., 20%) of the mold cavity volume. In the absence of the regulator 225, the volume consumption caused by the polymer composition can result in an increase in the pressure within the mold cavity. However, the regulator 225 effectively equalizes the internal cavity pressure with the volume change experienced during injection. Since some examples of the system rely on controlling the pressure of the single-phase solution prior to foaming to achieve acceptable foamed components, the regulator 225 of the gas backpressure source 226 is effective in further implementing pressure control.

[0098] The gas backpressure source 226 can supply any suitable fluid as the gas backpressure. In an example, the gas backpressure source 226 supplies a gas having a similar composition to the physical foaming agent. For example, if the physical foaming agent is nitrogen, the gas backpressure source 226 supplies nitrogen. If the physical foaming agent is carbon dioxide, the gas backpressure source 226 supplies carbon dioxide. It is also contemplated that the gas backpressure source 226 supplies air as the backpressure supplied to the mold cavity, and the air can be conditioned to adjust the humidity or temperature. Additionally, it is contemplated that the gas backpressure source 226 supplies any inert gas, regardless of the composition of the physical foaming agent. In yet another contemplated example, the gas backpressure source 226 is fluidly coupled to the physical foaming agent supply source 218 as a source of the gas supplied by the gas backpressure source 226 to the press 210 that holds the mold.

[0099] The unloader 214 (which will be discussed in more detail below in conjunction with Figure 23 to Figure 26 effectively opens the mold 201 having the foamed footwear article part therein. The opening of the mold 201 permits removal of the foamed footwear article part from the mold 201. After the foamed article has reached a sufficient temperature to provide dimensional stability to the foamed part during and after removal of the foamed part, the unloader 214 receives the mold 201 having the foamed part in the cavity of the mold. The temperature can be determined indirectly based on the time period elapsed after injection of the polymeric composition and / or based on the temperature regulation of the mold 201 at a temperature regulation bracket (e.g., temperature regulation bracket 2020) after injection of the polymeric composition. The unloader 214 effectively engages a first part of the mold (e.g., Fig. 9 the first carrier plate 908) to secure the mold 201 to the unloader 214, while the unloader 214 engages a second part of the mold 201 (e.g., Fig. 9 the second carrier plate 906) and separates the first part of the mold from the second part of the mold. This separation of the mold parts opens the mold to remove the foamed part from the cavity within the mold and to clear one or more runners of the mold. The unloader 214 also includes an RFID reader 256 that effectively reads the RFID tag (e.g., Fig.17 the RFID tag 1708) of the mold 201 positioned at the unloader 214. Like other RFID readers in the system 200, the RFID reader 256 can be used to identify, authenticate, and locate tools during operation of the system 200.

[0100] In an example, the robot 232 is a multi-axis articulated robotic manipulator that is effective to position the end effector 234 at least at the temperature regulating brackets 202, 204, 206, 208, the press 210, and / or the unloader 214. The robot 232 can be an industrial robot, such as an articulated robot, but it can be any suitable type of robot capable of maneuvering with multiple degrees of freedom (e.g., between 2 and 7 degrees of freedom based on Cartesian and / or polar coordinate systems). For example, a Selective Compliance Assembly Robot Arm (SCARA) robot or a humanoid robot are contemplated robot configurations. In some examples, the robot 232 rotates about the Z-axis (extending beyond the Figure 2 planar view) of the system 200 and moves along the Z-axis, thereby allowing the end effector 234 to be positioned at different heights within the system 200. In this example, the Z-axis defines the pivot point about which the robot 232 rotates and defines an arcuate motion path 236. When the end effector 234 is positioned at or within the various components of the system 200, the robot also moves in the X and Y-axis directions to pick up and place the die 201. It is also contemplated that in some examples the robot 232 also effectively rotates about the X-axis and / or the Y-axis. Thus, the robot 232 can be articulated with at least six degrees of freedom.

[0101] The end effector 234 is the arm-end tool of the robot 232, and an example of the end effector 234 is discussed in more detail in conjunction with Figures 7 and 8 the end effector 702. The end effector 234 is adapted to specifically manipulate the die 201 used in the system 200. As will be discussed in more detail in conjunction with Figures 9 and 10 the tool includes a plurality of keyways (e.g., Fig. 9 the first plate-manipulator keyway 912 and the second plate-manipulator keyway 910 of

[0102] to receive one or more protrusions (e.g., from the end effector 234 and / or other components of the system 200) to position, align, and / or secure the tool.

[0103] System 200 provides a motion path 236 representing a circular or arcuate path that allows for the primary transfer between components of system 200 to occur in a rotational manner about the Z-axis of robot 232. In an example, at least the temperature conditioning bracket 202, press 210, and unloader 214 are positioned on an arc (such as motion path 236) accessible by robot 232, within a set distance of the arc, or within the arc. It is envisioned that each of the temperature conditioning brackets 202, 204, 206, 208, unloader 214, and press 210 is positioned within three meters of a common arc, the origin of which is at the Z-axis rotation axis of robot 232. Positioning these components within at least three meters of the arc ensures that end effector 234 can be positioned at each of the components in a reasonable manner for throughput purposes of system 200. In other words, it is envisioned that the components of system 200 are within the three-dimensional workspace servable by robot 232 and end effector 234. As such, robot 232, through end effector 234, can pick up and place tools (e.g., die 201) at the components of system 200. System 200 emphasizes this throughput limitation where syringe 212 remains stationary and robot 232 is responsible for supplying tools (e.g., die 201) for continuous injection to syringe 212. In an alternative arrangement where the syringe moves to the tool, the motion of the syringe may be a limiting factor in system throughput.

[0104] Controller 216 includes a processor and memory and is configured to receive information, store information, process information, and communicate instructions to one or more components of system 200. Controller 216 is a computing device capable of managing, initiating, and controlling processes executed at one or more components of system 200. Controller 216 is logically coupled to one or more components of system 200 in a wired or wireless manner. As such, controller 216 can receive information from one or more components, store the information, determine processing steps to be executed by one or more components, and then communicate instructions for one or more components to perform for the production of components for a footwear article.

[0105] Controller 216 is programmable to execute one or more instructions to cause system 200 to manufacture foamed footwear components. The instructions include tool management through communication between one or more RFID readers of system 200. For example, RFID reader 238 of temperature conditioning bracket 202 interrogates and receives information from an RFID tag (e.g., Fig.17in response to the RFID tag 1708), which is associated with the mold 201 housed in a known compartment of the temperature regulating bracket 202. The RFID reader 238 communicates with the controller 216 to indicate information about the location of the specific RFID tag associated with the mold 201. The controller 216 also communicates with the thermocouple 240 to determine the measured temperature, such as the temperature regulating plate 203 within the compartment where the RFID tag identifying the mold 201 is located. The controller 216 associates the measured temperature with the mold 201. Information about what the mold 201 associated with the identified RFID tag is configured to form (such as a specific sole size of a specific footwear style) is also provided to the controller 216.

[0106] In an example, manufacturing goals are provided to the controller 216 to produce a specified quantity of a specific footwear style and / or footwear component size. In an example, the controller 216 is configured to determine which molds (e.g., mold 201) among the plurality of molds within the system 200 are capable of achieving the goal. The controller 216 is also configured to determine the appropriate process to be performed and when to perform it for the molds that are capable of achieving the goal. For example, the controller 216 knows one or more conditions of the molds (e.g., whether the mold contains a foamed product that has not been removed, whether the mold has reached a sufficient temperature-regulated state, whether the mold has had sufficient time since a specific operation), and based on the conditions of the molds, the controller determines which mold should be conveyed or otherwise used to achieve the manufacturing goal. In another example, the controller 216 may be responsible for achieving a manufacturing goal that includes a plurality of footwear component sizes to be manufactured within a provided time frame. In this example, the controller 216 considers the conditions of the various molds (e.g., mold 201) within the system 200 and determines which mold should be conveyed next to which part of the system 200. For example, when there are multiple temperature regulating brackets (e.g., 202, 204, 206, 208) in the system 200, the controller 216 can select one of the temperature regulating brackets 202, 204, 206, 208 based on a reduction in the travel time of the robot 232 for that specific operation or through a series of conveyances (e.g., considering what the next conveyance after the current conveyance will be, if the subsequent conveyance reduces more than the additional initial conveyance time, the total conveyance time can be reduced to make the current conveyance have a longer initial conveyance). Thus, the controller 216 effectively and dynamically adjusts component selection, tool selection, conveyance paths, etc., in an effort to increase the overall throughput of the system 200. This is contrary to the linear determination of traditional systems, which perform a first step and then a second step regardless of the conditions within the system that may delay the execution of the first step and / or the second step.

[0107] Continuing, controller 216 determines the instance of the next transfer. Controller 216 directs robot 232 to position end effector 234 at mold 201 that is currently at a known compartment of temperature regulating bracket 202. Then, end effector 234 grasps mold 201 and interrogates the RFID tag of mold 201 (e.g., RFID tag 1708 of Fig.17 ) with the RFID reader of end effector 234 (e.g., RFID reader 713 of Figure 7 ) to confirm that the correct mold has been selected. Then, end effector 234 communicates with controller 216 to indicate that mold 201 associated with the identified RFID tag is transferred to press 210 as directed. Figure 7 The robot 232 places the mold at the press 210 via the end effector 234. The RFID reader 254 of the press 210 interrogates the RFID tag of the stored mold 201. The RFID reader 254 then communicates with the controller 216 to confirm that the RFID tag of the mold 201 is positioned at the press 210. The press 210 secures the mold 201 and pairs the mold 201 with a hot runner plate (e.g., 1116, 1212 of Figure 2 ) to align the hot runner outlet (e.g., hot runner outlet 1513 of Fig. 15C ) and the backpressure outlet (e.g., gas backpressure outlet 1521 of Fig. 15B ) of the hot runner plate (e.g., 1116, 1212 of Figure 2 ) with appropriate ports on the mold 201. The controller 216 directs the gas backpressure source 226 to pressurize the cavity of the mold 201 to an appropriate pressure through the interaction of the mold 201 and the press 210 (e.g., through the backpressure outlet on the hot runner plate). Fig.17 The syringe 212 dispenses an appropriate single-phase solution and injects the metered single-phase solution into the mold 201 through the press 210 as pre-directed by the controller 216. In this instance, the controller 216 anticipates a specific mold for a future injection having a specific mold cavity volume. In anticipating this specific mold volume, the controller 216 directs the syringe 212 to prepare an appropriate single-phase solution volume for injection by the controller 216. This anticipation can include the controller 216 directing the metering source 220 to meter a specific amount of physical blowing agent into the syringe 212 and directing the hopper 222 to dispense a specific amount of polymeric material into the syringe 212 based on the anticipated injection volume of the mold to be received and its associated cavity.

[0108] Figure 2 Fig. 15C Figure 2 Fig. 15C Figure 2 Figure 2 Fig. 15B Fig. 15B Fig. 15B

[0109]

[0110] The controller 216 is notified of a successful injection into the mold cavity by the syringe 212. Then, in accordance with programmed operating instructions, the controller 216 directs the gas backpressure source 226 to release the gas backpressure at the mold 201 after a specified time from the start of injection (or other conditions such as the temperature of the injected material, the flow range of the injected material, or the temperature of the incoming material). As discussed above, the release of the gas backpressure in the mold cavity triggers the foaming of the injected polymer composition and the physical blowing agent. Then the controller 216 directs the robot 232 to retrieve the mold 201 (with the injected material) from the press 210 and place the mold 201 at a temperature conditioning support (such as the temperature conditioning support 204). Then the controller 216 may receive confirmation from the RFID reader of the end effector 234 (e.g., Figure 7 the RFID reader 713) that the mold 201 has been retrieved and placed. Additional confirmation may be received when the RFID reader (e.g., the RFID reader 242) of the temperature conditioning support (e.g., the temperature conditioning support 2020) for the mold 201 further interrogates the RFID tag from the mold 201. Then this confirmation is communicated to the controller 216. Additionally, a thermocouple (e.g., the thermocouple 244) associated with the compartment (where the mold 201 is located after injection) provides a temperature reading of the mold 201 as the now foamed injected polymer composition cools and becomes more dimensionally stable. The temperature is reported to the controller 216, and the controller 216 may associate the temperature with the mold 201.

[0111] Once the mold 201 has reached an appropriate time or temperature after injection by the syringe 212, the controller 216 directs the robot 232 to retrieve the mold 201 to be positioned at the unloader 214. The controller 216's determination of when the mold is movable to the unloader 214 is based in part on the time the controller 216 knew an injection into the mold cavity occurred before receiving the injection, the time the backpressure was released, the temperature of the mold before receiving the injection (or an approximation of the temperature based on an inferred reading of the temperature regulating plate from which the mold was selected), the temperature of the mold after injection at the temperature conditioning support (or an approximation thereof), the time the mold is temperature conditioned at the temperature conditioning support, and details of the mold (e.g., the size, style, volume of the mold cavity forming the footwear component). Collectively, the controller 216 collects and stores information throughout the process to optimize the throughput of the system 200.

[0112] At the unloader 214, the RFID reader 256 interrogates the RFID tag associated with the mold 201 ( Fig.17of the RFID tag 1708), and convey the identification of the mold 201 to the controller 216. The controller 216 initiates the unloading process of the foamed product from the mold 201. At the end of the unloading process, the controller 216 instructs the robot 232 to retrieve the mold 201 from the unloader 214 and store the mold 201 at a temperature-regulated support (e.g., temperature-regulated supports 202, 204, 206, 208). Then, the controller 216 can capture information about the processes performed on the mold 201 during the production of the foamed part. This data can be used for tool management (e.g., number of cycles) and quality control audits.

[0113] The quality control of the produced parts / articles is enhanced using the system 200. The system 200 is capable of tracking and collecting information associated with each article manufactured in the system 200. For example, time, temperature, pressure, material, machine parameters, environmental parameters, tool parameters, etc. can all be captured, recorded, and associated with a specific part produced from the system 200. If a defect or other characteristic is identified in conjunction with a specific article formed by the system 200, then a review of the conditions, parameters, and other variables associated with the manufacture of that specific article can be completed. It is possible to review the information in conjunction with a specific article produced in the system 200, in part due to the autonomy of the system 200. Since the tool moves autonomously through the system 200 without human intervention, the chain of custody of the tool for producing a specific article is maintained, and thus the captured information related to the formation of a specific article can be tracked in conjunction with a specific tool even before the specific article is formed. In other words, the system 200 effectively captures and maintains information useful in quality control and the review of the manufacturing process of a specific article formed by the system 200.

[0114] The above process is a non-limiting example of how the system 200 with the controller 216 can operate. It is envisioned that although a single controller 216 is depicted and described, in practice, multiple controllers can operate in concert to achieve the functions provided herein. For example, the robot 232, the press 210, the syringe 212, and / or the unloader 214 can have dedicated controllers that operate independently or under the guidance of the controller 216. As such, the use of the controller 216 is a general indicator of a computing device capable of controlling one or more aspects of the system 200, which one or more aspects can be divided among multiple controllers that communicate logically via a wired or wireless communication protocol.

[0115] System 200 is a non-limiting example of the systems contemplated herein. It should be understood that any number of individual components may be incorporated into system 200. For example, four temperature regulating brackets 202, 204, 206, 208 are depicted, but there may be one temperature regulating bracket, two temperature regulating brackets, three temperature regulating brackets, five temperature regulating brackets, or any suitable number of temperature regulating brackets. Similarly, for illustrative purposes, examples of the positioning of various components are provided, but alternative positionings are also contemplated. For example, it is contemplated that press 210 or unloader 214 may be positioned between two or more of the temperature regulating brackets (e.g., 204, 206) to optimize the travel time of robot 232 between the various components by minimizing it. Specifically, because die 201 travels sequentially from a temperature regulating bracket (e.g., temperature regulating brackets 202, 204, 206, 208) to press 210, to a temperature regulating bracket (e.g., temperature regulating brackets 202, 204, 206, 208), to unloader 214, to a temperature regulating bracket (e.g., temperature regulating brackets 202, 204, 206, 208), in the example, providing a temperature regulating bracket at an intermediate position between press 210 and unloader 214 can reduce the travel time of robot 232. Additionally, Figure 2 The schematic illustration is for illustrative purposes only and does not limit size, position, relative position, or scale. Additionally, it is contemplated that one or more components may be omitted from the system and / or one or more components may be introduced into the system.

[0116] Figure 3 A schematic plan view of a footwear component manufacturing system 300 in a second configuration in accordance with aspects of the present disclosure is depicted. Components of system 300 with similar numbers to those Figure 2 in will not be discussed in detail, but rather will be understood from the discussion of the similarly numbered elements in Figure 2 However, the second configuration of system 300 demonstrates a non-arc / rotary motion path 304 provided by robot 302. In this example, robot 302 is a gantry robot that effectively moves a tool (e.g., a die) linearly through system 300. As discussed in connection with Figure 2 system 200, system 300 is based on the concept of moving a tool (e.g., die 201) through the system, which is contrary to the traditional injection molding operation of moving a syringe 212 to the tool. This alternative method is particularly suitable for manufacturing footwear components having various injection volumes and significant foam volumes (e.g., part thickness), where the foam volume itself insulates and thus slows the cooling of the foamed part after foaming (e.g., due to the significant foam volume, the part itself insulates). As such, similar to Figure 2 system 200, system 300 is configured to move die 201 to syringe 212 rather than move syringe 212 to die 201.

[0117] The robot 302 operates in a manner similar to that described for the robot 232 in connection with Figure 2 . However, instead of the primarily rotational motion path as done in Figure 2 , the robot 302 has a primary motion capability in a linear fashion along the motion path 304. In addition to movement along the motion path 304, when the motion path 304 is in the Y-axis direction, the robot 302 can also move in the Z-axis and X-axis. This type of motion is sometimes referred to as a Cartesian robot. It is envisioned that additional motion fields are possible, such as rotation about any one of the X, Y, and / or Z axes.

[0118] In some instances, the linear (e.g., non-arc / rotational) primary motion path of the system 300 can provide additional scalability for the system 300 on an arc motion path system. For example, the linear distance can be extended infinitely to incorporate additional components that can be accessed by the robot 302. This is in contrast to the arc or rotational motion path of a robotic arm, which has a limited reach based on the arm configuration and thus has a finite circumferential length as the motion path along which components can be supported. Additionally, although components are depicted on one side of the motion path 304, in an instance, it is envisioned that components can be placed on both sides of the motion path, and two or more robots can operate in parallel motion paths or in a common motion path.

[0119] In an instance, the arrangement of components in the system 300 is provided to optimize the throughput of the system 300. For example, temperature regulation brackets (e.g., temperature regulation brackets 202, 204, 206, 208) are positioned on both sides of the unloader 214 and the press 210. However, it is envisioned that an alternative arrangement of components results in optimized throughput of the system 300 based on the configuration of the temperature regulation brackets, process parameters, and robot priorities. For example, it is envisioned that at least one temperature regulation bracket (e.g., temperature regulation brackets 202, 204, 206, 208) can be positioned between the press 210 and the unloader 214 to provide optimized throughput on the system based on process parameters (e.g., injection time, dwell time, robot speed). Additionally, it is envisioned that the temperature regulation brackets 202, 204, 206, 208, the unloader 214, and the press 210 are all positioned within three meters of a common line parallel to the motion path 304. This relative positioning ensures that the end effector 234 can effectively access each of the components without significantly sacrificing the throughput of the system 300 by compensating for excessive robot motion due to misalignment of the components of the system relative to the motion path of the robot 302.

[0120] System 300 is a non - limiting example of the systems envisioned herein. It should be understood that any number of individual components can be incorporated into the system. For example, four temperature - regulating brackets 202, 204, 206, 208 are depicted, but it could be one temperature - regulating bracket, two temperature - regulating brackets, three temperature - regulating brackets, five temperature - regulating brackets, or any number of temperature - regulating brackets. Similarly, for illustrative purposes, examples of the positioning of various components are provided, but alternative positionings are also envisioned. In addition, Figure 3 the schematic illustration is for illustrative purposes only and does not limit size, position, relative position, or scale. In addition, it is envisioned that one or more components can be omitted from system 300 and / or one or more components can be introduced into system 300.

[0121] Figure 4 A perspective view 400 of a temperature - regulating bracket 402 and a temperature - control unit 428 in accordance with aspects herein is depicted. The temperature - regulating bracket 402 is an example embodiment of the Figure 2 temperature - regulating brackets 202, 204, 206, and 208 discussed previously. The temperature - regulating bracket 402 includes a plurality of compartments 404, 406, 408, 410, 412, and 414. The plurality of compartments can be any number, such as one compartment, two compartments, three compartments, four compartments, six compartments, seven compartments, eight compartments, nine compartments, or ten compartments. For example, in an instance, the temperature - regulating bracket 402 can include four to eight compartments. The number of compartments is selected for optimization of system throughput. The number of compartments is limited based on the minimum distance for a tool and the end - effector of a robot to access, position, and remove the tool between stacked compartments. In some instances, the height of the temperature - regulating bracket (e.g., mold 201) is also limited to a height accessible by a robot (such as an arm - type robot with a limited reach). In addition, the number of compartments is partially limited by the ability of the temperature - control unit 428 to effectively regulate the temperature of the plurality of compartments. Accordingly, aspects envision that a temperature - regulating bracket 402 having four to eight compartments meets the identified conditions and provides effective throughput for the system. However, due to adjusting process parameters, components, and / or conditions, alternative ranges of compartments are envisioned and provided herein.

[0122] Each of the six compartments of the temperature - regulating bracket 402 is provided with a temperature - regulating plate, such as the temperature - regulating plate 416 in compartment 408. The temperature - regulating plate can be a separate component of the compartment, or it can be integrally formed in the compartment. The temperature - regulating plate 416 effectively regulates the temperature of the tool placed thereon. For example, as Figure 5 shown, the mold 502 is positioned on the temperature - regulating plate 416. In an instance, the temperature - regulating plate 416 includes a top surface 426, and when a tool is positioned on the temperature - regulating plate 416, the top surface 426 is in contact with the tool (e.g., Figure 5is interfaced with the mold 502), and the temperature regulating plate 416 includes a bottom surface which, in an example, is supported by the compartments.

[0123] The temperature regulating plate 416 includes fluid channels (not shown) extending between a top surface 426 and the bottom surface, which start at a fluid input port (not shown) and terminate at a fluid output port (not shown). The fluid input port is in fluid communication with the temperature control unit 428, and the fluid output port is in fluid communication with the temperature control unit 428 to allow a temperature regulating fluid to circulate between the temperature control unit 428 and the temperature regulating plate 416. The temperature regulating bracket 402 also includes a temperature regulating fluid manifold 436 that serves as a fluid connection between the temperature control unit 428 and the temperature regulating plate 416. The temperature regulating fluid manifold 436 effectively controls the distribution of the temperature regulating fluid from the temperature control unit 428 to the plurality of compartments. In an example, this distribution of the temperature regulating fluid controlled by the temperature regulating fluid manifold 436 provides a more equal temperature distribution of the temperature regulating fluid among the plurality of compartments.

[0124] The temperature regulating fluid manifold 436 can have one or more valves that are controlled dynamically or manually to further control the distribution of the temperature regulating fluid in a uniform (e.g., consistent flow rate, consistent temperature) manner. An example of a valve used by the temperature regulating fluid manifold 436 is the valve 434. The valve 434 can be controlled by a controller (e.g., Figure 2 the controller 216) to adjust the flow of the temperature regulating fluid provided to the temperature regulating plate 416. For example, if the temperature regulating plate 416 is not in use, the valve 434 can restrict the flow of the temperature regulating fluid to attempt to conserve energy used for temperature regulating the temperature regulating plate 416 when the tool is not being adjusted. The temperature control unit 428 is at least partially in fluid communication with the fluid input port via a supply line 432, and the temperature control unit 428 is at least partially in fluid communication with the fluid output port via a return line 430. Each of the supply line 432 and the return line 430 can be in fluid communication with a respective manifold (e.g., the temperature regulating fluid manifold 436).

[0125] The temperature regulating plate 416 also includes a first protrusion 418 extending outward from the top surface 426. The size, shape, and position of the first protrusion 418 are set on the top surface 426 to be received in a first plate alignment keyway 1704 in the bottom surface of the tool, which will be discussed in more detail below in connection with Fig.17 The top surface 426 also includes a second protrusion 420 extending outward from the top surface 426. The size, shape, and position of the second protrusion 420 are set on the top surface 426 to be received by Fig.17 Fig.17 ​The second plate alignment keyway 1706 of the tool is received in the bottom surface of the tool. The first protrusion 418 is asymmetric with respect to the second protrusion 420 in one or more characteristics. These characteristics include but are not limited to the length of the protrusion extending from the top surface 426, the cross-section of the protrusion taken in a plane parallel to the top surface 426, the cross-section of the protrusion taken in a plane perpendicular to the top surface 426, the position of the protrusion on the top surface 426, the size (e.g., width) of the protrusion, or any combination thereof.

[0126] The asymmetry between the first protrusion 418 and the second protrusion 420 effectively ensures the correct orientation and correct position of the tool within the compartment. This correct orientation and positioning ensure that an end effector (e.g., Figure 2 the end effector 234) operating with very strict tolerances (e.g., less than 2 millimeters) can secure the tool without human operator intervention. The correct orientation and positioning also ensure that a tool having an RFID tag is properly positioned relative to the RFID reader 438 to be interrogated and verified in a particular compartment. Additionally, the orientation and position confirmation provided by the asymmetry of the two protrusions also ensure that the tool is properly aligned with the thermocouple (e.g., Figure 4 the thermocouple 424) of the temperature regulating plate 416. In an example, the thermocouple 424 is placed in the recess 422 to prevent interference with the tool when the tool is positioned on and removed from the temperature regulating plate 416. In this example, the thermocouple 424 is recessed into the recess 422 such that the thermocouple is flush with or slightly recessed from the top surface 426.

[0127] The temperature control unit 428 is Figure 2 an example embodiment of the temperature control unit 228 of the tool. The temperature control unit 428 effectively regulates the conditioning fluid (e.g., heating or cooling) to a temperature of 15 degrees Celsius to 90 degrees Celsius, 50 degrees Celsius to 80 degrees Celsius, and / or 55 degrees Celsius to 70 degrees Celsius. It is contemplated that the temperature control unit 428 serves two or more temperature regulating brackets (e.g., Figure 2 the temperature regulating brackets 202 and 204 of the tool). For example, the temperature control unit 428 has a plurality of inlets and outlets for fluid connection to a plurality of components (such as two temperature regulating brackets) via supply line 432 and return line 430.

[0128] Figure 5 depicts a configuration 500 having a temperature regulating bracket 402 and a temperature control unit 428 with a plurality of molds 502, 504 in accordance with aspects herein. The first mold 502 is supported in the compartment 408 on the temperature regulating plate 416. The second mold 504 of the plurality of molds is depicted in the compartment 414. Figure 4

[0129] Figure 6 ​Depicts a temperature regulation bracket 402 according to various aspects herein Figure 5 The rear perspective view 600 of the temperature regulation bracket 402. The rear perspective view more clearly illustrates the second protrusion 420, the recess 422, and the RFID reader 438. Figures 4 to 6 An exemplary temperature regulation bracket 402 is provided. It should be understood that temperature regulation brackets of any size can be implemented with any number of compartments, temperature regulation plates, and configurations. Thus, although Figures 4 to 6 a specific temperature regulation bracket is provided and described, it is not intended to limit the systems and methods provided herein.

[0130] Figure 7 Depicts an end effector 702 in a first configuration 700 according to various aspects herein. The end effector 702 is an exemplary embodiment of the end effector 234 previously discussed Figure 2 The end effector 702 includes a first side 704 and a second side 706. The first side 704 and the second side 706 are slidably positioned on the end effector 702 to move between Figure 8 the first distance 718 and the second distance 802 depicted. This slidable movement allows the first arm 704 and the second arm 706 to converge on the first side and the second side of a tool (e.g., Fig. 9 the mold 900) respectively to engage the end effector 702 with the tool. The tool will be described hereinafter with respect to Fig. 9 this.

[0131] The first arm 704 and the second arm 706 are in a parallel configuration such that when the first arm 704 and the second arm 706 are positioned between the first distance and the second distance, they converge on and align with the tool to operate within the tight tolerances of a robot (e.g., Figure 2 the robot 232) that controls the end effector 702. In other words, the first arm 704 and the second arm 706 remain parallel to the sides of the tool, and when the first arm 704 and the second arm 706 move to the engagement configuration, the first arm 704 and the second arm 706 will engage the sides. The parallel arrangement allows for a secure engagement and operation within tight tolerances.

[0132] The first arm 704 includes a first protrusion 708 and a second protrusion 710. Each of the first protrusion 708 and the second protrusion 710 extends outwardly from the first arm 704 towards the second arm 706. Similarly, the second arm 706 includes a third protrusion 714 and a fourth protrusion 716 that extend outwardly from the second arm 706 towards the first arm 704. The first protrusion 708 is asymmetric with respect to the second protrusion 710 in one or more characteristics. These characteristics include, but are not limited to, protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, and any combination thereof. Similarly, the third protrusion 714 is asymmetric with respect to the fourth protrusion 716 in one or more characteristics. These characteristics include, but are not limited to, protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, and any combination thereof. It is contemplated that the first protrusion 708 and the third protrusion 714 are symmetric in one or more characteristics, and the second protrusion 710 and the fourth protrusion 716 are symmetric in one or more characteristics. For example, the first protrusion 708 may have a cylindrical volume, while the second protrusion 710 may be a linear volume. In this example, the second protrusion 710 having a linear volume will not engage a keyway configured to receive the cylindrical volume of the first protrusion 708.

[0133] The characteristics of each protrusion are adapted to be received in and thus engage a corresponding keyway in a tool such as a mold. This coordination between the protrusion characteristics and the associated keyway allows the end effector 702 to securely engage the tool in a known position and orientation, and similarly position the tool in a known position and orientation.

[0134] The end effector 702 includes an RFID reader 713 received in a recess 712 of the first arm 704. The position of the recess 712 is selected such that the RFID reader 713 can interrogate an RFID tag (e.g., Fig. 9 RFID tag 1708 of Fig.17 on a specific location of the engaged mold (e.g., Figure 2 mold 900 of Fig. 9engage and disengage with the mold 900).

[0135] Figure 8 depicts the end effector 702 in the second configuration 800 in accordance with aspects herein. As Figure 7 depicted, the first arm 704 and the second arm 706 converge in a sliding motion as depicted by the direction indicator 804. This convergence causes a distance 802 to extend between the first arm 704 and the second arm 706. In an example, the second configuration 800 is adapted to engage and secure a mold (e.g., Figure 8 the mold 900) with the mold 900). Fig. 9 the mold 900) engage and secure the mold.

[0136] Figure 7 and Figure 8 the end effector 702 are non-limiting examples of end effectors contemplated herein. Although specific structures, configurations, and elements are depicted and described, additional or alternative structures, configurations, and / or elements are contemplated to form effective end effectors in the systems and methods contemplated herein.

[0137] Fig. 9 depicts a perspective view of the mold 900 in accordance with aspects herein. The mold 900 is a particular form of tool generally referenced herein. In the systems (e.g., Figure 2 the system 200) and methods provided herein, it is contemplated to utilize alternative tools (such as alternative molds) and such alternative tools are effective. The mold 900 includes a first mold portion 903 and a second mold portion 905. It is contemplated that each of the mold portions 903, 905 includes a mold cavity (e.g., the mold cavity 1420 of FIG. 14) that effectively forms a component (e.g., a footwear sole component) using the systems and methods provided herein. For example, the first mold portion 903 effectively forms a right sole portion and a left sole portion of a pair of footwear. Similarly, the second mold portion 905 effectively forms a right sole portion and a left sole portion to form a second pair of footwear. In this example, the first mold portion 903 includes a first mold cavity for the right sole and a second mold cavity for the left sole. The second mold portion 905 includes a third mold cavity for the right sole of the second pair and a fourth mold cavity for the left sole of the second pair. It is contemplated that the mold cavity volume of the first mold portion 903 is similar to or equal to the mold cavity volume of the second mold portion 905. This commonality of mold volumes allows for a consistent injection volume to be distributed by a manifold (e.g., Fig.18B the injection manifold 1811) to serve as a conduit between a syringe (e.g., Figure 2 the 212) and the mold cavity. In an example, maintaining consistency between the mold volumes injected with a common injection shot from the syringe provides greater control over the resulting product.

[0138] The mold 900 includes a first top mold plate 902 and a second top mold plate 904. The mold 900 includes a first carrier plate 908 and a second carrier plate 906. The mold 900 includes an annular mold plate 924 and a tool latch assembly 918. The tool latch assembly 918 includes a first portion 917 extending from the first carrier plate 908 toward the second carrier plate 906 and a second portion 919 extending from the second carrier plate 906 toward the first carrier plate 908. The first portion 917 and the second portion 919 of the tool latch assembly 918 are offset and positioned parallel to engage and link when the biasing pin 922 extends out from the first portion 917 toward the second portion 919 and extend into the orifice 920 of the second portion 919 in the biased position. The biasing pin 922 can be manipulated by a key (e.g., Fig.24 key 2606 of the unloader 2300) from an unloader (e.g., Fig.24 to recess the biasing pin 922 from the orifice 920, allowing the first portion 917 and the second portion 919 to slide apart and the first carrier plate 908 to space itself from the second carrier plate 906, which allows the mold 900 to open. With the biasing pin 922 engaged in the orifice 920, the mold 900 is locked in the closed position.

[0139] Each of the carrier plates 906, 908 includes keyways intended to engage with protrusions of different components from the system, which will be discussed in more detail below. The first carrier plate 908 includes a first plate-manipulator keyway 912 and a second plate-manipulator keyway 910. The second carrier plate 906 includes a first plate-opening keyway 914 and a second plate-opening keyway 916. The first plate-manipulator keyway 912 and the second plate-manipulator keyway 910 are asymmetric in at least one characteristic. One or more characteristics include keyway depth, cross-sectional shape, position, size, or any combination. For example, the first plate-manipulator keyway 912 has a cylindrical volume and the second plate-manipulator keyway 910 has a linear volume.

[0140] In fact, the first plate-manipulator keyway 912 is adapted to receive a third protrusion 714 from the Figure 7 end effector 702, and the second plate-manipulator keyway 910 is adapted to receive a fourth protrusion 716 from the Figure 7 end effector 702. Similarly, the first plate-opening keyway 914 is adapted to receive a first protrusion 2320 from the unloader 2300, which will be discussed in connection with Fig.25 and the second plate-opening keyway 916 is adapted to receive a protrusion from the Fig.25The second protrusion 2322 of the unloader 2300. It is contemplated that the tool side opposite the positions of the first plate - actuator keyway 912, the second plate - actuator keyway 910, the first plate - opening keyway 914, and the second plate - opening keyway 916 has similar keyways. The similar keyways may be symmetric with the corresponding keyways on the side depicted in Fig. 9 Alternatively, it is contemplated that the keyways on the side of the mold 900 opposite the side depicted in Fig. 9 are asymmetric in one or more characteristics with respect to their corresponding keyways on the side of the mold 900 depicted in Fig. 9 .

[0141] Fig.10 Depicts a side view of the mold 900 in accordance with aspects of the present disclosure in combination with Fig. 9 discussed herein. The mold 900 is provided as a non - limiting example of a tool that can be implemented in the systems and methods contemplated herein. The tool can produce alternative foamed components; having alternative elements, alternative configurations, alternative sizes, and alternative arrangements. As such, the systems and methods contemplated herein can implement alternative tools within the contemplated approaches.

[0142] Fig.11 Depicts a perspective view of a press 1100 in accordance with aspects of the present disclosure. The press 1100 is an example embodiment of the press 210 previously discussed in combination with Figure 2 . Figure 2 The disclosure of the press 210 in Fig.12 is applied herein to the press 1100. The press 1100 has a frame 1102, and the frame 1102 has a movable support platform 1104. The movable support platform 1104 can be moved by one or more actuators, such as Fig.12 the first actuator 1202 and Fig. 9 the second actuator 1204. The press 1100 further includes a platen 1110 having a top surface 1111 and an opposite bottom surface 1113. The bottom surface 1113 of the platen is positioned on the movable support platform 1104, and the top surface 1111 of the platen is positioned to receive and support a tool, such as the mold 900 from Fig. 9 . The press 1100 further includes a press lock 1115 that can be moved between a locked configuration and an unlocked configuration. In the locked configuration, the press lock 1115 secures the tool (e.g., Fig.13The depicted mold (900). The clamp lock (1115) includes a pair of sliding fingers (1106, 1108) that move in a direction transverse to the direction of movement of the movable support platform (1104). The pair of sliding fingers includes a first finger (1106) and a second finger (1108). The first finger (1106) and the second finger (1108) are capable of moving in unison to engage a common surface of the tool, thereby securing the tool to the platen (1110). A second pair of fingers (not shown) also moves in a direction transverse to the direction of movement of the movable support platform (1104) and in a direction that is not in unison with the pair of sliding fingers (1106, 1108). The pair of fingers (1106, 1108) and the second pair of fingers work together to secure the tool (e.g., the mold 900 as depicted Fig.13 to the platen (1110). The platen (1110) also includes a first protrusion (1112) that extends from the top surface (1111) toward the hot runner plate (1116) and the second hot runner plate (1212). The platen (1110) also includes a second protrusion (1114) that extends from the top surface (1111) toward the hot runner plate (1116) and the second hot runner plate (1212).

[0143] The first protrusion (1112) is asymmetric with respect to the second protrusion (1114) in one or more characteristics. These characteristics include, but are not limited to, the length of the protrusion extending from the top surface of the platen (1110), the cross-section of the protrusion taken in a plane parallel to the top surface of the platen (1110), the position of the protrusion on the top surface of the platen (1110), the size (e.g., width) of the protrusion, or any combination thereof.

[0144] The asymmetry between the first protrusion (1112) and the second protrusion (1114) effectively ensures the correct orientation and correct position of the tool (e.g., the mold 900 as depicted Fig.13 within the press (1100). This correct orientation and positioning ensures alignment of the tool with the hot runner plate (1116) and, by extension, ensures alignment of the tool with the injection manifold (1120), which serves as a conduit for injecting the polymer composition into the tool. The correct orientation and positioning also ensure that the tool with the RFID tag is properly positioned relative to the RFID reader (1118) to be interrogated and confirmed within the press (1100). Additionally, the orientation and position confirmation provided by the asymmetry of the two protrusions (1112, 1114) also ensure proper alignment of the tool with the thermocouple (if present) of the platen (1110).

[0145] The first protrusion (1112) and the second protrusion (1114) operate in a manner similar to that of the first protrusion (418) and the second protrusion (420) of the temperature regulation bracket (402) discussed in connection with Figure 4 the temperature regulation bracket (402). In other words, the common alignment keyways in the tool are effectively used to align the tool in at least two components of the system, such as the temperature regulation bracket (402) and the press (1100).

[0146] In an example, the platen 1110 includes an adjustable fluid passageway (not shown) extending between a top surface 1111 and a bottom surface 1113. The adjustable fluid passageway has an inlet (not shown) and an outlet (not shown) that permit fluid coupling of the platen 1110 with a temperature control unit (e.g., Figure 2 temperature control unit 204 of ). In this way, the platen 1110 can be used, in part, in a manner similar to that described for the temperature regulating plate 416 of the temperature regulating bracket 402 of Figure 4 to regulate the tool during and / or after injection.

[0147] Fig.12 A front view of a press 1100 from Fig.11 in a first configuration 1200 in accordance with aspects herein is depicted. The press 1100 is an example embodiment of the press 210 of Figure 2 . The first configuration 1200 positions the movable support platform 1104 in a retracted platform position. The first actuator 1202 and the second actuator 1204 can be any type of actuator, such as a pneumatic actuator, a hydraulic actuator, an electric linear actuator, etc. The positioning of the movable support platform 1104 allows the press 1100 to secure a tool (e.g., a mold 900 as depicted in Fig.13 ) against the hot runner plates 1116, 1212 to form an effective seal, thereby allowing a single-phase solution to be fluidly transferred from the press 1100 to the tool and for maintaining a gas backpressure in the cavities of the tool when transferred from the press 1100. The first configuration 1200 positioning the movable support platform 1104 in the retracted platform position allows a tool (such as the mold 900 of Fig. 9 ) to be positioned on the platen 1110 and secured by a press lock 1115.

[0148] The hot runner plates 1116, 1212 are positioned statically to the press, such as by bolts, latches, or other fasteners. In this way, when the movable support platform 1104 moves from the first configuration 1200 to the Fig.13 depicted second configuration 1300, the distance between the movable support platform 1104 and the hot runner plates 1116, 1212 decreases such that the distance in the first configuration 1200 is greater than the distance in the second configuration 1300.

[0149] A hot runner plate, such as the hot runner plate 1116, provides a mechanism for maintaining the molten polymer composition within the injection manifold 1120 in a molten state. To achieve this, the hot runner plate 1116 includes a channel (not shown) within the hot runner plate 1116 that effectively circulates a conditioning fluid at a certain temperature to heat the hot runner plate 1116 and the associated injection manifold 1120 to a temperature sufficient to maintain the molten polymer in a molten state between injections. The hot runner plate 1116 includes an inlet 1208 and an outlet 1210 that are fluidly coupled by a channel extending through the hot runner plate 1116 for circulating the conditioning fluid.

[0150] The second hot runner plate 1212 provides a mechanism for maintaining the molten polymer composition within the injection manifold 1120 in a molten state. To achieve this purpose, the hot runner plate 1212 includes a channel (not shown) within the hot runner plate 1212 that effectively circulates a conditioning fluid at a certain temperature to heat the hot runner plate 1212 and the associated injection manifold 1120 to a temperature sufficient to maintain the molten polymer in a molten state between injections. The hot runner plate 1212 includes an inlet 1205 and an outlet 1207 that are fluidly connected by a channel extending through the hot runner plate 1212 for circulating the conditioning fluid.

[0151] The use of a hot runner plate (e.g., hot runner plate 1116, second hot runner plate 1212) in the physical foaming operation reduces the Figure 2 The waste generated by the extended cold runner extending between the injector 212 and the tool is reduced. By maintaining a portion of the conduit between the injector and the tool as a hot runner, the polymer composition will not solidify in those portions heated by the hot runner plates 1116, 1212 between injections. Additionally, as previously discussed, in the example, the time between injecting the polymer composition into the tool and reducing the gas back pressure determines the acceptability of the foamed part. Depending on the injection volume, mold cavity characteristics, runner characteristics and other variables, this time can be 1 second, 2 seconds, 3 seconds, 4 seconds, 5 seconds or 6 seconds, and can be affected by the temperature of the injected molten polymer composition. Therefore, when Figure 2 When the syringe 212 doses material for subsequent injections, different times may elapse between shots, and therefore Figure 2 The flow channel system or the manifold of the injector 212 (e.g., Fig.18B The molten polymer composition in the manifold 1811 or other locations may drop in temperature at different levels without the hot runner plate (e.g., the hot runner plate 1116, the second hot runner plate 1212). Therefore, in an example, a hot runner plate (e.g., the hot runner plate 1116, the second hot runner plate 1212) is applied to the system in order to achieve consistent foamed parts regardless of the time between injections or other variables during consecutive injections.

[0152] Fig.13 depicts a front view of a press 1100 with a die 900 in a second configuration 1300 in accordance with various aspects of the present disclosure. As depicted, the movable support platform 1104 is raised so that the die 900 is in fluid communication with the hot runner plates 1116, 1212. As previously discussed, this fluid communication allows a single-phase solution to be transferred from Fig.11 the syringe 212 through the injection manifold 1120 through the hot runner plates 1116, 2121 to the cavity of the die 900 while remaining a single-phase solution. Similarly, the fluid communication between the hot runner plates 1116, 1212 and the die 900 allows backpressure to be supplied to the die 900 from a gas backpressure supply source (such as Figure 2 the gas backpressure source 226). Figure 2

[0153] The injection manifold 1120 distributes a single-phase solution from Figure 2 the syringe 212 through the hot runner plates 1116, 1212 to the die 900. The injection manifold 1120 also maintains the single-phase solution as a single-phase solution between successive shots or injections into the tool. In an example, when the injection manifold 1120 contacts the die 900 through the hot runner plates (e.g., the hot runner plate 1116, the second hot runner plate 1212), the manifold accomplishes this in part through a valve that opens when the press 1100 creates fluid communication between the die 900 and the hot runner plates 1116, 1212.

[0154] The press 1100 is depicted as having a particular configuration, structure, and arrangement; however, the press 1100 is a non-limiting example of a press contemplated herein. Alternative arrangements (such as omitting the hot runner plates, platen), alternative actuators, alternative press locking mechanisms, etc. are contemplated within the scope of the systems and methods provided herein.

[0155] Fig.14A A perspective view of a die 900 in accordance with various aspects of the present disclosure is depicted. The die 900 has a first die portion 1401 and a second die portion 1403 that are in fluid communication with the hot runner plates 1116 and 1212 that form a tool assembly 1400. A gas backpressure port 1404 is depicted as extending from a side of the hot runner plate 1212. The gas backpressure port 1404 provides a conduit through the hot runner plate 1212 for fluidly coupling a gas backpressure supply source to the cavity of the die 900 (e.g., Fig. 14B the die cavity 1420) in a second portion associated with the hot runner plate 1212. Similar gas backpressure ports are in Fig.14Aextends through the hot runner plate 1116 on the opposite side that is not visible. The gas backpressure ports (not shown) of the hot runner plate 1116 also provide conduits through the hot runner plate 1116 for supplying a gas backpressure source (e.g., Figure 2 the gas backpressure source 226) to be fluidly coupled to the cavity of the mold 900 in a portion of the mold 900 associated with the hot runner plate 1116.

[0156] The second hot runner plate 1212 includes a plurality of nozzle receiving openings 1405a to 1405h extending through the hot runner plate 1212 toward the mold 900. The hot runner plate 1116 includes a plurality of nozzle receiving openings 1402a to 1402h extending through the hot runner plate 1116 toward the mold 900. Each of the nozzle receiving openings 1402a to 1402h and 1404a to 1404h effectively receives a nozzle (e.g., Fig.18B the nozzle 1807) from the manifold, as shown in more detail in Fig. 15B and Fig. 15C . The nozzle (e.g., Fig.18B the nozzle 1807) effectively fluidly couples the gate of the mold 900 (e.g., Fig. 14B the gate 1422) to the syringe 212, thereby allowing fluid communication of the molten composition from the syringe 212 to the mold cavity (e.g., Fig. 14B the mold cavity 1420).

[0157] Fig. 14B Depicts a partial exploded view of a Fig.14A tool assembly 1400 according to aspects herein, showing the second mold plate 1406 separated from the mold ring plate 1408. The second mold plate 1406 includes a peripheral wall 1410 that forms a boundary along the sides of the mold cavity wall 1412. Additionally, the mold ring plate 1408 includes a mold cavity wall 1414 that at least partially encloses the mold ring cavity 1416, and the mold cavity wall 1414 includes a first peripheral ridge 1418 that traverses the perimeter of the mold ring cavity 1416. When the second mold plate 1406 is layered adjacent or contiguous to the mold ring plate 1408, such as when assembling the first mold portion 1401, the peripheral wall 1410 nests within the mold cavity wall 1414 to at least partially enclose a portion of the mold ring cavity 1416. Additionally, the peripheral wall 1410 abuts the first peripheral ridge 1418 to at least partially seal and form the mold cavity 1420.

[0158] One aspect of the present disclosure includes a mold system having a common runner plate (e.g., a common hot runner plate or a common cold runner plate) and an array of two or more molds (e.g., the first mold portion 1401 and the second mold portion 1403 of FIG. 14), each mold in the array being configured to interface with the common runner plate and including a three-dimensional mold cavity size. Additionally, the three-dimensional mold cavity size of the first mold of the array is for a footwear component of a first shoe size such that the first mold includes a first runner configuration. The three-dimensional mold cavity size of the second mold of the array is for a footwear component of a second shoe size. In one aspect, each of the first shoe size and the second shoe size is in the range of US men's size 3.5 to US men's size 15, or US men's size 5 to US men's size 12, or US men's size 6 to US men's size 11, or US men's size 7 to US men's size 10. For example, the first shoe size can be in the range of US men's size 3.5 to US men's size 8, or US men's size 5 to US men's size 7.5, or US men's size 6 to US men's size 7; and the second shoe size can be in the range of US men's size 8.5 to US men's size 15, or US men's size 9 to US men's size 12, or US men's size 9 to US men's size 10.

[0159] Fig.15A depicts a front view 1500 of a mold 900 and hot runner plates 1116, 1212 in accordance with aspects herein. Referring Fig.14A to Fig. 15B and Fig. 15C , some of the walls of the hot runner plate 1212 are omitted to more clearly illustrate some of the internal components of the hot runner plate 1212. For example, the hot runner plate 1212 includes eight nozzle receiving sleeves 1505a to 1505h, each of which receives a corresponding nozzle (e.g., Fig.18B the nozzle 1807) of the injection manifold 1120. Each nozzle receiving sleeve 1505a to 1505h includes a nozzle receiving opening 1402a (see Fig.14A ) and a sleeve outlet 1507. The sleeve outlet 1507 includes a peripheral outer edge 1515 that forms a nozzle seat 1517 against which the tip of the nozzle (e.g., Fig.18B the nozzle 1807) is biased when the nozzle is then fully inserted into the nozzle receiving sleeve.

[0160] The hot runner plate 1116 also includes hot runners (e.g., 1509) that convey material from each nozzle (e.g., Fig.18B the nozzle 1807) after the material is dispensed. For example, each hot runner (e.g., 1509) includes a connection with the sleeve outlet (e.g., Fig. 15CIn the cross-sectional view of 1507), a fluidly connected hot runner inlet (e.g., 1511), and includes a hot runner outlet 1513. In one aspect of the present disclosure, the hot runner inlet (e.g., 1511) is spaced from the hot runner outlet (e.g., 1513) by a distance within the range of about 1 cm to about 3 cm. Thus, when the material is dispersed from the nozzle (e.g., Fig.18B nozzle 1807 of), a sprue is formed in the hot runner (e.g., 1509), and the sprue has a length within the range of about 1 cm to about 3 cm. In one aspect of the present disclosure, the sprue length provides a gripping area where a tool can grip the sprue to remove the cured material from the runner in the mold (e.g., Fig. 9 mold 900 of).

[0161] The hot runner plate 1116 includes various components that help control the conditions associated with the injection molding system. For example, the hot runner plate 1116 includes a regulated fluid line 1519 for conveying a regulated fluid through the hot runner plate 1116. The regulated fluid can be regulated to include a temperature for maintaining, increasing, or decreasing the temperature of the components of the hot runner plate, and the components of the hot runner plate include a hot runner (e.g., 1509), nozzle receiving sleeves 1505a to 1505h, and the nozzle (e.g., Fig.18B nozzle 1807 of) when inserted into the sleeve (see also Fig.12 , which depicts an inlet 1208 and an outlet 1210 located on the outer wall of the hot runner plate 1116). Thus, when the thermoplastic elastomer composition (e.g., a single-phase solution having a supercritical fluid as a physical blowing agent) is dispensed from the nozzle (e.g., Fig.18B nozzle 1807 of), the temperature in the hot runner plate 1116 can be maintained high enough to delay the transition of the supercritical fluid to a gas and / or maintain the polymer composition in a molten state.

[0162] In a further aspect, the hot runner plate 1116 includes a gas conduit 1501 for fluid communication with a gas backpressure source 226 through Fig.14A gas backpressure port 1404 of and Figure 2 to a gas backpressure outlet 1521, which is effectively in fluid communication with the mold (e.g., Fig. 9 mold 900 of).

[0163] In one aspect of the present disclosure, the hot runner plates 1116, 1212 are directly coupled to Fig.18AUniversal hot runner plates for injection manifolds 1120. For example, one or more fasteners may couple hot runner plates 1116, 1212 to injection manifold 1120. Compared to the present disclosure, some conventional injection molding systems may have separate hot runner plates that each interface with a different cold runner plate (or other unregulated temperature plate) and connect and disconnect from the manifold or nozzle during each injection cycle. This aspect of the present disclosure includes a universal hot runner plate that can be mounted to a nozzle and can interface with an array of different molds, each mold in the array including a different mold cavity, a different gate scheme, or any combination thereof. For example, mold cavities for molding parts of shoes of different sizes may differ in volume and / or shape, and the gate scheme may differ by including different gate locations and / or gate numbers. In various aspects, instead of multiple gates serving a single mold cavity, a single gate may serve the mold cavity. Additionally, hot runner plate 1116 is piped to all components for controlling aspects of the molding process, including regulated fluid line 1519 and gas conduit 1501. Hot runner plates are generally associated with higher costs (e.g., adding piping for temperature regulating elements). A universal hot runner plate can particularly reduce costs for multiple sets of molds because, instead of having to fabricate a hot runner plate for each mold, a single common hot runner plate can be used in multiple sets of molds. Additionally, costs can be reduced over time because there are fewer parts to store, maintain, repair, move, handle, etc. Although the figures of the present disclosure illustrate hot runner plates 1116 and 1212, which provide an interface between syringe nozzle 1807 and the tool, in other aspects of the present disclosure, a universal cold runner plate or other type of universal runner plate may provide the interface between syringe nozzle 1807 and the tool.

[0164] Fig.16 Depicts a side view 1600 of mold 900 and hot runner 1212 in accordance with aspects herein Fig.14A of mold 900 and hot runner 1212 in accordance with aspects herein Fig.17 Depicts a bottom plan view 1700 of mold 900 in accordance with aspects herein Fig.14A of mold 900 in accordance with aspects herein. First plate alignment keyways 1704 and second plate alignment keyways 1706 are depicted on bottom surface 1702 of first carrier plate 908. As previously discussed, first plate alignment keyways 1704 and second plate alignment keyways 1706 are effectively used to receive alignment protrusions from system components such as Figure 2 temperature regulating bracket 402 of Fig.11 press 1100 of Fig.23 unloader 2300 of

[0165] Also depicted is an RFID tag 1708. The RFID tag 1708 is recessed into the bottom surface 1702 to prevent contact with the Figure 2 The RFID tag 1708 provides a connection with the mold (e.g., Figure 5 1708) such that when the RFID tag 1708 is interrogated, the unique identifier causes the system 200 to know the location of the mold and / or an RFID reader (e.g., Figure 4 The RFID reader 438) thereby identifies the RFID tag 1708.

[0166] Fig.18A Depicts alignment with syringe 1806 according to aspects of the present disclosure. Fig.11 A perspective view 1800 of the press 1100 is shown. A syringe 1806, which may be referred to as an injection molding barrel, terminates in a nozzle 1804. The syringe 1806 is Figure 2 1806. The nozzle 1804 is operatively coupled to the syringe port 1802 of the injection manifold 1120. The syringe port 1802 is sized and configured to engage with the nozzle 1804 to form a fluid connection that allows the single-phase solution to remain as a single-phase solution as it is transferred from the syringe 1806 to the injection manifold 1120. The syringe port 1802 provides a fluid connection through the injection manifold 1120 to the manifold nozzle (e.g., Fig.18B The nozzles 1807) of the manifolds extend through the hot runner plates 1116, 1212 and are connected to the conduits 1803. Fig.13 The mold 900 forms a fluid connection, and the mold 900 is fixed and compressed in the press 1100.

[0167] refer to Fig.18B, an example of a set of injection nozzles (e.g., 1807) is shown as part of an injection manifold 1120 with the outer wall of the injection manifold 1120 removed. The injection manifold 1120 includes a syringe port 1802 that connects to a nozzle 1804 of a syringe 1806. The injection manifold 1120 also includes a series of internal components (not shown) that receive deposits / injections of the thermoplastic elastomer composition from the syringe 1806 and divide the injections into multiple deposits for separate distribution through the nozzles (e.g., 1807). The injection manifold 1120 may also include one or more sensors (e.g., thermocouples) (not shown) for monitoring conditions (e.g., temperature, pressure, etc.) of the injection manifold 1120 that may affect the thermoplastic elastomer composition, and a manifold temperature regulation unit 1811 for maintaining, increasing, or decreasing the temperature of the injection manifold 1120. For example, the manifold temperature regulation unit 1811 may include a regulated fluid line 1805 for holding and conveying a coolant or a heated regulating fluid. As such, when the deposits are distributed from each nozzle (e.g., 1807) into the hot runner plates 1116, 1212, the state of the thermoplastic elastomer composition (e.g., a single-phase solution) can be maintained. For example, the injection manifold 1120 may maintain the thermoplastic elastomer composition under conditions beneficial for maintaining the blowing agent in a supercritical fluid phase and reducing the likelihood of transitioning to a gas. In another aspect, the injection manifold 1120 includes a syringe-pin assembly (e.g., 1809) for each nozzle (e.g., 1807) that can selectively insert a pin (or other obstruction) into the tip of each nozzle to block material flow.

[0168] In another aspect of the present disclosure, the nozzles 1807 are arranged in nozzle groups, including two to six nozzles. For example, in FIG. 18b, the nozzles 1807 are arranged in four groups, each group having four linearly aligned nozzles, and in other aspects, the groups may include two, three, five, or six linearly aligned nozzles. Each group of nozzles is positioned to co-inject material into a single mold cavity. For example, in one aspect of the present disclosure, each group of four nozzles is configured to inject material into a single mold cavity having the three-dimensional shape of a footwear component (e.g., a footwear sole). In one aspect, the four nozzles optimize the available footprint and the injection system space operable to distribute material into a mold cavity having the three-dimensional shape of a footwear sole. That is, the three-dimensional shape of an average-sized footwear sole includes a length, and the four nozzles can optimally use that length to evenly distribute the injections of material into the mold cavity such that each injection foams and cures in a desired manner.

[0169] In Fig.18B which, the injection manifold 1120 includes sixteen nozzles 1807, each nozzle capable of being inserted into Fig.14AThe hot runner plates 1116 and 1212 are depicted as corresponding nozzle receiving openings (eg, 1402 ).

[0170] Fig.19 Depicted are paired and fluidly connected according to aspects of the present invention Fig.18A 1900 is a perspective view of a press 1100 and an injector 1806. The injector 1806 includes physical blowing agent ports 1902, 1904. The physical blowing agent ports 1902, 1904 provide for connecting the injector 1806 to a dosing source (e.g., Figure 2 The syringe 1806 also includes a polymer composition hopper 1906 that supplies the polymer composition to the syringe 1806 to be converted into a single-phase solution. The syringe may include one or more physical foaming agent ports. The physical foaming agent ports (such as physical foaming agent ports 1902, 1904) may be orifices extending through one or more surfaces (such as a surface defining a portion of the syringe).

[0171] Fig. 20 Depicted is a perspective view 2000 of the syringe 1806 of FIG. 18 in accordance with aspects herein. Fig. 20 A section line 22-22 is provided in the figure, which will be defined hereinafter. Fig. 22 cross section. Fig.21 Describes the various aspects of this article Fig. 20 Side view 2100 of syringe 1806.

[0172] Fig. 22 Depicts a cross-sectional view taken along section line 22-22 according to aspects of the present invention Fig.21 2200 of the cross-sectional view of the syringe 1806. The syringe 1806 includes a screw 2202. The screw 2202 can be rotated by an electric motor, a hydraulic motor or other rotating mechanism (not shown). The screw rotation speed affects the melting of the polymer composition, the formation of a single-phase solution, and the injection. As such, the screw rotation is 20 rpm to 120 rpm. The screw 2202 is used to transmit the polymer composition and compress the polymer composition through the syringe 1806, which increases the pressure experienced by the polymer composition in the syringe. The syringe also includes a plurality of heating elements extending along the length of the syringe 1806. The selection mark of the heating element is heating elements 2210, 2212, 2214, 2216. The heating element effectively heats the polymer composition to a molten state. The friction / shear-induced heat generated by the screw 2202 pushing the polymer composition through the syringe 1806 can also contribute to the melting of the polymer composition. The heating element can use induction heating, resistance heating, regulating fluid, etc.

[0173] Syringe 1806 is depicted as having at least three general regions. A first region 2204 represents a portion of syringe 1806 where the polymer composition is heated and compressed. A second region 2206 represents a portion of syringe 1806 where a physical blowing agent is introduced with the molten polymer composition. A third region 2208 represents a portion of syringe 1806 where the physical blowing agent and the molten polymer composition combine to form a single-phase solution. In an example, the third region 2208 is also effectively used to meter the volume of the single-phase solution for subsequent injection of the shot, which volume will be fluidly conveyed through nozzle 1804 to the manifold, as previously described.

[0174] While a particular syringe is depicted and described, syringe 1806 is a non-limiting example. Within the scope of the systems and methods provided herein, alternative syringe configurations, arrangements, and / or structures are envisioned while remaining within the scope envisioned herein.

[0175] Fig.23 A perspective view of an unloading machine 2300 in accordance with aspects herein is depicted. Unloading machine 2300 is an example embodiment of the unloading machine 214 described in Figure 2 The unloading machine includes a frame 2302, an unloading machine plate 2304, a first unloading machine arm 2318, a second unloading machine arm 2324, an unloading machine lock 2313 having fingers 2312, 2314, 2316, and the unloading machine plate 2304. The unloading machine plate includes a first protrusion 2308, a second protrusion 2306, and a recess 2310 that includes an RFID reader 2311.

[0176] Unloading machine 2300 effectively opens a tool (e.g., Fig.26 the mold 900 shown) for unloading a foamed article (e.g., a footwear component 100) contained within a cavity of the tool (e.g., Fig. 14B the cavity 1420 of). Unloading machine 2300 secures the tool to the unloading machine plate 2304 by sliding the unloading machine lock 2313 having fingers 2312, 2314, 2316 onto a portion of the tool such as Fig. 9 the first carrier plate of the mold 900 of. The unloading machine lock 2313 is capable of transitioning between an unlocked configuration and a locked configuration by sliding the fingers 2312, 2314, 2316 in a plane parallel to the top surface 2315 of the unloading machine plate 2304. After securing the tool to the unloading machine plate 2304, the first unloading machine arm 2318 and the second unloading machine arm 2324 can engage another portion of the tool such as Fig. 9engages with the second carrier plate 906 of the mold 900. The engagement is achieved by a first protrusion 2320 extending outward from the first unloading arm 2318 towards the second unloading arm 2324 and a second protrusion 2322 extending outward from the first unloading arm 2318 towards the second unloading arm 2324. The first protrusion 2320 is configured to be received in a keyway (such as Fig.10 the first plate-opening keyway 914), and the second protrusion 2322 is configured to be received in a keyway (such as Fig.10 the second plate-opening keyway 916).

[0177] The first protrusion 2320 is asymmetric with respect to the second protrusion 2322 in one or more characteristics. These characteristics include but are not limited to protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, and any combination thereof. Similarly, a third protrusion extending from the second unloading arm 2324 is asymmetric with respect to a fourth protrusion also extending from the second unloading arm 2324 in one or more characteristics. These characteristics include but are not limited to protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, and any combination thereof. In an example, the first protrusion and the third protrusion are symmetric in at least one characteristic. In an example, the second protrusion and the fourth protrusion are symmetric in at least one characteristic.

[0178] The first unloading arm 2318 and the second unloading arm 2324 are slidably positioned between an open configuration and a closed configuration. The open configuration has a first distance between the first unloading arm 2318 and the second unloading arm 2324, and the closed configuration has a second distance between the first unloading arm 2318 and the second unloading arm 2324. This directional movement in the horizontal manner as depicted in the figure is non-uniform. For example, when the first unloading arm 2318 moves to the left, the second unloading arm 2324 moves to the right, which represents the open configuration. Similarly, when the first unloading arm 2318 moves to the right, the second unloading arm 2324 moves to the left, which represents the closed configuration. The sliding movement can be achieved by a power actuator, such as an electric linear actuator, a pneumatic actuator, a hydraulic actuator, or other moving mechanisms (not shown).

[0179] The first unloading arm 2318 and the second unloading arm 2324 are also configured to move in an alternative direction (such as Fig.23move in unison in the vertical direction (as depicted). For example, when the first unloading arm 2318 moves upward, the second unloading arm 2324 also moves upward, which represents the lifting configuration. Similarly, when the first unloading arm 2318 moves downward, the second unloading arm 2324 also moves downward, which represents the closed configuration. The unison movement can be achieved by a power actuator, such as an electric linear actuator, a pneumatic actuator, a hydraulic actuator, or other moving mechanisms. Thus, the first unloading arm 2318 and the second unloading arm 2324 effectively move in unison with each other in the first direction and non-unison with each other in the lateral direction.

[0180] Fig.24 depicts a side view 2400 of the unloader 2300 in accordance with aspects of the present disclosure. Fig.23 of the unloader 2300. Fig.25 depicts a cross-sectional view of the unloader 2300 in a first configuration 2500 in accordance with aspects of the present disclosure. Fig.24 of the unloader 2300.

[0181] Fig.25 depicts a first vertical distance 2502 between the first unloading arm 2318 and the unloader plate 2304 and a first horizontal distance 2504 between a pair of fingers 2312, 2316. This first configuration 2500 represents the lifting configuration of the unloading arm and the open configuration of the unloader lock. Fig.26 depicts a cross-sectional view of the unloader 2300 with a die 900 in a second configuration 2600 in accordance with aspects of the present disclosure. Fig.24 of the unloader 2300. Fig.26Depicts a second vertical distance 2602 between the first unloading arm 2318 and the unloading plate 2304 and a second horizontal distance 2604 between a pair of fingers 2312, 2316. This second configuration 2600 represents a closed configuration of the first unloading arm 2318 and the second unloading arm 2324 and a locked configuration of the unloading lock 2313. In the locked configuration, a pair of fingers 2312, 2316 engage with the first carrier plate 908 of the mold 900 and fix the first carrier plate 908. The engagement of the pair of fingers 2312, 2316 fixes the first carrier plate 908 to the unloading plate 2304, resists the upward force exerted by the first unloading arm 2318 and the second unloading arm 2324 when they engage with the second carrier plate 906, and lifts the second carrier plate 906. This lifting action separates the second carrier plate 906 from the first carrier plate 908, which allows access to the internal volume of the mold cavity so that the foamed product can be removed. Thus, it is envisioned that the first unloading arm 2318 and the second unloading arm 2324 are configured to move through at least three positions in their consistent direction of movement. The first position is when the mold is closed, the second position is when the mold is partially opened to remove scrap material from the runner system of the mold, and the third position is when the mold is opened to a greater extent so that the foamed product can be removed from the mold cavity. It is envisioned that a fixed-time movement delay or stop of 1 second to 120 seconds is provided between the transition of the second position and the third position. In an example, this intentional delay allows for the automatic removal of scrap, such as by an auxiliary robot.

[0182] The first unloading arm 2318 further includes a key 2606 that extends outwardly from the first unloading arm 2318 toward the second unloading arm 2324. The key 2606 is a protrusion that engages with Fig.10 the biasing pin 922 that is biased into the locked configuration. The second unloading arm 2324 further includes a key 2607 (as best shown in Fig.24 ) that extends outwardly from the second unloading arm 2324 toward the first unloading arm 2318. The key 2607 is a protrusion that engages with Fig.10 the biasing pin 922 that is biased into the locked configuration.

[0183] When the first unloading arm 2318 and the second unloading arm 2324 move inconsistently with each other, each of the first unloading arm 2318 and the second unloading arm 2324 respectively includes a key (such as the key 2606 and the key 2607), and the key engages with a corresponding biasing pin (e.g., Fig.10 in the tool latch assembly 918 of Fig.10engages with the biasing pin 922). When the first unloading arm 2318 and the second unloading arm 2324 converge, their respective keys (i.e., key 2606 and key 2607) engage with the tool latch assembly to release the mechanical lock caused by the biasing pin. During unlocking of the tool latch assembly (e.g., Fig.10 the tool latch assembly 918) by the unloader 2300, it is contemplated that the unloader 2300 (such as via the unloading arms 2318, 2324) compresses the tool to relieve the shear pressure applied by the second part of the tool latch assembly interacting with the biasing pin on the biasing pin (e.g., Fig.10 the biasing pin 922). The compression of the tool by the unloader reduces the interaction between the second part of the tool latch assembly and the biasing pin in the locked configuration to allow the converging force of the unloading arms to compress the biasing pin inward and press it out of the second part of the tool latch assembly.

[0184] Although a specific unloader is depicted and described, the unloader 2300 is a non - limiting example. Within the scope of the systems and methods provided herein, it is contemplated that alternative unloader configurations, arrangements, and / or structures may be implemented while remaining within the scope contemplated herein.

[0185] Fig. 27 Flowchart 2700 depicting a first method of physically foaming a footwear component in accordance with aspects herein is shown. At block 2702, the step of temperature - regulating the mold is performed. The temperature regulation can be done at a temperature - regulating bracket, and the temperature regulation causes the mold to reach a temperature of 15 degrees Celsius to 90 degrees Celsius. In an alternative range, the mold temperature is regulated to a temperature of 50 degrees Celsius to 70 degrees Celsius. In an additional alternative range, the mold temperature is regulated to a temperature of 55 degrees Celsius to 65 degrees Celsius.

[0186] At block 2704, the method continues where the end - effector engages with the mold. This engagement can occur due to one or more protrusions of the end - effector being received in one or more keyways of the mold. The protrusions can be asymmetrical such that the orientation and position of the mold can be determined based on the engagement of the end - effector with the mold. The end - effector engages reversibly with the mold such that the end - effector engages with the mold to transfer the mold and disengages from the mold to place and store the mold.

[0187] At block 2706, the step of transferring the mold by the end - effector is provided. The transfer is performed by a robot manipulating the position of the end - effector in a macroscopic space. The mold is transferred by the end - effector to a press. The transfer can be in a generally arcuate shape caused by the robot rotating about a major axis. In an example, the transfer can be in a generally non - arcuate shape, such as a linear motion patch provided by a Cartesian or gantry - type robot.

[0188] At block 2708, the method continues where a gas backpressure is applied to the mold. The gas backpressure can be supplied by a hot runner fixed to the press and in fluid communication with the mold. The gas backpressure can pressurize the cavity of the mold to at least the critical pressure of the physical blowing agent used in the method. The gas provided for the gas backpressure can be any material such as nitrogen, carbon dioxide, or air. In an example, the material of the gas backpressure is similar to the composition of the physical blowing agent (e.g., the physical blowing agent is supercritical fluid nitrogen; the gas backpressure is supplied by nitrogen gas).

[0189] At block 2710, the method continues where a single-phase solution comprising a polymer composition and a physical blowing agent is injected into the cavity of the mold. The single-phase solution comprises a polymer composition and a supercritical fluid in a ratio of X to Y, or X1 to Y1, or X2 to Y2. The injected single-phase solution is allowed to remain a single-phase solution for a period of time without supercritical fluid coming out of the solution. In an example, the period of time can be from 0.5 seconds to 10 seconds. This delayed foaming of the polymer composition provides an opportunity for the injected polymer composition to disperse in the mold cavity before expanding as part of the foaming action, which can produce a more consistent foamed article.

[0190] At block 2712, the method continues where the gas backpressure is released from the mold cavity to below the critical pressure of the supercritical fluid that is the physical blowing agent. When the pressure is reduced below the critical pressure, the supercritical fluid undergoes a phase change to a gas, causing the blowing agent to come out of the solution and form bubbles, which form the cell structure of the resulting foamed article. It is contemplated that a regulator continuously releases the gas backpressure during the injection process, but the release of the regulator is designed to maintain a consistent pressure in the mold cavity. Block 2712 represents the pressure being reduced to a level sufficient to activate the physical blowing agent.

[0191] It is contemplated that the mold can be transferred to a temperature conditioning rack after the foaming action is initiated. The mold and the foamed article are allowed to be temperature conditioned at the temperature conditioning rack. The conditioning time can vary, but in an example, it is from 1 minute to 90 minutes. This conditioning time allows the foamed article to cure in the mold and gain dimensional stability before being removed from the mold.

[0192] At block 2714, the method continues by removing the footwear component from the mold. The removal can occur at an unloading machine (to which the mold is transferred). The removal of the footwear component formed in the mold can be, for example, manually removed by a human operator, or it can be removed in an automated manner, such as by an end effector for an assisting robot that effectively secures and removes the foamed article / component from the mold cavity.

[0193] Fig.28Depicts flowchart 2800 representing a second method of physically foaming a footwear component in accordance with various aspects of the present disclosure. At block 2802, the method includes temperature conditioning a mold. At block 2804, the method includes applying a gas backpressure to the cavity of the mold. At block 2806, the method includes injecting a single-phase solution into the cavity of the mold. At block 2808, the method includes releasing the gas backpressure to a pressure that causes a physical blowing agent to come out of the solution and foam the polymer composition. At block 2810, the method includes removing the foamed footwear component from the mold.

[0194] Fig.29 Depicts flowchart 2900 representing a third method of physically foaming a footwear component in accordance with various aspects of the present disclosure. At block 2902, the method includes mating a mold with a hot runner plate and a platen at a press. For example, the press compresses the mold between the platen and the hot runner plate to form a fluid connection between the mold and the hot runner plate, thereby effectively transferring the single-phase solution while maintaining the single-phase solution as a single-phase solution. At block 2904, the method includes injecting a single-phase solution into the cavity of the mold. The single-phase solution including a physical blowing agent and a polymer composition is injected through one or more nozzles extending through the hot runner plate. At block 2906, the method includes removing the footwear component from the cavity of the mold.

[0195] Fig.30 Depicts flowchart 3000 representing a fourth method of physically foaming a footwear component in accordance with various aspects of the present disclosure. At block 3002, the method includes reading an RFID tag associated with a mold by an RFID reader of a temperature conditioning bracket. At block 3004, the method includes associating a temperature with the mold based on the RFID tag. For example, a thermocouple effectively measures the temperature of a temperature conditioning plate on which the mold can be located and with which the RFID reader is also associated. Thus, the controller is able to associate the temperature of the temperature conditioning plate with the mold based on the mold location determined from an RFID reader interrogation of the RFID tag. At block 3006, the method continues where the controller selects a mold from a plurality of molds. Mold selection occurs when the associated temperature of the mold indicates that the mold is sufficiently conditioned for use in a system for forming a physically foamed article. At block 3008, the method includes injecting a single-phase solution into the cavity of the mold. At block 3010, the method includes removing the footwear component from the cavity.

[0196] Material

[0197] Foamed thermoplastic elastomer composition

[0198] The present disclosure relates to an article including a foam component, the foam component including a foamed thermoplastic elastomer composition. The foam component includes a foamed thermoplastic elastomer composition having a multi-cellular foam structure (e.g., a multi-cellular open-cell or closed-cell foam structure). The foam component can include a foamed thermoplastic elastomer composition having a multi-cellular open-cell structure. The article can be a component for a footwear article, a clothing article, or a sports equipment article, such as a cushioning element. In one example, the article is a cushioning element for a footwear article (such as a midsole or a midsole component).

[0199] It has been found that thermoplastic elastomer compositions (i.e., polymer compositions including one or more thermoplastic elastomers) (including thermoplastic polyester compositions (i.e., polymer compositions including one or more thermoplastic polyester elastomers)) can be used to form multi-cellular foams having advantageous properties for consumer articles (such as cushioning elements). As used herein and further discussed below, the term polyester can refer to polyester homopolymers and / or copolyester polymers having at least one polyester monomer segment. When foamed as described herein, these multi-cellular foams retain thermoplastic properties such that the thermoplastic elastomer composition of the foam can be easily recycled and reused. For example, once foamed, the thermoplastic elastomer composition can be ground, melted to eliminate its foam structure and foamed again, or it can be ground, melted to eliminate its foam structure and molded into an article having a non-foamed structure (i.e., a solid article).

[0200] The foam component disclosed herein is formed by foaming a thermoplastic elastomer composition into a multi-cellular foam having an open-cell or closed-cell foam structure. The thermoplastic elastomer composition can be a thermoplastic polyester composition including one or more thermoplastic polyester elastomers. Examples of thermoplastic polyesters include polymers having one or more carboxylic acid functional groups present in the polymer backbone, one or more side chains, or both in the polymer backbone and one or more side chains. One or more carboxylic acid functional groups of the thermoplastic polyester can include free carboxylic acids, salts of carboxylic acids, or acid anhydrides of carboxylic acids. The carboxylic acid functional group of the thermoplastic polyester can be an acrylic functional group or a methacrylic functional group.

[0201] Based on the total weight of the thermoplastic elastomer composition, the thermoplastic elastomer composition may comprise at least 90 wt%, or at least 95 wt%, or at least 99 wt% of a polymer component, which polymer component comprises all of the polymer compositions present in the thermoplastic elastomer composition. In some aspects, based on the total weight of the thermoplastic polyester composition, the thermoplastic polyester composition comprises at least 90 wt%, or at least 95 wt%, or at least 99 wt% of a polymer component, which polymer component comprises all of the thermoplastic polyesters present in the thermoplastic polyester composition, such as one or more thermoplastic polyester elastomers as disclosed herein based on the total weight of the thermoplastic polyester composition. In some such aspects, the thermoplastic elastomer composition (or thermoplastic polyester composition) is substantially free of non-polymer components. The non-polymer components may comprise all of the non-polymer compositions present in the thermoplastic elastomer composition or thermoplastic polyester composition, or may comprise specific types of non-polymer compositions present in the thermoplastic elastomer composition or thermoplastic polyester composition. Examples of non-polymer components may include one or more of nucleating agents, non-polymer fillers, chemical blowing agents, colorants such as pigments and / or dyes, processing aids, and the like. In some instances, the thermoplastic elastomer composition (or thermoplastic polyester composition) is substantially free of nucleating agents, or substantially free of non-polymer fillers, or substantially free of colorants, or substantially free of both non-polymer nucleating agents and non-polymer fillers, or substantially free of non-polymer nucleating agents, non-polymer fillers, and colorants. Using thermoplastic polyester compositions having low levels of non-polymeric ingredients such as nucleating agents, fillers, and colorants increases the likelihood of reusing and recycling these compositions because these compositions can be used in applications where the presence of one or more of these ingredients is undesirable or would require dilution by addition of virgin polymer. Additionally, compared to compositions having high levels of non-polymeric ingredients, the absence of high levels of fillers or colorants in the polymer composition can reduce the specific gravity of the foam and can permit the formation of a foam having an open-cell foam structure, which can further reduce the specific gravity of the foam.

[0202] Articles or foam components comprising a thermoplastic elastomer foam can be formed by injection molding and foaming a thermoplastic elastomer polymer composition as described herein to form the article or foam component, which can be directly incorporated into a footwear article, apparel, or sports equipment without any additional processing, i.e., the size and / or outer surface of the injection molded foam may not require any modification. When using a physical blowing agent, it has been found that the size of injection molded foams formed from thermoplastic elastomer compositions, including thermoplastic polyester compositions, is very stable because the foam article or component shrinks very little after release from the mold and does not require any additional processing to stabilize the foam, thus allowing the use of a "one-to-one" injection molding process, where the size of the resulting molded foam article or component is substantially the same as the size of the mold used in the injection molding process. Alternatively, the injection molded foam article or component can be further processed, such as by stabilizing the foam using an annealing process, by compression molding the injection molded foam article or component into a finished foam, and / or by applying a coating or decorative element to the injection molded foam article or component.

[0203] Features of Thermoplastic Elastomer Foam Components

[0204] The disclosed thermoplastic elastomer foams (i.e., foams formed by expanding a thermoplastic elastomer composition as disclosed herein) (including thermoplastic polyester foams) can exhibit various beneficial properties. For example, the thermoplastic elastomer foams can exhibit beneficial delamination tear, such as high delamination tear values for sole components in footwear articles. In some aspects, when determined using the delamination tear test method described herein, the thermoplastic elastomer foams can have a delamination tear value greater than about 1.5 kilograms per centimeter (kg / cm), or greater than about 2.0 kg / cm, or greater than about 2.5 kg / cm. In some aspects, when determined using the delamination tear test method described herein, the thermoplastic elastomer foams can have a delamination tear value of 1.0 kg / cm to 4.5 kg / cm, or 1.0 kg / cm to 4.0 kg / cm, or 1.5 kg / cm to 4.0 kg / cm, or 2.0 kg / cm to 3.5 kg / cm, or 2.5 kg / cm to 3.5 kg / cm. The thermoplastic elastomer foams can have a delamination tear value of 0.8 kg / cm to 4.0 kg / cm, or 0.9 kg / cm to 3.0 kg / cm, or 1.0 to 3.0 kg / cm, or 1.0 kg / cm to 2.5 kg / cm, or 1 kg / cm to 2 kg / cm. In some aspects, the thermoplastic elastomer foams are injection molded and have a delamination tear value of 0.7 kg / cm to 2.5 kg / cm, or 0.8 kg / cm to 2.0 kg / cm, or 0.9 to 1.5 kg / cm, or 1.0 kg / cm to 2.5 kg / cm, or 1.0 kg / cm to 2.2 kg / cm. The thermoplastic elastomer foams can have an open-cell foam structure. The thermoplastic elastomer foams can be the product of physical foaming of a thermoplastic elastomer composition as disclosed herein, i.e., a foam formed using a physical blowing agent (i.e., a physical foaming agent). As used herein, thermoplastic elastomer foams should be understood to refer to foamed materials having thermoplastic and elastomeric properties. The thermoplastic elastomer foams can be the foamed product of a thermoplastic elastomer composition, which, based on the total weight of the thermoplastic elastomer composition, includes less than 10 weight percent, or less than 5 weight percent, or less than 1 weight percent of non-polymeric components. In some aspects, the thermoplastic elastomer foams are injection molded (i.e., not exposed to a separate compression molding step after being formed by injection molding and removed from the injection mold). In other aspects, the thermoplastic elastomer foams are injection molded and subsequently compression molded in a separate compression mold that has different dimensions from the mold used in the injection molding step.

[0205] The density or specific gravity of the disclosed thermoplastic elastomer foams (including thermoplastic polyester foams) is also an important physical property to consider when the foam is used in apparel articles, footwear, or sports equipment. As discussed above, the thermoplastic elastomer foams of the present disclosure exhibit low density or specific gravity, which beneficially reduces the weight of the midsole or other components that include the thermoplastic elastomer foam.

[0206] When determined using the specific gravity testing method described herein, the thermoplastic elastomer foams (including thermoplastic polyester foams) of the present disclosure can have a specific gravity of from 0.02 to 0.22, or from 0.03 to 0.12, or from 0.04 to 0.10, or from 0.11 to 0.12, or from 0.10 to 0.12, or from 0.15 to 0.20, or from 0.15 to 0.30. In some aspects, when determined using the specific gravity testing method described herein, the thermoplastic elastomer foam can have a specific gravity of from 0.15 to 0.22, such as from 0.17 to 0.22 or from 0.18 to 0.21. Alternatively or additionally, when determined using the specific gravity testing method described herein, the thermoplastic elastomer foam can have a specific gravity of from 0.01 to 0.10, or from 0.02 to 0.08, or from 0.03 to 0.06, or from 0.08 to 0.15, or from 0.10 to 0.12. For example, the specific gravity of the thermoplastic elastomer foam can be from 0.15 to 0.2, or from 0.10 to 0.12. The thermoplastic elastomer foam can be injection molded, or can be injection molded and subsequently compression molded. In some aspects, when determined using the specific gravity testing method described herein, the thermoplastic elastomer foam has a specific gravity of about 0.7 or less, or 0.5 or less, or 0.4 or less, or 0.3 or less. In some aspects, when determined using the specific gravity testing method described herein, the thermoplastic elastomer foams (including the thermoplastic elastomer foam present in the midsole and midsole components) can have a specific gravity of from 0.05 to 0.25, or from 0.05 to 0.2, or from 0.05 to 0.15, or from 0.08 to 0.15, or from 0.08 to 0.20, or from 0.08 to 0.25, or from 0.1 to 0.15. In some aspects, when determined using the specific gravity testing method described herein, the thermoplastic elastomer foam has a specific gravity of from about 0.15 to about 0.3, or from about 0.2 to about 0.35, or from about 0.15 to about 0.25. The thermoplastic elastomer foam article or article component can be formed by injection molding without a subsequent compression molding step. The thermoplastic elastomer foam can have an open cell foam structure. The thermoplastic elastomer foam can be a foamed product of a thermoplastic elastomer composition that includes less than 10 wt%, or less than 5 wt%, or less than 1 wt% non-polymeric components, based on the total weight of the thermoplastic elastomer composition.

[0207] When determined using the density testing method described herein, the thermoplastic elastomer foams of the present disclosure (including thermoplastic polyester foams) can have a density of from 0.02 grams per cubic centimeter (g / cc) to 0.22 g / cc, or from 0.03 g / cc to 0.12 g / cc, or from 0.04 g / cc to 0.10 g / cc, or from 0.11 g / cc to 0.12 g / cc, or from 0.10 g / cc to 0.12 g / cc, or from 0.15 g / cc to 0.2 g / cc, or from 0.15 g / cc to 0.30 g / cc. In some aspects, when determined using the density testing method described herein, the thermoplastic elastomer foam can have a density of from 0.15 g / cc to 0.22 g / cc, such as from 0.17 g / cc to 0.22 g / cc or from 0.18 g / cc to 0.21 g / cc. Alternatively or additionally, when determined using the density testing method described herein, the thermoplastic elastomer foam can have a density of from 0.01 g / cc to 0.10 g / cc, or from 0.02 g / cc to 0.08 g / cc, or from 0.03 g / cc to 0.06 g / cc, or from 0.08 g / cc to 0.15 g / cc, or from 0.10 g / cc to 0.12 g / cc. For example, the density of the thermoplastic elastomer foam can be from 0.15 g / cc to 0.2 g / cc, or from 0.10 g / cc to 0.12 g / cc. The thermoplastic elastomer foam can be injection molded, or can be injection molded and subsequently compression molded. In some aspects, when determined using the density testing method described herein, the thermoplastic elastomer foam has a density of about 0.7 g / cc or less, or 0.5 g / cc or less, or 0.4 g / cc or less, or 0.3 g / cc or less, or 0.2 g / cc or less. In some aspects, when determined using the density testing method described herein, the thermoplastic elastomer foams (including the thermoplastic elastomer foams present in the midsole and midsole components) can have a density of from 0.05 g / cc to 0.25 g / cc, or from 0.05 g / cc to 0.2 g / cc, or from 0.05 g / cc to 0.15 g / cc, or from 0.08 g / cc to 0.15 g / cc, or from 0.08 g / cc to 0.20 g / cc, or from 0.08 g / cc to 0.25 g / cc, or from 0.10 g / cc to 0.15 g / cc. In some aspects, when determined using the density testing method described herein, the thermoplastic elastomer foam has a density of about 0.15 g / cc to about 0.30 g / cc, or about 0.20 g / cc to about 0.35 g / cc, or about 0.15 g / cc to about 0.25 g / cc. The thermoplastic elastomer foam article or article component can be formed by injection molding without a subsequent compression molding step. The thermoplastic elastomer foam can have an open-cell foam structure.The thermoplastic elastomer foam can be a foamed product obtained by foaming a thermoplastic elastomer composition, which, based on the total weight of the thermoplastic elastomer composition, comprises less than 10 wt%, or less than 5 wt%, or less than 1 wt% of non-polymeric components.

[0208] When determined using a 45 mm diameter cylindrical sample for the cyclic compression test of samples, the thermoplastic elastomer foam portion (including the thermoplastic polyester foam portion) of the article or article component can have a stiffness of about 200 kPa to about 1000 kPa, or about 300 to about 900 kPa, or about 400 to about 800 kPa, or about 500 to about 700 kPa. When determined using a foot-shaped sample for the foot-shaped cyclic compression test, the thermoplastic elastomer foam portion of the article or article component can have a stiffness of about 100 N / mm to about 400 N / mm, or about 150 N / mm to about 350 N / mm, or about 200 N / mm to about 300 N / mm, or about 225 N / mm to about 275 N / mm. The thermoplastic elastomer foam article or article component can be formed by injection molding without a subsequent compression molding step. The thermoplastic elastomer foam can have an open-cell foam structure. The thermoplastic elastomer foam can be a foamed product obtained by foaming a thermoplastic elastomer composition, which, based on the total weight of the thermoplastic elastomer composition, comprises less than 10 wt%, or less than 5 wt%, or less than 1 wt% of non-polymeric components.

[0209] When determined using the durometer hardness test described herein, the thermoplastic elastomer foam portion (including the thermoplastic polyester portion) of the article or article component can have an Asker C durometer hardness of about 30 to about 50, or about 35 to about 45, or about 30 to about 45, or about 30 to about 40. The thermoplastic elastomer foam article or article component can be formed by injection molding without a subsequent compression molding step. The thermoplastic elastomer foam can have an open-cell foam structure. The thermoplastic elastomer foam can be a foamed product obtained by foaming a thermoplastic elastomer composition, which, based on the total weight of the thermoplastic elastomer composition, comprises less than 10 wt%, or less than 5 wt%, or less than 1 wt% of non-polymeric components.

[0210] The energy input of the foam is the integral of the force-displacement curve during foam loading during cyclic compression testing. The energy return of the foam is the integral of the force-displacement curve during foam unloading during cyclic compression testing. When determined using a 45 mm diameter cylindrical sample for the sample cyclic compression test, the thermoplastic elastomer foam portion (including the thermoplastic polyester foam portion) of the article or article component can have an energy return of from about 200 millijoules (mJ) to about 1200 mJ, or from about 400 mJ to about 1000 mJ, or from about 600 mJ to about 800 mJ. When determined using a full-sole cyclic compression test with a full-sole sample, the thermoplastic elastomer foam portion of the article or article component (e.g., a footwear sole for a US men's size 10) can have an energy input of from about 2000 millijoules (mJ) to about 9000 mJ, or from about 3000 mJ to about 8000 mJ, or from about 4500 mJ to about 6500 mJ. The thermoplastic elastomer foam article or article component can be formed by injection molding without a subsequent compression molding step. The thermoplastic elastomer foam can have an open-cell foam structure. The thermoplastic elastomer foam can be a foamed product of a foamed thermoplastic elastomer composition that includes less than 10 wt%, or less than 5 wt%, or less than 1 wt% non-polymeric components, based on the total weight of the thermoplastic elastomer composition.

[0211] Energy efficiency (EE) is a measure of the percentage of energy of the thermoplastic elastomer foam portion (including the thermoplastic polyester foam portion) of an article or component that is returned when it is released after being compressed under load, which can provide improved performance for sports footwear, such as for reducing energy loss or dissipation during running. This is especially true for running and other sports footwear. In some aspects, when determined using a 45 mm diameter cylindrical sample for the sample cyclic compression test, the thermoplastic elastomer foam portions of the articles and components provided herein have an energy efficiency of at least 50%, or at least 60%, or at least 70%, or at least about 75%, or at least about 80%, or at least about 85%. When determined using a 45 mm diameter cylindrical sample for the sample cyclic compression test, the thermoplastic elastomer foam portions of the articles and components provided herein can have an energy efficiency of from about 50% to about 97%, or from about 60% to about 95%, or from about 60% to about 90%, or from about 60% to about 85%, or from about 65% to about 85%, or from about 70% to about 85%, or from about 70% to about 90%, or from about 70% to about 95%. The thermoplastic elastomer foam article or article component can be formed by injection molding without a subsequent compression molding step. The thermoplastic elastomer foam can have an open-cell foam structure. The thermoplastic elastomer foam can be a foamed product of a foamed thermoplastic elastomer composition that includes less than 10 wt%, or less than 5 wt%, or less than 1 wt% non-polymeric components, based on the total weight of the thermoplastic elastomer composition.

[0212] The resulting foam can have a multi-cellular closed-cell or open-cell foam structure. A cell is a hollow structure formed during the foaming process, where gas bubbles are formed in the thermoplastic elastomer composition by a blowing agent. The cell walls are generally defined by the thermoplastic elastomer composition. A "closed cell" forms a separate volume that is completely enclosed and not in fluid communication with an adjacent separate volume. A "closed-cell structure" refers to a foam structure in which at least 50% or more of the cells are closed cells, or at least 60% or more of the cells are closed cells, or at least 80% of the cells are closed cells, or at least 90% of the cells are closed cells, or at least 95% of the cells are closed cells. An "open-cell structure" refers to a foam structure in which less than 50%, or less than 40%, or less than 20%, or less than 10%, or less than 5%, or less than 4%, or less than 3%, or less than 1% of the cells are closed cells.

[0213] The disclosed open-cell and closed-cell thermoplastic elastomer foams can have an average cell size (e.g., maximum width or length) measured linearly from one side of a cell to the opposite side of the cell. For example, in some aspects of the present disclosure, the open-cell and closed-cell thermoplastic elastomer foams can have an average cell size of about 50 microns to about 1000 microns, or about 80 microns to about 800 microns, or about 100 microns to about 500 microns. These are example cell sizes for one aspect of the present disclosure, where the foam forms part of a footwear article, and in other aspects, when the foam forms other footwear articles, the cell size can be larger or smaller. Additionally, the open-cell and closed-cell thermoplastic elastomer foams can form all or part of a non-footwear article, and in those cases, the foam can have a cell diameter that includes these example cell sizes, is less than these example cell sizes, is greater than these example cell sizes, or any combination thereof.

[0214] For both open-cell and closed-cell structures, the proportion of cells in the thermoplastic elastomer foam having a cell diameter of about 50 microns to about 1000 microns is preferably not less than 40% relative to all cells, or not less than 50% or not less than 60% relative to all cells. If the proportion of cells is less than 40%, the cell structure will tend to be non-uniform and / or have a rough cell structure. As used herein, a "rough cell structure" refers to a foam structure in which the average cell diameter is greater than 1 mm, and / or for greater than 20% of the cells, a 1 mm line drawn across the maximum dimension of the cell will not cross the cell wall or strut (i.e., the open cell wall or a portion thereof).

[0215] The number of open cells and / or closed cells in the foam and the cell diameter of the cells can be determined visually, for example, by capturing an image of a cut surface with a camera or digital microscope, determining the number of cells, the number of open cells and / or the number of closed cells, and determining the area of the cells and converting it to an equivalent circle diameter.

[0216] Methods for manufacturing foams disclosed by the manufacturing facility

[0217] In some examples, the disclosed foamed thermoplastic elastomer compositions can be prepared by various methods as disclosed herein and known in the art. That is, the disclosed articles or article components (such as midsoles, midsole components, inserts, and insert components) can be prepared by injection molding a melt composition comprising a polymer composition (such as a thermoplastic elastomer composition) using a physical blowing agent, using a combination of a physical blowing agent and a chemical blowing agent, or only using a chemical blowing agent as described herein. The disclosed foam components (e.g., the disclosed foam articles or components) can be prepared by the methods disclosed below.

[0218] Disclosed herein are methods for making foam articles or components, the methods comprising: forming a mixture of a molten thermoplastic elastomer composition (e.g., a polymer composition) and a blowing agent; injecting the mixture into a mold cavity; causing the thermoplastic elastomer composition to foam, thereby forming a foamed thermoplastic elastomer composition; curing the foamed thermoplastic elastomer composition, thereby forming a foam article having a multi-cellular foam structure; and removing the foam article from the mold cavity. In some aspects, forming the mixture of the thermoplastic elastomer composition and the blowing agent comprises forming a single-phase solution of a liquid, gas, or supercritical fluid blowing agent and the molten thermoplastic elastomer composition. In some aspects, the mixture is a single-phase solution of supercritical nitrogen or supercritical carbon dioxide and the polymer composition. In a specific example, the mixture is a single-phase solution of supercritical nitrogen in a thermoplastic polyester composition. In some aspects, based on the total weight of the thermoplastic elastomer composition, the thermoplastic elastomer composition comprises less than 10 wt%, or less than 5 wt%, or less than 1 wt% of non-polymeric components. In such aspects, injecting the mixture into the mold cavity can comprise injecting the single-phase solution into the mold cavity and then cooling the single-phase solution in the mold cavity before reducing the pressure in the mold cavity to a level at which the supercritical fluid phase transitions to a gas, and the gas drips out of the solution in the molten polymer, forming gas bubbles in the molten polymer and causing the molten polymer to foam. In some aspects, foaming forms a foam having an open-cell foam structure.

[0219] Also disclosed is a method for making a foam article or component, the method comprising: forming a mixture of a molten thermoplastic elastomer composition and a blowing agent; injecting the mixture into a mold cavity; causing the molten thermoplastic elastomer composition to foam in the mold cavity to form a thermoplastic elastomer foam; curing the thermoplastic elastomer foam in the mold cavity to form a molded foam article comprising a thermoplastic elastomer composition having a multi-cellular foam structure; and removing the molded foam article from the mold cavity. In some aspects, the temperature of the mixture at the point where it foams in the mold cavity is from about the melting temperature of the thermoplastic elastomer composition to about 50 °C above the tail temperature of the thermoplastic elastomer composition. In some aspects, the melting temperature of the thermoplastic elastomer composition is the melting temperature of the polymer component of the thermoplastic elastomer composition. In other aspects, the melting temperature of the thermoplastic elastomer composition is the melting temperature of the thermoplastic elastomer present in the thermoplastic elastomer composition. In still other aspects, the melting temperature of the thermoplastic elastomer present in the thermoplastic elastomer composition is the melting temperature of the thermoplastic elastomer having the highest melting temperature of all the polymers present in the polymer component of the thermoplastic elastomer composition. In still other aspects, the melting temperature is the melting temperature of a thermoplastic polyester (such as a polyester elastomer) present in the thermoplastic elastomer composition. Foaming can occur when the mixture is at a foaming temperature, where the foaming temperature is from about the melting temperature of the thermoplastic elastomer to about 50 °C above the tail temperature of the thermoplastic elastomer. In some aspects, forming the mixture of the thermoplastic elastomer composition and the blowing agent comprises forming a single-phase solution of a supercritical fluid and the molten thermoplastic elastomer composition. The thermoplastic elastomer composition can comprise less than 10 wt%, or less than 5 wt%, or less than 1 wt% non-polymeric components, based on the total weight of the thermoplastic elastomer composition. If more than one thermoplastic elastomer is present in the thermoplastic elastomer composition, the melting temperature can be the highest melting temperature of the thermoplastic elastomers present in the composition. In such aspects, injecting the mixture into the mold cavity can comprise injecting the single-phase solution into the mold cavity and then cooling the single-phase solution in the mold cavity before reducing the pressure in the mold cavity to a level at which the supercritical fluid phase transitions to a gas and the gas drops out of the solution in the thermoplastic elastomer composition, forming gas bubbles in the thermoplastic elastomer composition and causing the thermoplastic elastomer to foam. The foaming can form a foam having an open-cell foam structure.

[0220] Dynamic scanning calorimetry (DSC) is used to determine the melting temperature and the tail temperature of a thermoplastic elastomer composition, or a polymeric component of a thermoplastic elastomer composition, or an individual thermoplastic elastomer present in a thermoplastic elastomer composition, and an exemplary method is described below. Briefly, 10 to 30 mg of undried resin pellets are cycled from -90 °C to 225 °C at 20 °C / min and cooled to -90 °C at 10 °C / min. In some cases, the experiment is run using a heat-cool-heat curve with a heating and cooling rate of 10 °C / min, a minimum temperature of 0 °C, and a maximum temperature of 250 °C. The analysis should be determined in duplicate. The melting temperature and glass transition temperature values are recorded from the second cycle. The melt "peak" is identified as the local maximum of the second heating cycle. If there is more than one peak in the DSC curve, the peak occurring at the hotter temperature is selected as the temperature reference. The tail is identified as the intersection of the tangent to the line on the higher temperature side of the melt peak with the extrapolated baseline.

[0221] The disclosed foamed thermoplastic elastomer composition can be prepared using a suitable syringe. The syringe can have a motor to rotate a screw within the syringe. The syringe can include a single screw or a twin screw and can include various elements of various sizes and pitches suitable for mixing or kneading the particular materials used.

[0222] The various components included in the foamed thermoplastic elastomer composition described herein can be added to the syringe through one or more ports. The various components can be added as a melt or as solid particles of a suitable size (e.g., chips or pellets), which can be melted when they are mixed in the barrel of the syringe. The contents of the syringe can be heated to melt the composition. When a melt is present in the barrel of the syringe, a physical blowing agent such as a supercritical fluid can be added to the melt. In one example, a thermoplastic polyester foam is prepared by using a physical blowing agent that causes the composition to foam in a mold cavity, and the resulting thermoplastic elastomer foam is thus substantially free of unreacted chemical blowing agents or decomposition or degradation products of chemical blowing agents. The thermoplastic elastomer composition can be added to the syringe as a melt at a temperature close to the melting temperature of the polymeric components of the composition.

[0223] If a chemical blowing agent is used, the processing (melting) temperature used can be sufficiently below the temperature at which the chemical blowing agent is triggered. To foam the composition, the temperature near the syringe outlet or within the mold cavity can be raised to a temperature close to or at the triggering temperature of the chemical blowing agent, thereby creating a chemically foamed thermoplastic polyester foam as the composition exits the syringe (e.g., when injecting the composition into the mold cavity) or within the mold cavity. Additionally or alternatively, the temperature of the runner leading to the mold cavity or the mold cavity or both can be at or above the triggering temperature of the chemical blowing agent, thereby creating a chemically foamed thermoplastic elastomer foam within the runner and / or the mold cavity.

[0224] Alternatively or additionally, a physical blowing agent can be used to foam the thermoplastic elastomer composition to form a physically foamed thermoplastic elastomer foam, or a physically and chemically foamed thermoplastic elastomer foam. For example, a supercritical fluid (such as supercritical carbon dioxide or supercritical nitrogen) can be mixed with the molten thermoplastic elastomer composition in the barrel of the syringe to form a single-phase solution. A pressure drop can be used to cause the supercritical fluid to transform into a gas phase and foam the thermoplastic elastomer composition. In one aspect, a gas backpressure can be applied to the mold cavity and the runner leading to the mold cavity. The backpressure can be high enough to keep the supercritical fluid in the solution within the runner and the mold cavity. Once a dose of the single-phase solution is within the mold cavity, the backpressure within the mold cavity can be reduced to a level at which the supercritical fluid phase transforms into a gas and drips out of the solution in the molten thermoplastic elastomer composition, creating gas bubbles within the thermoplastic elastomer composition and foaming the thermoplastic elastomer composition within the mold cavity. In one aspect, the thermoplastic elastomer composition includes less than 10 wt%, or less than 5 wt%, or less than 1 wt% of non-polymeric components, by total weight of the thermoplastic elastomer composition, and the multi-cellular foam has an open-cell structure.

[0225] Articles, cushioning elements, or article components (such as midsoles, midsole components, inserts, and insert components) can be prepared by injection molding the thermoplastic elastomer compositions described herein using a physical blowing agent. The injection molding process can use a screw-type syringe, which allows for maintaining and controlling the pressure in the syringe barrel. The injection molding machine can allow for metering and delivering a supercritical fluid (such as carbon dioxide or nitrogen) into the thermoplastic elastomer composition prior to injection. The supercritical fluid can be mixed into the thermoplastic elastomer composition within the injection barrel and then injected into the mold cavity. These physical processes will cause the molten thermoplastic elastomer composition to expand (foam) when the temperature and / or pressure is changed to the point where the solubility of the supercritical fluid in the molten thermoplastic elastomer composition changes and the supercritical fluid transitions to a gas phase. The injection molding process can include using an injection molding process that forms a multi-cellular foam structure, such as the "MUCELL" process (Trexel Inc., Wilmington, Massachusetts, USA), to physically foam the compositions described herein.

[0226] Thermoplastic elastomer foams described herein can be made using a process involving impregnating the thermoplastic elastomer composition with a physical blowing agent at a first concentration or first pressure (e.g., at or above the softening temperature of the composition). As used herein, the term "impregnating" generally refers to dissolving or suspending the physical blowing agent in the composition. The impregnated composition can then be foamed, or it can be cooled (when applicable) and re-softened (when applicable) to be foamed at a later time. In some aspects, the impregnated molten thermoplastic elastomer composition forms a single-phase solution that includes a supercritical fluid (such as carbon dioxide or nitrogen) dissolved in the molten thermoplastic elastomer composition. In one aspect, the thermoplastic elastomer composition includes less than 10 wt%, or less than 5 wt%, or less than 1 wt% non-polymeric components, based on the total weight of the thermoplastic elastomer composition.

[0227] The solubility of the physical blowing agent in the thermoplastic elastomer composition is reduced by pressure and / or temperature changes, causing the impregnated thermoplastic elastomer composition (e.g., a single-phase solution) to foam. The pressure and / or temperature changes can occur immediately after the impregnated composition exits the syringe or barrel, or can occur in the runner leading to the mold cavity, or can occur in the mold cavity. For example, the system can include a hot runner or gas backpressure or both, which control and maintain the temperature and pressure of the impregnated composition until and including the moment the composition enters the mold cavity. In some aspects, the temperature and pressure of the impregnated composition are controlled and maintained such that the impregnated composition remains a single-phase solution until and including the moment it enters the mold cavity. Once the single-phase solution has flowed into the mold cavity, the temperature or pressure or both can be changed to reduce the solubility of the supercritical fluid in the molten thermoplastic elastomer composition, causing the molten thermoplastic elastomer composition to expand into a foam, including a foam having an open-cell foam structure. The reduction in the solubility of the physical blowing agent can release an additional amount of gas (e.g., to produce a secondary expansion of the partially foamed thermoplastic elastomer composition) to further expand the composition and form a foam structure (e.g., a foam having a multi-cellular structure). Alternatively or additionally, a chemical blowing agent can be activated in the thermoplastic elastomer composition in the mold cavity to produce a secondary expansion of the partially foamed thermoplastic elastomer composition.

[0228] Chemical blowing agents can be endothermic or exothermic, which refers to the type of decomposition or degradation they undergo to produce the gas (which is used to produce the foam). The decomposition or degradation can be triggered by the thermal energy present in the molding system. Endothermic blowing agents absorb energy and typically release gas upon decomposition, such as carbon dioxide. Exothermic blowing agents release energy and generate gas upon decomposition, such as nitrogen. Regardless of the chemical blowing agent used, the thermal variables of the foamed thermoplastic elastomer composition and the thermal variables of the blowing agent to be decomposed or degraded are combined such that process parameters are selected such that the thermoplastic elastomer composition can be foamed and molded, and the blowing agent can decompose or degrade at the appropriate stage of the foaming and molding process.

[0229] Thermoplastic elastomer composition

[0230] The thermoplastic elastomer composition disclosed herein comprises one or more thermoplastic elastomers. The one or more thermoplastic elastomers can be one or more thermoplastic polyester elastomers. In some aspects, based on the total weight of the thermoplastic elastomer composition, the thermoplastic elastomer composition comprises at least 90 wt%, or at least 95 wt%, or at least 99 wt% of a thermoplastic resin component, wherein the thermoplastic resin component comprises all polymers present in the composition. The thermoplastic resin component comprises one or more thermoplastic elastomers. The thermoplastic resin component can comprise at least one thermoplastic polyester elastomer. The thermoplastic resin component can comprise more than one thermoplastic polyester elastomer. The thermoplastic resin component can comprise one or more thermoplastic polyester elastomers and one or more thermoplastic polyesters that are not elastomers. In some aspects, the thermoplastic resin component comprises one or more thermoplastic polyesters and further comprises one or more thermoplastic polymers, each of which is not a polyester. The one or more thermoplastic polymers, each of which is not a polyester, can each be a thermoplastic elastomer. Alternatively, in other aspects, the thermoplastic resin component consists essentially of one or more thermoplastic elastomers. Optionally, the thermoplastic resin component can consist essentially of one or more thermoplastic polyester elastomers. In some aspects, based on the total weight of the thermoplastic elastomer composition, the thermoplastic elastomer composition comprises less than 10 wt%, or less than 5 wt%, or less than 1 wt% of non-polymeric components. In some aspects, the thermoplastic elastomer composition is substantially free of non-polymeric nucleating agents, or substantially free of non-polymeric fillers, or substantially free of colorants, or substantially free of non-polymeric processing aids, or substantially free of both non-polymeric nucleating agents and non-polymeric fillers, or substantially free of non-polymeric nucleating agents, non-polymeric fillers, colorants and non-polymeric processing aids. In some such aspects, based on the total weight of the thermoplastic elastomer composition, the thermoplastic elastomer composition comprises less than 10 wt%, or less than 5 wt%, or less than 1 wt% of solid colorants. In one aspect, the thermoplastic elastomer composition consists essentially of one or more thermoplastic elastomers. In another aspect, the thermoplastic elastomer composition consists essentially of one or more thermoplastic polyester elastomers. It should be understood that thermoplastic polyester elastomers can refer to thermoplastic polyester homopolymer elastomers, thermoplastic copolyester elastomers or both. In various aspects, thermoplastic copolyester elastomers can comprise copolyesters having two or more types of polyester monomer segments, or copolyesters comprising polyester monomer segments and one or more non-polyester monomer segments.

[0231] In some aspects, the resin component of the thermoplastic elastomer composition, including all polymer compositions present in the thermoplastic polyester composition, consists essentially of one or more thermoplastic elastomers or consists essentially of one or more thermoplastic polyesters. In various aspects, the thermoplastic polyester may include chain units derived from one or more olefins and chain units derived from one or more ethylenically unsaturated acid groups.

[0232] The thermoplastic elastomer composition may have a melt flow index of about 5 to about 40, or about 10 to about 20, or about 20 to about 30 as determined at 210 °C using a 2.16 kg weight. Alternatively or additionally, the thermoplastic elastomer composition may have a melt flow index of about 5 to about 40, or about 10 to about 20, or about 20 to about 30 as determined at 220 °C using a 2.16 kg weight. Alternatively or additionally, the thermoplastic elastomer composition may have a melt flow index of about 5 to about 40, or about 10 to about 20, or about 20 to about 30 as determined at 230 °C using a 2.16 kg weight.

[0233] The thermoplastic elastomer (including the thermoplastic polyester) may have a weight average molecular weight of: about 50,000 Daltons to about 1,000,000 Daltons; or about 50,000 Daltons to about 500,000 Daltons; or about 75,000 Daltons to about 300,000 Daltons; or about 100,000 Daltons to about 250,000 Daltons; or about 100,000 Daltons to about 500,000 Daltons.

[0234] The thermoplastic elastomer (including the thermoplastic copolyester) may be a terpolymer. In some aspects, the thermoplastic copolyester may be a terpolymer derived from moieties of ethylene, acrylic acid, and methyl acrylate or butyl acrylate. In some aspects, the ratio of the total weight parts of acrylic acid in the thermoplastic copolyester to the total weight of the thermoplastic copolyester is about 0.05 to about 0.6, or about 0.1 to about 0.6, or about 0.1 to about 0.5, or about 0.15 to about 0.5, or about 0.2 to about 0.5.

[0235] The thermoplastic elastomer may be a terpolymer including a plurality of first segments, a plurality of second segments, and a plurality of third segments. In some aspects, the thermoplastic elastomer is a thermoplastic copolyester including: (a) a plurality of first segments, each first segment derived from a dihydroxy-terminated polyglycol; (b) a plurality of second segments, each second segment derived from a diol; and (c) a plurality of third segments, each third segment derived from an aromatic dicarboxylic acid. In various aspects, the thermoplastic copolyester is a block copolymer. In some aspects, the thermoplastic copolyester is a multi-block copolymer. In further aspects, the thermoplastic copolyester is a random copolymer. In still further aspects, the thermoplastic copolyester is a condensation copolymer.

[0236] Thermoplastic elastomers (including thermoplastic copolyesters) may have the following ratio of the first segment to the third segment: about 1:1 to about 1:5 by weight of each of the first segment and the third segment; or about 1:1 to about 1:4 by weight of each of the first segment and the third segment; or about 1:1 to about 1:2 by weight of each of the first segment and the third segment; or about 1:1 to about 1:3 by weight of each of the first segment and the third segment.

[0237] Thermoplastic elastomers (including thermoplastic copolyesters) may have the following ratio of the second segment to the third segment: about 1:1 to about 1:2 by weight of each of the first segment and the third segment; or about 1:1 to about 1:1.52 by weight of each of the first segment and the third segment.

[0238] Thermoplastic elastomers (including thermoplastic copolyesters) may have a first segment derived from a poly(alkylene oxide) diol having the following number-average molecular weight: about 250 daltons to about 6000 daltons; or about 400 daltons to about 6,000 daltons; or about 350 daltons to about 5,000 daltons; or about 500 daltons to about 3,000 daltons; or about 2,000 daltons to about 3,000 daltons.

[0239] Thermoplastic elastomers (including thermoplastic copolyesters) may have a first segment derived from a poly(alkylene oxide) diol such as poly(ethylene ether) diol; poly(propylene ether) diol; poly(tetramethylene ether) diol; poly(pentamethylene ether) diol; poly(hexamethylene ether) diol; poly(heptamethylene ether) diol; poly(octamethylene ether) diol; poly(nonamethylene ether) diol; poly(decamethylene ether) diol; or a mixture thereof. In a further aspect, the thermoplastic copolyester may have a first segment derived from a poly(alkylene oxide) diol such as poly(ethylene ether) diol; poly(propylene ether) diol; poly(tetramethylene ether) diol; poly(pentamethylene ether) diol; poly(hexamethylene ether) diol. In yet a further aspect, the thermoplastic copolyester may have a first segment derived from poly(tetramethylene ether) diol.

[0240] Thermoplastic elastomers (including thermoplastic copolyesters) can have a second segment derived from a diol having a molecular weight of less than about 250. The diol from which the second segment is derived can be a C2 to C8 diol. In a further aspect, the second segment can be derived from ethylene glycol; propylene glycol; butylene glycol; pentylene glycol; 2-methylpropylene glycol; 2,2-dimethylpropylene glycol; hexylene glycol; 1,2-dihydroxycyclohexane; 1,3-dihydroxycyclohexane; 1,4-dihydroxycyclohexane; and mixtures thereof. In yet a further aspect, the second segment can be derived from 1,2-ethylene glycol, 1,3-propylene glycol, 1,4-butylene glycol, 1,6-hexylene glycol, and mixtures thereof. In still a further aspect, the second segment can be derived from 1,2-ethylene glycol. In a further aspect, the second segment can be derived from 1,4-butylene glycol.

[0241] Thermoplastic elastomers (including copolyesters) can have a third segment derived from an aromatic C5 to C16 dicarboxylic acid. The aromatic C5 to C16 dicarboxylic acid can have the following molecular weights: less than about 300 daltons; about 120 daltons to about 200 daltons; or one or more values of molecular weights within any of the foregoing ranges, or a molecular weight range encompassing any subrange of the foregoing ranges. In some cases, the aromatic C5 to C16 dicarboxylic acid is terephthalic acid, phthalic acid, isophthalic acid, or a derivative thereof. In a further aspect, the aromatic C5 to C16 dicarboxylic acid is a diester derivative of terephthalic acid, phthalic acid, or isophthalic acid. In yet a further aspect, the aromatic C5 to C16 dicarboxylic acid is terephthalic acid or a dimethyl ester derivative thereof.

[0242] The thermoplastic copolyester can include: (a) a plurality of first copolyester units, each of the plurality of first copolyester units including a first segment derived from a dihydroxy-terminated polyalkylene glycol and a third segment derived from an aromatic dicarboxylic acid, wherein the first copolyester unit has a structure represented by

[0243] Formula 1:

[0244]

[0245] wherein R1 is the group remaining after removing the terminal hydroxyl group from the poly(alkylene oxide) glycol of the first segment, wherein the poly(alkylene oxide) glycol of the first segment is a poly(alkylene oxide) glycol having a number-average molecular weight of about 400 to about 6000; and wherein R2 is the group remaining after removing the carboxyl group from the aromatic dicarboxylic acid of the third segment; and (b) a plurality of second copolyester units, each of the plurality of second copolyester units including a second segment derived from a diol and a third segment derived from an aromatic dicarboxylic acid, wherein the second copolyester unit has a structure represented by Formula 2:

[0246] wherein R3 is the group remaining after removing the hydroxyl groups from the diols of the second segment derived from the diol, wherein the diol is a diol having a molecular weight of less than about 250; and wherein R2 is the group remaining after removing the carboxyl groups from the aromatic dicarboxylic acids of the third segment.

[0247] The thermoplastic copolyester can include a plurality of first copolyester units having a structure represented by Formula 3:

[0248]

[0249] wherein R is H or methyl; wherein y is an integer having a value of 1 to 10; wherein z is an integer having a value of 2 to 60; and wherein the weight-average molecular weight of each of the plurality of first copolyester units is from about 300 daltons to about 7,000 daltons. In some aspects, in the foregoing formula, y can be an integer having a value of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range of the foregoing integer values. In some aspects, in the foregoing formula, z is an integer having a value of 5 to 60; an integer having a value of 5 to 50; an integer having a value of 5 to 40; an integer having a value of 4 to 30; an integer having a value of 4 to 20; an integer having a value of 2 to 10; or z can be any set or range of the foregoing integer values. In some aspects, R is hydrogen. In still further aspects, R is methyl. In some cases, R is hydrogen and y is an integer having a value of 1, 2, or 3. Alternatively, in other cases, R is methyl and y is an integer having a value of 1.

[0250] The thermoplastic copolyester can include a plurality of first copolyester units having a structure represented by Formula 4:

[0251]

[0252] wherein z is an integer having a value of 2 to 60; and wherein the weight-average molecular weight of each of the plurality of first copolyester units is from about 300 daltons to about 7,000 daltons. In some aspects, in the foregoing formula, y can be an integer having a value of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range of the foregoing integer values. In some aspects, in the foregoing formula, z is an integer having a value of 5 to 60; or an integer having a value of 5 to 50; or an integer having a value of 5 to 40; or an integer having a value of 4 to 30; or an integer having a value of 4 to 20; or an integer having a value of 2 to 10.

[0253] The thermoplastic copolyester can include a plurality of first copolyester units having a weight average molecular weight of from about 400 Daltons to about 6,000 Daltons; or from about 400 Daltons to about 5,000 Daltons; or from about 400 Daltons to about 4,000 Daltons; or from about 400 Daltons to about 3,000 Daltons; or from about 500 Daltons to about 6,000 Daltons; or from about 500 Daltons to about 5,000 Daltons; or from about 500 Daltons to about 4,000 Daltons; or from about 500 Daltons to about 3,000 Daltons; or from about 600 Daltons to about 6,000 Daltons; or from about 600 Daltons to about 5,000 Daltons; or from about 600 Daltons to about 4,000 Daltons; or from about 600 Daltons to about 3,000 Daltons; or from about 2,000 Daltons to about 3,000 Daltons.

[0254] The thermoplastic copolyester can include a plurality of second copolyester units, each of the plurality of second copolyester units having a structure represented by

[0255] Formula 5:

[0256]

[0257] where x is an integer having a value from 1 to 20; wherein the foam article has a multi-cellular closed-cell or open-cell foam structure. In some aspects, in the foregoing formula, x is an integer having the following values: 2 to 18; 2 to 17; 2 to 16; 2 to 15; 2 to 14; 2 to 13; 2 to 12; 2 to 11; 2 to 10; 2 to 9; 2 to 8; 2 to 7; 2 to 6; 2 to 5; 2 to 4; or x can be any integer value or set of integer values within the foregoing ranges or values, or any range of integer values that encompasses a sub-range of the foregoing integer value ranges. In additional aspects, x is an integer having a value of 2, 3, or 4.

[0258] The thermoplastic copolyester can include a plurality of second copolyester units, each of the plurality of second copolyester units having a structure represented by

[0259] Formula 6:

[0260]

[0261] Based on the total weight of the thermoplastic copolyester, the thermoplastic copolyester may include a weight percentage range of a plurality of first copolyester units such that the weight percentage range is from about 30 wt% to about 80 wt%; or from about 40 wt% to about 80 wt%; or from about 50 wt% to about 80 wt%; or from about 30 wt% to about 70 wt%; or from about 40 wt% to about 70 wt%; or from about 50 wt% to about 70 wt%; or from about 40 wt% to about 65 wt%; or from about 45 wt% to about 65 wt%; or from about 50 wt% to about 65 wt%; or from about 55 wt% to about 65 wt%; or from about 40 wt% to about 60 wt%; or from about 45 wt% to about 60 wt%; or from about 50 wt% to about 60 wt%; or from about 55 wt% to about 60 wt%.

[0262] In some aspects, the thermoplastic elastomer (including the thermoplastic copolyester) may include phase-separated domains. For example, a plurality of first segments derived from dihydroxy-terminated polyglycols may phase-separate into domains mainly including the first segments. In addition, a plurality of second segments derived from diols may phase-separate into domains mainly including the second segments. In other aspects, the thermoplastic copolyester may include phase-separated domains mainly including a plurality of first copolyester units, each of the plurality of first copolyester units including a first segment derived from dihydroxy-terminated polyglycol and a third segment derived from aromatic dicarboxylic acid, wherein the first copolyester unit has a structure represented by Formula 1:

[0263]

[0264] wherein R1 is the group remaining after removing the terminal hydroxyl group from the poly(alkylene oxide) glycol of the first segment, wherein the poly(alkylene oxide) glycol of the first segment is a poly(alkylene oxide) glycol having a number average molecular weight of from about 400 to about 6000; and wherein R2 is the group remaining after removing the carboxyl group from the aromatic dicarboxylic acid of the third segment; and other phase-separated domains mainly including a plurality of second copolyester units, each of the plurality of second copolyester units including a second segment derived from diol and a third segment derived from aromatic dicarboxylic acid, wherein the second copolyester unit has a structure represented by Formula 2:

[0265]

[0266] wherein R3 is the group remaining after removing the hydroxyl group from the diol of the second segment derived from diol, wherein the diol is a diol having a molecular weight less than about 250; and wherein R2 is the group remaining after removing the carboxyl group from the aromatic dicarboxylic acid of the third segment.

[0267] In other aspects, the thermoplastic copolyester can include a phase-separated domain mainly including a plurality of first copolyester units, and each of the plurality of first copolyester units has a structure represented by Formula 3:

[0268]

[0269] wherein R is H or methyl; wherein y is an integer having a value of 1 to 10; wherein z is an integer having a value of 2 to 60; and wherein the weight-average molecular weight of each of the plurality of first copolyester units is from about 300 daltons to about 7,000 daltons. In some aspects, in the foregoing formula, y can be an integer having a value of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range of the foregoing integer values. In some aspects, in the foregoing formula, z is an integer having a value of 5 to 60; an integer having a value of 5 to 50; an integer having a value of 5 to 40; an integer having a value of 4 to 30; an integer having a value of 4 to 20; an integer having a value of 2 to 10; or z can be any set or range of the foregoing integer values. In some aspects, R is hydrogen. In still further aspects, R is methyl. In some cases, R is hydrogen and y is an integer having a value of 1, 2, or 3. Alternatively, in other cases, R is methyl and y is an integer having a value of 1.

[0270] In other aspects, the thermoplastic copolyester can include a phase-separated domain mainly including a plurality of first copolyester units, and each of the plurality of first copolyester units has a structure represented by Formula 4:

[0271]

[0272] wherein z is an integer having a value of 2 to 60; and wherein the weight-average molecular weight of each of the plurality of first copolyester units is from about 300 daltons to about 7,000 daltons. In some aspects, in the foregoing formula, y can be an integer having a value of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10; or y can be any set or range of the foregoing integer values. In some aspects, in the foregoing formula, z is an integer having a value of 5 to 60; or an integer having a value of 5 to 50; or an integer having a value of 5 to 40; or an integer having a value of 4 to 30; or an integer having a value of 4 to 20; or an integer having a value of 2 to 10.

[0273] The thermoplastic copolyester can include a phase-separated domain mainly including a plurality of first copolyester units having the following molecular weights: from about 400 Daltons to about 6,000 Daltons; or from about 400 Daltons to about 5,000 Daltons; or from about 400 Daltons to about 4,000 Daltons; or from about 400 Daltons to about 3,000 Daltons; or from about 500 Daltons to about 6,000 Daltons; or from about 500 Daltons to about 5,000 Daltons; or from about 500 Daltons to about 4,000 Daltons; or from about 500 Daltons to about 3,000 Daltons; or from about 600 Daltons to about 6,000 Daltons; or from about 600 Daltons to about 5,000 Daltons; or from about 600 Daltons to about 4,000 Daltons; or from about 600 Daltons to about 3,000 Daltons; or from about 2,000 Daltons to about 3,000 Daltons.

[0274] In other aspects, the thermoplastic copolyester can include a phase-separated domain including a plurality of second copolyester units, and each second copolyester unit among the plurality of second copolyester units has a structure represented by Formula 5:

[0275]

[0276] where x is an integer having a value of 1 to 20; and where the foam product has a multi-cellular closed-cell or open-cell foam structure. In some aspects, in the foregoing formula, x is an integer having the following values: 2 to 18; or 2 to 17; or 2 to 16; or 2 to 15; or 2 to 14; or 2 to 13; or 2 to 12; or 2 to 11; or 2 to 10; or 2 to 9; or 2 to 8; or 2 to 7; or 2 to 6; or 2 to 5; or 2 to 4.

[0277] In other aspects, the thermoplastic copolyester can include a phase-separated domain including a plurality of second copolyester units, and each second copolyester unit among the plurality of second copolyester units has a structure represented by Formula 6:

[0278]

[0279] The thermoplastic copolyester can include phase-separated domains that, based on the total weight of the thermoplastic copolyester, include a weight percentage range of a plurality of first copolyester units such that the weight percentage range is from about 30 wt% to about 80 wt%; or from about 40 wt% to about 80 wt%; or from about 50 wt% to about 80 wt%; or from about 30 wt% to about 70 wt%; or from about 40 wt% to about 70 wt%; or from about 50 wt% to about 70 wt%; or from about 40 wt% to about 65 wt%; or from about 45 wt% to about 65 wt%; or from about 50 wt% to about 65 wt%; or from about 55 wt% to about 65 wt%; or from about 40 wt% to about 60 wt%; or from about 45 wt% to about 60 wt%; or from about 50 wt% to about 60 wt%; or from about 55 wt% to about 60 wt%.

[0280] In various aspects, the thermoplastic elastomer composition can include one or more thermoplastic polyester homopolymers, wherein the thermoplastic polyester homopolymer includes any one of the polyester monomer segments or units or their modifications disclosed herein. In the same or alternative aspects, the thermoplastic elastomer composition can include one or more thermoplastic polyester homopolymers, wherein the thermoplastic polyester homopolymer includes any polyester homopolymer that exhibits any or all of the characteristics and parameters discussed herein with respect to thermoplastic elastomers and / or thermoplastic elastomer compositions.

[0281] The disclosed thermoplastic elastomer compositions, the polymer components of the compositions, or the individual thermoplastic elastomers in pure form can be characterized by one or more properties. In some aspects, when determined using the cyclic tensile test method described herein, the thermoplastic elastomer composition or polymer component or polymer has a maximum load of from about 10 Newtons to about 100 Newtons, or from about 15 Newtons to about 50 Newtons, or from about 20 Newtons to about 40 Newtons.

[0282] The tensile strength of the thermoplastic elastomer composition or the polymer component of the thermoplastic elastomer composition or the thermoplastic elastomer in pure form is another important physical characteristic. When determined using the cyclic tensile test method described herein, the thermoplastic elastomer composition or polymer component or elastomer can have a tensile strength of from 5 kg / cm² to 25 kg / cm², or from 10 kg / cm² to 23 kg / cm², or from 15 kg / cm² to 22 kg / cm².

[0283] When determined using the cyclic tensile test method described herein, the thermoplastic elastomer composition or the polymer component of the thermoplastic elastomer composition or the thermoplastic elastomer in pure form can have a tensile modulus of from about 2 MPa to about 20 MPa or from about 5 MPa to about 15 MPa.

[0284] Exemplary but non-limiting thermoplastic elastomers (including thermoplastic polyesters) that can be used in the disclosed methods, foams, and articles include "HYTREL" 3078, "HYTREL" 4068, and "HYTREL" 4556 (DuPont, Wilmington, Delaware, USA); "PELPRENE" P30B, P40B, and P40H (Toyobo U.S.A. Inc., New York, NY, USA); "TRIEL" 5300, "TRIEL" 5400, and blends thereof (Samyang Corporation, Korea); "KEYFLEX" BT1028D, BT1033D, BT1035D, BT1040D, BT1045D, and BT1047D (LG Chem, Korea); and "KOPEL" KP3340, KP3346, KP3347 (Kolon Plastics, Inc., Korea).

[0285] The disclosed thermoplastic elastomer compositions can also include one or more ionomers, such as any of the "SURLYN" polymers (DuPont, Wilmington, Delaware, USA). The foams as described herein can be prepared by a process / method that includes receiving the compositions as described herein and physically foaming the compositions to form thermoplastic elastomer foams having a density of about 0.7 grams per cubic centimeter or less, or 0.5 grams per cubic centimeter or less, or 0.4 grams per cubic centimeter or less, or 0.3 grams per cubic centimeter or less.

[0286] The disclosed thermoplastic elastomer compositions can also include one or more thermoplastic polyurethanes, such as "FORTIMO" (Mitsui Chemicals, Inc., Tokyo, Japan); "TEXIN" (Covestro LLC, Pittsburgh, Pennsylvania, USA); and "BOUNCELL-X" (Lubrizol Advanced Materials, Inc., Brecksville, Ohio, USA).

[0287] The disclosed thermoplastic elastomer composition may further include one or more olefin polymers. The olefin polymers may include ethylene-based copolymers, propylene-based copolymers, and butene-based copolymers. In some aspects, the olefin polymer is an ethylene-based copolymer such as styrene-ethylene / butene-styrene (SEBS) copolymer; ethylene-propylene-diene monomer (EPDM) copolymer; ethylene-vinyl acetate (EVA) copolymer; ethylene-alkyl acrylate (EAA) copolymer; ethylene-alkyl methacrylate (EAMA) copolymer; any copolymer thereof, and any blend thereof. In some aspects, the ratio V of the total weight parts of the olefin polymer present in the composition to the total weight parts of the thermoplastic polyester in the composition is from about 0.0 to about 0.6, or from about 0.0 to about 0.4, or from about 0.01 to about 0.4, or from about 0.01 to about 0.6, or from about 0.1 to about 0.4.

[0288] The disclosed thermoplastic elastomer composition may further include an ethylene-vinyl acetate (EVA) copolymer. By weight of the copolymer, the ethylene-vinyl acetate (EVA) copolymer may have a vinyl acetate content in a range, such as about 50% to about 90%, or about 50% to about 80%, or about 5% to about 50%, or about 10% to about 45%, or about 10% to about 30%, or about 30% to about 45%, or about 20% to about 35%.

[0289] Characterization of Thermoplastic Elastomer Composition

[0290] Parts Sampling Procedure

[0291] When the composition or material is incorporated into a component (such as the sole structure or midsole or outsole of a footwear article), this procedure can be used to obtain a sample of the foam composition or material. A sample of the component including the composition or material is obtained when the component is formed or cut from the footwear article using a blade. This process is performed by separating the component from the associated footwear upper (if present) and removing any material from the top surface of the article (e.g., corresponding to the top surface). For example, the top surface of the article can be skived, ground, scraped, or otherwise cleaned to remove any upper adhesives, yarns, fibers, foams, etc. that may potentially interfere with the test results.

[0292] The resulting component samples include the composition or material. As such, any testing using the component sampling procedure can simulate how the composition or material will function as part of a footwear article. As specified by the test method, the component can be tested as a complete component (e.g., a complete midsole component), or it can be removed to serve as a sample having a specific geometry. A sample of the component is taken at a location along the component providing a substantially constant thickness of the component (within plus or minus 10% of the average thickness), such as in the forefoot region, midfoot region, or heel region of the article. Unless otherwise specified, the desired harvested geometry is a cylindrical disc having a 45 mm diameter and a cylindrical height of at least about 10 mm, preferably about 20 to 25 mm.

[0293] Density test

[0294] Measure the density of the samples obtained using the component sampling procedure using a digital balance or a Densicom tester (Qualitest, Plantation, FL, USA). For each sample, determine the sample volume in cubic centimeters and then weigh each sample (g). The density of the sample is the mass divided by the sample volume, given in grams per cubic centimeter.

[0295] Specific gravity test

[0296] This test is applicable to testing closed-cell foams and open-cell foam samples having a substantially uniform closed skin. Measure the specific gravity (SG) of the samples obtained using the component sampling procedure using a digital balance or a Densicom tester (Qualitest, Plantation, FL, USA). Weigh each sample (g) and then immerse it in a distilled water bath (22 °C ± 2 °C). To avoid errors, remove the air bubbles on the surface of the sample, for example, by wiping isopropyl alcohol on the sample before immersing it in water, or by using a brush to remove the air bubbles after immersing the sample in water. Record the weight of the sample in distilled water. Calculate the specific gravity using the following formula:

[0297]

[0298] Force / displacement test (foot-shaped cyclic compression test)

[0299] The force / displacement behavior of foams and foamed articles can be measured using intact midsole samples, intact outsole samples, separated midsole, and / or separated midsole, using a foot form to test impact to accurately simulate full load. For these tests, a cyclic compression test device such as an Instron Electropuls E10000 (Instron Corporation, Norwood, Massachusetts, USA) is used to apply a 2000 N load to the midsole with a foot form at a load rate of 5 Hz, testing a US men's size 10 midsole and a men's size 9 foot form for impact. Each sample is compressed to the peak load at 5 Hz for 100 cycles. Energy input (J), energy return (J), energy efficiency (energy return / energy input), energy efficiency percentage (100*(energy return / energy input)), and maximum displacement (mm) are measured from the generated force-displacement curve. The stiffness of a particular foam sample is the maximum load divided by the displacement at the maximum load, giving a value in N / mm. The reported value for each metric is the average of the metrics from cycles 60, 70, 80, and 90.

[0300] Sample cyclic compression test

[0301] The force / displacement behavior of foams and foamed articles can also be, or alternatively, measured using samples harvested from larger components (e.g., cylindrical discs harvested from a footwear midsole), and the method for obtaining the samples is described in the "Component Sampling Procedure" section of the present disclosure. In one test method, when testing a sample (e.g., a cylindrical disc harvested from a larger component), a compression platen with at least 2 times the diameter (e.g., the diameter of the cylindrical disc) is used to test the sample along the length axis of the part. Additionally, the sample is compressed to the peak load (e.g., 50% strain) at 5 Hz for 500 cycles. Stiffness, efficiency, and energy return are measured from the force-displacement curves of cycles 200, 300, 400, and 500, and the reported value for each metric is the average of each metric between cycles 200, 300, 400, and 500. Stiffness, efficiency, and energy return are defined as follows, with example property ranges provided in parentheses (which may depend on the sample geometry). Stiffness is the stress at the maximum strain divided by the maximum strain (e.g., 200 to 1000 kPa). Efficiency is the integral of the unloading force-displacement curve divided by the integral of the loading force-displacement curve (e.g., 0.50 to 0.97). Energy return is the integral of the unloading curve (e.g., 200 to 1200 mJ).

[0302] Cyclic tensile test

[0303] Cyclic tensile tests were performed on solid samples prepared using a component sampling procedure. These solid samples had a dog-bone shape as described in ASTM D638 with a thickness of 2 mm. During the test, the samples were placed under a preload of 5 N. The strain was controlled to elongate the samples to 6% elongation at a strain rate of 5 Hz. Stiffness was the load at 6% strain divided by the elongation at 6% strain, giving a value in N / mm. The maximum load (N) observed during the test cycle of 500 cycles was also recorded.

[0304] Durometer Hardness Test-Shore A

[0305] The tests for obtaining the hardness value of the foam product are as follows. Flat foam samples were prepared using a component sampling procedure, where the samples had a minimum thickness of 6 mm for Shore A durometer testing. If necessary, the samples could be stacked to make up the minimum thickness. The samples were large enough to allow all measurements to be performed at least 12 mm from the sample edge and at least 12 mm from any other measurement. The area of the test region was flat and parallel, with an area of at least 6 mm in diameter. At least 5 hardness measurements and tests were performed using a 1 kg head weight.

[0306] Split tear test

[0307] The split peel test can determine the internal tear strength of the foam material. Samples can be provided using a component sampling procedure. The samples were die-cut into a rectangular shape that was 1.54 cm wide, 15.24 cm long (1 inch × 6 inches), and 10 mm thick (±1 mm). At one end, a cut was made in the sample that bisected the thickness, which extended the entire width of the sample and was 3 cm from the end of the sample. Starting from the end of the cut, 5 marks were placed at 2 cm intervals along the length of the sample. The cut end of the sample was placed in the jaws of a tensile testing machine. Each section of the sample was held in the jaws in such a way that the original adjacent cut edges formed a straight line connecting the centers of the jaws. The crosshead speed was set at 50 mm / min. The tear strength was measured throughout the separation of the crosshead. If necessary, a sharp knife could be used to keep the foam separating the center of the sample, and the readings caused by the cut of the knife were discarded. The lowest split peel strength value (between each of the 2 cm marks) for each of the five marked segments of the sample was recorded. The average split peel strength value for each sample was recorded. If a segment of the sample had a bubble measured greater than 2 mm, the tear strength of that segment was discarded, and the bubble was recorded as a test defect. If more than one segment of the sample had bubbles greater than 2 mm, the entire sample was discarded.

[0308] Energy intensity

[0309] The energy intensity is used to form specificMeasure of the energy of the foam product, in kilowatt-hours (kW-h). To obtain the energy intensity, first calculate, determine or measure the energy (in kW-H) required to produce a batch or lot of articles such as cushioning elements (such as pairs of midsole 122) from the granulate to the finished part. For example, for a physical foaming process, the measured energy may include the energy required for all energy-consuming steps such as: preheating the mold and the hot runner (if utilized), melting the granulate, generating gas backpressure, injecting the molten plastic, introducing supercritical fluid, cooling the mold and / or the workpiece and ejecting the workpiece from the mold. Then divide the total energy required to produce this batch of cushioning element pairs by the number of cushioning element pairs produced in this batch.

[0310] Zero shear viscosity

[0311] Determine the zero-shear viscosity using the flow curve obtained on a rotational rheometer. The zero-shear viscosity is determined as the apparent viscosity of the polymer melt measured at a shear rate of 1 x 10 -2 1 / s when the polymer is heated 10°C above its melting temperature. Measure the apparent viscosity using a cone-and-plate rotational fixture under continuous flow. The temperature of the rotational fixture is maintained at the polymer melt temperature. The gap and geometry of the cone are chosen such that the measured torque is completely within the measurement limits of the rheometer.

[0312] Melt flow index test

[0313] Determine the melt flow index according to the test method detailed in ASTM D1238-13 "Standard Test Method for Measuring Melt Flow Rate of Thermoplastics by Extrusion Plastometer", using Procedure A described therein, with samples prepared using the component sampling procedure. Briefly, the melt flow index measures the extrusion rate of a thermoplastic through an orifice at a specified temperature and load. In the test method, approximately 7 grams of the sample are loaded into the barrel of a melt flow device heated to a specified temperature of 210°C, 220°C or 230°C. A weight of 2.16 kilograms is applied to the plunger and the molten sample is forced through the die. The timed extrudate is collected and weighed. Calculate the melt flow rate value (in g / 10 min) and report these melt flow rate values at the specified temperature (i.e., 210, 220 or 230°C) and the weight applied to the plunger (i.e., 2.15 kilograms).

[0314] Recycled material

[0315] Next, refer to Fig. 20 the flowchart of, and according to aspects of the present disclosure, generally describes at 2000 an improved method or control strategy for manufacturing a foamed polymer article such as Figure 1 the midsole 122. At Fig. 20Some or all of the operations illustrated and described in further detail below may represent algorithms corresponding to processor-executable instructions that may be stored, for example, in main memory or secondary memory or remote memory and executed, for example, by a local or remote controller, processing unit, control logic circuitry, or other module or device or network of devices to perform any one or all of the above or below-described functions associated with the disclosed concepts. One or more of the illustrated operations may be performed manually or manually assisted by a person skilled in the art. It should be recognized that the order of execution of the illustrated operation blocks may be changed, additional blocks may be added, and some of the described blocks may be modified, combined, or eliminated.

[0316] Fig.31 Method 3100 is initialized, for example, at block 3101 in response to the input of an activation command signal received from the human-machine interface (HMI) of a central control terminal. The initial phase of the manufacturing process may include supplying, obtaining, and / or utilizing (collectively referred to as "receiving") the various materials, tools, and machines required to manufacture the foamed polymer article. For example, at process block 2003, a batch of recycled plastic material is obtained from an available repository of polymer recyclates. As used herein, the term "recycled plastic" may encompass used or excess or scrapped plastic that is put into the recycling stream, including wholesale recycling of entire products, disassembly of products, and recycling of only selected parts thereof, recycling of manufacturing by-products, all of which may require sorting and cleaning of any collected materials. For at least some embodiments, waste and scrap thermoplastic polyester elastomer (TPE-E) compositions (e.g., regenerated from foamed or unfoamed virgin TPE-E materials and / or virgin TPE-E compositions) may be recycled and then incorporated into foamed articles produced with at least some virgin TPE-E and / or virgin TPE-E compositions. The recycled TPE-E composition may be derived from one or more reactants such as poly(alkylene oxide) diol materials and / or aromatic dicarboxylic acid materials. The recycled thermoplastic polyester elastomer composition may have a weight-average molecular weight in the range of from about 50,000 daltons to about 200,000 daltons.

[0317] Once the batch of recycled plastics is received and any incidental sorting, cleaning, and other pre-processing is completed at process block 3103, the method 3100 shreds, shaves, cuts, and / or grinds (collectively referred to as "grinding") the batch of recycled plastics at process block 3105. As a non-limiting example, a dedicated recycling station may be responsible for grinding the recycled TPE-E into a granular or pelletized form; the ground recycled material may be produced in real time or stored in inventory and reused when desired. Alternatively, "grinding" may include feeding the hot compound of the recyclate into an extruder equipped with a perforated die; a cutter immediately in front of the die slice extrudes the compound line into granular pellets. The cut pellets are then cooled while being conveyed to a sifter to separate out irregularly sized pellets. The "regrind" thermoplastic polymer composition may be derived from re-extruded material, such as unfoamed, TPE-E composition waste from a die runner, which passes through an extruder, is pelletized, and returned to the resin. Regrind can also be derived from injected foam material, such as virgin TPE-E composition resin, which is injected and foamed during normal processing, scrapped, and then shredded and reintroduced as regrind. The ground regrind material can have an irregular shape with a major length dimension of about 1 to 10 mm, and the virgin polymer material has a pellet size of about 1 to 10 mm.

[0318] At process block 3107, the ground recycled material is mixed with a composition of virgin polymer material. As used herein, the terms "mixing" and "blending" can be used interchangeably and synonymously mean combining or admixing, wherein the resulting mixed batch may or may not be homogeneous throughout the mixture. The recycled material can be contrasted with the virgin material because the original "virgin" material is neither injected into the mold assembly nor expanded and formed into a final product by the activation of the mixed foaming agent. The virgin polymer composition can be a general polymer composition that is the same or similar to the recyclate, or alternatively, it can be a polymer composition that is distinguishable from the recyclate. In order to correctly calibrate the operating parameters of the injection molding system and control the functional properties of the resulting foamed polymer article, a metered amount of ground recycled material is mixed with a predetermined amount of virgin polymer material to form a mixed batch of virgin and recycled materials. In at least some embodiments, the metered amount is limited to about 20% by mass or less of the total mass of the mixed batch. Depending on the intended application, it may be desirable to incorporate from about 10 to about 50 parts recycled TPE-E composition to about 80 to about 100 parts virgin TPE-E composition into a newly foamed TPE-E article by the methods described herein.

[0319] Continue to refer Fig.31, Method 3100 continues to process block 3109, which has instructions for processing the recycled material before, during, or after mixing with the virgin material. Processing the recycled material can include adding a blowing agent / foaming agent, filler, pigment, and / or processing aids. In at least some embodiments, a blowing agent is incorporated as a separate component into the mixture of recycled and virgin polymeric materials to cause expansion of the mixture during molding. The blowing agent can include a suitable stimulant that, alone or in combination with other substances, is capable of creating a cellular structure in the plastic. The blowing agent can include a fluid that expands when pressure is released.

[0320] For at least some applications, it may be desirable to add a physical blowing agent to the mixture of recycled and virgin materials during or after melting of the mixture. When injection molding a midsole, it may be desirable to inject the physical blowing agent into the polymer melt composition. The physical blowing agent can consist of one or more supercritical fluids (SCF), such as supercritical nitrogen or carbon dioxide, which dissolve into the polymer melt composition under pressure to form a single-phase solution (SPS). As yet another option, Method 3100 can be characterized by the absence of chemical blowing agents for forming the foamed polymer article. The SCF concentration can in particular be specified by the desired solubility and the desired density. For some embodiments, in addition to or in place of the physical blowing agent, a chemical foaming agent can also be used.

[0321] Prior to introduction into the final mold for forming the foamed polymer article, many other additives can be incorporated into the recycled batch, including fillers, activators, homogenizers, pigments, flame retardants, lubricants, and other suitable additives. Non-limiting examples of filler materials include talc, mica silicate, sulfate-bearing, magnesium hydroxide, magnesium carbonate, magnesium silicate, calcium carbonate, and other commercially available fillers. In addition to ethylene-vinyl acetate (EVA) or TPE-based materials, the polymer composition can also contain rubber fillers, such as ethylene-propylene rubber (EPR), styrene-isoprene-styrene (SIS) copolymer rubber, styrene-butadiene rubber, and other polyolefin resins. In other examples, polyethylene wax can be used as a processing aid, stearic acid can be used as a lubricant, dicumyl peroxide can be used as a polymerization initiator, zinc oxide can be used as an activator for the blowing agent, and titanium dioxide can be used as a white pigment or carbon black can be used as a black pigment.

[0322] Fig.31The process block 3111 includes memory-stored, processor-executable instructions for melting the shredded recycled material and the virgin polymer material into a polymer melt composition. It should be understood that the shredded recycled material and the virgin polymer material can be melted separately and then flow into the mixed polymer melt composition. Otherwise, the mixed batch of recycled and virgin polymer materials produced at process block 3107 can be heated into a polymer melt composition. For at least some embodiments, the mixture of shredded recycled material and virgin polymer material has a setpoint temperature in the range from about 190 °C to about 215 °C. Additionally, the mixed batch of shredded recycled material and virgin polymer material can have an average peak crystallization temperature in the range from about 135 °C to about 165 °C.

[0323] Once the polymer composition is complete and ready for molding, the processed recycled and virgin materials are pressured and injected (commonly referred to as "shot") into one or more internal cavities of a mold assembly to form a foamed polymer article, as indicated at process block 3113. After the SCF is injected into the polymer melt composition (where the SCF dissolves in the melt to form a molten SPS), the molten SPS flows into the internal mold cavity. The SCF serves as a physical blowing agent to expand the molten TPE-E composition and thereby fill the mold cavity. The pressure within the mold cavity is reduced or eliminated to release the SCF from the SPS, and the expanded melt is cooled and solidified. To provide a "closed-loop" molding system with circular sustainability that eliminates most, if not all, of the manufacturing waste and scrap, the mass of the recycled thermoplastic resin within the internal mold cavity can be greater than or equal to the mass of the mixed thermoplastic resin within any filling portion fluidly coupled to the cavity.

[0324] To ensure the integrity and desired performance characteristics of the resulting foamed polymer article, one or more operating parameters of the injection molding system can be adjusted to accommodate the mass percentage of recycled material incorporated into the polymer mixture. For example, the injection molding system can be set to a molding melt temperature of about 210 °C to about 215 °C, where the batch melt temperature is approximately 190 °C and the crystallization temperature is approximately 147 °C. In addition to the selective control of the mold temperature, the gas backpressure release rate and the holding time can be recalibrated for a TPE-E polymer melt composition having approximately 20 mass% of recycled TPE-E composition to, for example, regulate the cooling rate within the mold cavity (e.g., a higher pressure drop results in a faster cooling rate and a shorter cooling time). The system operating parameters can be selectively modified to ensure that the polymer melt composition remains within a pre-calculated melt temperature - crystallization temperature optimum point within a selected time range during the processing cycle.

[0325] At process block 3115, the foamed polymer article is ejected from the inner mold cavity. For at least some embodiments, the formed foamed polymer article has an average cell size of less than about 0.68 mm or in some embodiments from about 0.18 mm to about 0.58 mm (e.g., calculated by volume of the longest cell dimension). For at least some embodiments, the foamed polymer article may exhibit some and / or all of the following characteristics: (1) an energy efficiency of from about 55% to about 95%, or in some preferred configurations, a target efficiency of 70% to 85%; (2) an energy return of from about 1000 millijoules (mJ) to about 7000 mJ, or in some preferred configurations, a target return of 4500 mJ to 5500 mJ (e.g., using a standard midsole geometry); and / or (3) a density of from about 0.15 grams per cubic centimeter (g / cc) to about 0.25 g / cc, or in some preferred configurations, a target density of 0.18 g / cc to 0.20 g / cc.

[0326] As yet another option, the formed foamed polymer article may exhibit the following ratio of energy efficiency to energy intensity (EE / EI): greater than about 1.125, or for some embodiments greater than about 1.35, or for some desired embodiments greater than about 1.5, or optionally from about 1.6 to 2.1. Similarly, the formed foamed polymer article may exhibit the following ratio of energy efficiency to the product of energy intensity and density (EE / (EI*ρ)): greater than about 5.25, or for some embodiments greater than about 6.3, or for some desired embodiments greater than about 7.0, or optionally from about 8.8 to 11.2. Additionally, the formed foamed polymer article may exhibit the following ratio of energy return to energy intensity (ER / EI): greater than about 6,375, or for some embodiments greater than about 7,650, or for some desired embodiments greater than about 8,500, or optionally from about 9,900 to 11,300. The formed foamed polymer article may exhibit the following ratio of energy return to the product of energy intensity and density (ER / (EI*ρ)): greater than about 33,750, or for some embodiments greater than about 40,500, or for some desired embodiments greater than about 45,000, or optionally from about 55,400 to 62,500.

[0327] For at least some embodiments, a foamed polymer sole component made from both recycled and virgin thermoplastic materials can have an energy return measurement within a predefined tolerance of the energy return measurement of a comparable sole component formed from only virgin thermoplastic materials. The predefined tolerance can be from about 75% to about 99% of the energy return measurement of the comparable sole component. The foamed sole component and the comparable sole component can share comparable shape, size, and / or molding method. At this point, method 3100 can terminate or can loop back to block 3101 and run in a repeatable or continuous loop.

[0328] It is envisioned that the disclosed manufacturing systems and methods can utilize any logically related source of recycled plastic materials in order to conserve natural resources, minimize the use of raw materials, and divert waste from landfills, with the hope of achieving a “circular economy.” In this regard, aspects of the present disclosure relate to a “closed-loop” manufacturing process that limits the available source of recycled materials to manufacturing by-products (e.g., gate or runner trimmings) and reground defective articles (e.g., visually or mechanically defective foamed polymer footwear sole elements). Implementing such a “closed-loop” manufacturing process can desirably optimize material use efficiency by achieving, for example, zero or near-zero waste of polymer materials in the manufacture of foamed polymer articles.

[0329] As Fig.31 an extension, modification, or independent process of method 3100, a method of producing a foamed polymer article can consist of a series of controlled manufacturing steps, including performing one or more production batches to form one or more types of foamed polymer articles. A “production batch” can be represented by a predefined number of articles (e.g., 220 to 260 articles per hour) of a designated design / model having a preset shape, size, and material composition (e.g., a one-piece TPE-E midsole for a women's size 7 running shoe), which are produced substantially continuously by a particular production line. Each batch may exhibit different quantifiable production variables, including: the average article mass m AA (e.g., the average total mass per batch of all articles or the average individual article mass or all articles per batch), and the average article defect rate (e.g., the ratio of the total number of defective articles produced to the total number of articles per batch). Because the process can produce multiple product enclosures (e.g., their number and geometry are distinguishable from one another), the tools used for each geometry may consume different volumes of raw materials and generate different volumes of manufacturing by-products.

[0330] As will be further explained in detail below, a production line can generate a baseline average byproduct value (e.g., unfoamed byproducts generated upstream of the tool and / or foamed byproducts generated downstream of the tool). For a particular production batch, the amount of average byproduct quality can be calculated as the sum of: (1) the amount of byproducts generated for each geometry produced in a batch divided by the number of each geometry in the batch; and (2) the residual upstream byproduct quality / batch. As a non-limiting example, the batch size of a production batch can include a total of 100 articles, including 20 of a first geometry, 20 of a second geometry, and 60 of a third geometry. In this case, the byproduct quality can be calculated as: (total byproduct quality of the first geometry) / 20 + (total byproduct quality of the second geometry) / 20 + (total byproduct quality of the third geometry) / 60 + upstream and / or downstream byproduct quality.

[0331] For at least some embodiments, a production batch can be limited to a preset quantity of a single batch for manufacturing a single article design having a predefined shape and size. Alternatively, a large-scale production batch can include multiple lot batches of different types of polymer articles, where each type has its own shape and size. These lot production batches can be executed simultaneously or sequentially, with each batch producing the same quantity or a different quantity of articles. When multiple lot batches are part of a larger large-scale production batch, the average article quality m AA of that large-scale batch can be calculated as the arithmetic sum of the respective average article qualities of all the discrete batches, i.e.: m AA-1 + m AA-2 + … + m AA-n . Similarly, the average article defect rate of the large-scale batch can be calculated as the arithmetic mean of the respective average article defect rates of all the discrete lot batches, i.e.:

[0332]

[0333] After completing a single production batch or a set of discretized lot batches of foamed polymer articles, the method can include regenerating and recycling one or more batches of manufacturing byproducts associated with that one batch or multiple batches. Recycling byproduct materials can be recovered from sections of the molding system upstream of the mold (e.g., from a hot runner or cold runner plate), from sections of the molding system downstream of the mold (e.g., mold flash and trim), and / or from within the mold itself (e.g., the inlet and outlet gates of the mold annular cavity). In this example, the manufacturing byproducts can have an average byproduct quality m AB(e.g., average total by-product mass / batch or average by-product mass per article / batch). When multiple batch runs are conducted, the average by-product mass for the entire large-scale production batch can be calculated as the arithmetic sum of the respective average by-product masses, i.e.: m AB-1 +m AB-2 +…+m AB-n . Alternatively, the average by-product mass can be calculated as the arithmetic sum of: (1) the first by-product mass associated with the first batch run divided by the first quantity of the first polymer articles in that batch; (2) the second by-product mass associated with the second batch run divided by the second quantity of the second polymer articles in that batch; … and (n) the nth by-product mass associated with the nth batch run divided by the nth quantity of the polymer articles in that batch.

[0334] Before, during, or after retrieving the batch of manufactured by-products, the method can further include regenerating and recycling one or more batches of defective articles associated with the production batch. According to the footwear example above, the recycled defective material can be retrieved from pre-consumer footwear and, if desired, from post-consumer footwear. For pre-consumer products, defective foamed articles can be identified by any commercially available technique for identifying manufacturing defects. For example, an injection molding system can incorporate a system automated vision inspection station and a system automated mechanical test station downstream of the Fig. 9 or Fig.14A tool components. The vision inspection station can utilize high-definition digital cameras and machine learning algorithms to search for and label any of a plurality of predefined visual defects (e.g., dimensional defects, surface fouling, profile defects, etc.). Additionally, the mechanical test station can be in the nature of an impact testing machine with a linear force sensor operably coupled to a motor-driven final forming plunger. The plunger and sensor together measure the stiffness, energy efficiency, energy return, etc. of each foam article, and if any of these measurements fall outside the corresponding manufacturing tolerance range, the article is labeled as defective.

[0335] Continuing with pre-consumer defective products, there will be an associated average defect mass m AD ( / batch). This average defect mass m AD can be calculated as the arithmetic product of the article defect rate and the average article mass m AA , or For embodiments where multiple batch runs are performed as part of a larger large-scale production batch, the average defect mass m AD can be the arithmetic mean of the respective average defect masses associated with each production batch, i.e.: (m AD-1 +m AD-2 +…+m AD-n) / n. To implement a "closed-loop" manufacturing process, the system can be restricted as follows:

[0336] (m AB +m AD ) / m AA ≤0.2

[0337] During the closed-loop manufacturing process, foam polymer waste (manufacturing by-products and defective articles) can be directly added to the injection barrel for subsequent injection into the mold cavity. The foam polymer waste can be crushed or shredded, mixed with virgin pellets, and fed together into the same injection barrel. In this case, a powered screw-type "ram" feeder can be used to push the waste material back into the tool assembly. Before re-feeding the material, the foam polymer waste can be shredded at least once, or in at least some applications, shredded two or more times to ensure that the discrete waste elements are generally uniform in shape and size. If it is determined that the foam polymer waste cannot be directly added to the injection barrel, then processing, melting, and re-pelletizing of the foam waste may be required. In this case, the waste material will be shredded one or more times, fed into a separate extrusion line where it is melted and extruded, and then pelletized to form pellets with a geometry and density similar to virgin pellets. These "new" waste material pellets can then be combined with virgin pellets in the injection barrel.

[0338] The operating parameters of the injection molding system will potentially vary depending on the type and volume of recycled material used to form the foamed polymer article. For example, the melt temperature may be modified to successfully process the recycled material: when foaming, the crystallization temperature of the recycled material may increase (i.e., the crystallization temperature is closer to the melt temperature). Accordingly, the melt composition may need to be processed at a higher temperature compared to the processing temperature typically used for pure virgin materials. For at least some footwear midsole embodiments, the production variables for each batch can be based on the following parameters: approximately 0.2 kg / pair, approximately 2 pairs (4 midsoles) / minute, an 8-hour shift, and runner waste of approximately 10% to approximately 15% relative to the weight of each pair of midsoles.

[0339] Definitions

[0340] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It should be further understood that terms as defined in a commonly used dictionary should be interpreted as having a meaning consistent with their meaning in the context of this specification and the relevant art, and should not be interpreted in an idealized or overly formal sense unless expressly so defined in this document.

[0341] The terms "comprises", "comprising", "including", and "having" are inclusive and thus specify the presence of stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0342] As used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "foam particles", "midsole", or "adhesive" includes but is not limited to two or more such foam particles, midsoles, or adhesives, etc.

[0343] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0344] As used herein, "in substance or substantially" means at least 80%, 85%, 90%, 95% or more, as determined based on weight, volume or unit.

[0345] The terms "first", "second", "third", etc. may be used to describe various elements, components, regions, layers, and / or sections. These elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are only 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 order or sequence unless the context clearly dictates otherwise. Thus, a first element, component, region, layer or segment discussed below may be referred to as a second element, component, region, layer or segment without departing from the teachings of the exemplary configuration.

[0346] As used herein, modifiers such as "upper", "lower", "top", "bottom", "upward", "downward", "vertical", "horizontal", "longitudinal", "lateral", "front", "rear", etc. are relative terms and, unless otherwise defined or made clear in accordance with the present disclosure, are intended to place the orientation of various structures or structures of a footwear article in the context of a footwear article worn by a user standing on a flat, horizontal surface.

[0347] When recited in a claim, the term "receive", such as "receive an upper for a footwear article", is not intended to require any particular delivery or receipt of the item being received. Instead, for purposes of clarity and readability, the term "receive" is used only to enumerate the item that will be referred to in a subsequent element of the claim.

[0348] The terms "at least one" and "one or more" elements are used interchangeably and have the same meaning including a single element and a plurality of elements, and may also be represented by the suffix "(s)" at the end of the element. For example, "at least one polyamide", "one or more polyamides" and "polyamide" can be used interchangeably and have the same meaning.

[0349] It should be noted that ratios, concentrations, amounts and other numerical data may be expressed herein in a range format. When the range includes one or both of the limits, ranges excluding any one or both of the included limits are also included in the present disclosure. For example, the phrase "x to y" includes the range from 'x' to 'y' and ranges greater than 'x' and less than 'y'. The range may also be expressed as an upper limit, such as 'about x, y, z or less', and should be interpreted as including the specific ranges of 'about x', 'about y' and 'about z' as well as the ranges of 'less than x', 'less than y' and 'less than z'. Similarly, the phrase 'about x, y, z or greater' should be interpreted as including the specific ranges of 'about x', 'about y' and 'about z' as well as the ranges of 'greater than x', 'greater than y' and 'greater than z'. In addition, the phrase "about 'x' to 'y'" (where 'x' and 'y' are numerical values) includes "about 'x' to about 'y'". It should be understood that such a range format is used for convenience and brevity, and therefore, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the range limits, but also all individual numerical values or sub-ranges subsumed within that range as if each numerical value and sub-range were explicitly recited. By way of illustration, the numerical range of "about 0.1% to 5%" should be interpreted to include not only the explicitly recited values of about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3% and 4%) and sub-ranges (e.g., 0.5%, 1.1%, 2.4%, 3.2% and 4.4%) within the indicated range.

[0350] Due to expected variations known to those skilled in the art (e.g., limitations and variability in measurements), the terms "about" and "substantially" are used herein with respect to measurable values and ranges.

[0351] As used herein, the term "optional" or "optionally" means that the subsequently described component, event or circumstance may or may not occur, and the description includes the cases where the component, event or circumstance occurs and the cases where it does not occur.

[0352] Unless otherwise specified, the temperatures mentioned herein are based on atmospheric pressure (i.e., one atmosphere).

[0353] Before proceeding with the examples, it should be understood that the present disclosure is not limited to the specific aspects described and can, of course, vary accordingly. By studying the following figures and detailed description, other systems, methods, features, and advantages of the foam composition and its components will be or will become apparent to those of ordinary skill in the art. All such additional systems, methods, features, and advantages are intended to be included in this specification, within the scope of the present disclosure, and protected by the appended claims. It should also be understood that the terms used herein are for the purpose of describing particular aspects only and are not intended to be limiting. Those skilled in the art will recognize many variations and modifications of the aspects described herein. These variations and modifications are intended to be included in the teachings of the present disclosure and covered by the claims herein.

[0354] Although specific elements and steps are discussed in relation to each other, it should be understood that any element and / or step provided herein is contemplated to be combinable with any other element and / or step, regardless of the explicit provisions to the contrary, while still remaining within the scope provided herein. Since many possible embodiments of the present disclosure can be made without departing from the scope of the present disclosure, it should be understood that all content set forth herein or shown in the accompanying figures should be interpreted as illustrative and not restrictive.

[0355] As used herein and in connection with the claims listed below, the term "any of the clauses" or similar variations of said term are intended to be interpreted such that the features of the claims / clauses can be combined in any combination. For example, exemplary clause 4 may indicate a method / device as described in any of clauses 1 to 3, which is intended to be interpreted such that the features of clause 1 and clause 4 can be combined, the elements of clause 2 and clause 4 can be combined, the elements of clause 3 and clause 4 can be combined, the elements of clause 1, clause 2, and clause 4 can be combined, the elements of clause 2, clause 3, and clause 4 can be combined, the elements of clause 1, clause 2, clause 3, and clause 4 can be combined, and / or other variations. Additionally, the term "any of the clauses" or similar variants of said term are intended to include "any one of the clauses" or other variants of such terms, as indicated by some of the examples provided above.

[0356] The following clauses are aspects contemplated herein.

[0357] Clause 1. A physical foaming injection molding system for a footwear component formed from a polymer composition, the system comprising: a temperature control unit; a temperature regulating bracket that is effectively coupled to the temperature control unit, wherein the temperature regulating bracket is adapted to regulate the temperature of a mold maintained at the temperature regulating bracket; a syringe that includes a physical foaming agent port; a physical foaming agent supply source that is fluidly coupled to the syringe physical foaming agent port; a press that is paired with the syringe; an unloader that includes a frame, an unloader plate, and a pair of unloader arms, wherein the unloader arms move uniformly in a first direction and non-uniformly in a second direction; and a robot that includes an end effector adapted to reversibly engage with the mold, wherein the robot is positioned relative to the temperature regulating bracket, the press, and the unloader to manipulate the end effector at the temperature regulating bracket, the press, and the unloader to reversibly engage with the mold.

[0358] Clause 2. The system according to Clause 1, wherein the temperature regulating bracket includes a plurality of compartments.

[0359] Clause 3. The system according to any one of Clauses 1 to 2, wherein the temperature regulating bracket includes a temperature regulating inlet fluidly coupled to a temperature regulating outlet, wherein the temperature control unit is fluidly coupled to the temperature regulating bracket via the temperature regulating inlet and the temperature regulating outlet.

[0360] Clause 4. The system according to any one of Clauses 1 to 3, wherein the temperature regulating bracket includes an RFID reader.

[0361] Clause 5. The system according to any one of Clauses 1 to 4, wherein the temperature regulating bracket includes a temperature regulating plate.

[0362] Clause 6. The system according to Clause 5, wherein the temperature regulating plate includes an RFID reader.

[0363] Clause 7. The system according to Clause 5, wherein the temperature regulating plate includes a thermocouple.

[0364] Clause 8. The system according to Clause 5, wherein the temperature regulating plate includes a top surface and a bottom surface, and wherein the bottom surface of the temperature regulating plate is supported by the temperature regulating bracket.

[0365] Clause 9. The system according to Clause 8, wherein the top surface of the temperature regulating plate includes a first protrusion extending outward from the temperature regulating top surface.

[0366] Clause 10. The system according to Clause 9, wherein the top surface of the temperature regulation plate includes a second protrusion that extends outward from the top surface of the temperature regulation and is effectively received by the mold.

[0367] Clause 11. The system according to Clause 10, wherein the first protrusion of the temperature regulation plate is asymmetric with respect to the second protrusion of the temperature regulation plate in one or more characteristics.

[0368] Clause 12. The system according to Clause 11, wherein the one or more characteristics include protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, or any combination thereof.

[0369] Clause 13. The system according to Clause 9, wherein the first protrusion on the top surface of the temperature regulation plate is asymmetrically located on the top surface of the temperature regulation plate and is configured to be received by the bottom plate of the mold for alignment on the temperature regulation plate.

[0370] Clause 14. The system according to Clause 8, wherein the temperature regulation plate includes a fluid passage extending between the top surface of the temperature regulation plate and the bottom surface of the temperature regulation plate.

[0371] Clause 15. The system according to any one of Clauses 1 to 14, wherein the temperature regulation bracket includes four to eight compartments, and each of the four to eight compartments includes a temperature regulation plate, an RFID reader, and a thermocouple.

[0372] Clause 16. The system according to any one of Clauses 1 to 15, wherein the temperature regulation bracket further includes a regulating fluid manifold fluidly connected to the temperature regulation unit.

[0373] Clause 17. The system according to Clause 16, wherein the regulating fluid manifold is fluidly connected to two or more temperature regulation plates supported by the temperature regulation bracket.

[0374] Clause 18. The system according to any one of Clauses 1 to 17, wherein the temperature control unit effectively regulates the regulating fluid to a temperature of 15 degrees Celsius to 90 degrees Celsius.

[0375] Clause 19. The system according to Clause 18, wherein the temperature control unit includes a heat exchanger.

[0376] Clause 20. The system according to any one of Clauses 1 to 19, wherein the temperature control unit is fluidly connected to the temperature regulation bracket.

[0377] Clause 21. The system according to any one of Clauses 1 to 20, wherein the press includes a movable support platform and an actuator connected to the support platform, and wherein the actuator effectively adjusts the position of the support platform within the press.

[0378] Clause 22. The system according to any one of Clauses 1 to 21, wherein the press includes a common runner plate, and the common runner plate includes a plurality of outlets.

[0379] Clause 23. The system according to any one of Clauses 1 to 22, wherein the syringe is paired with the press via the common runner plate.

[0380] Clause 24. The system according to any one of Clauses 1 to 23, wherein the common runner plate is a hot runner plate and the plurality of outlets are hot runner outlets.

[0381] Clause 25. The system according to any one of Clauses 1 to 24, wherein the press includes a hot runner plate and a support plate, and the hot runner plate and the support plate are movably positioned in a first configuration having a first distance therebetween and a second configuration having a second distance therebetween, wherein the first distance is greater than the second distance.

[0382] Clause 26. The system according to Clause 25, wherein the hot runner plate is statically positioned in the press and the support plate is movably positioned in the press.

[0383] Clause 27. The system according to any one of Clauses 1 to 26, wherein the press includes a press lock, and the press lock is movable between an unlocked configuration and a locked configuration, and wherein the press lock effectively fixes the mold in the press when in the locked configuration.

[0384] Clause 28. The system according to Clause 27, wherein the press lock includes a pair of sliding fingers, and when transitioning between the unlocked configuration and the locked configuration, the pair of sliding fingers move in the lateral direction of the press.

[0385] Clause 29. The system according to any one of Clauses 1 to 28, wherein the press includes: a support platform; and a platen having a top surface and a bottom surface, and wherein the bottom surface of the platen is supported by the support platform.

[0386] Clause 30. The system according to Clause 29, wherein the platen includes temperature regulating fluid channels extending between the top surface and the bottom surface of the platen, and the temperature regulating fluid channels of the platen are fluidly coupled to a temperature control unit.

[0387] Clause 31. The system according to Clause 29, wherein the top surface of the platen includes a first protrusion extending outwardly from the top surface of the platen.

[0388] Clause 32. The system according to Clause 31, wherein the top surface of the platen includes a second protrusion extending outwardly from the top surface of the platen and effectively received by the mold.

[0389] Clause 33. The system according to Clause 32, wherein the first protrusion of the platen is asymmetric with respect to the second protrusion of the platen in one or more characteristics.

[0390] Clause 34. The system according to Clause 33, wherein the one or more characteristics include protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, or any combination thereof.

[0391] Clause 35. The system according to Clause 29, wherein the first protrusion on the top surface of the platen is asymmetrically located on the top surface of the platen and is configured to be received by the bottom plate of the mold for alignment on the platen.

[0392] Clause 36. The system according to Clause 35, wherein the syringe includes a plurality of heating elements along the longitudinal length of the syringe.

[0393] Clause 37. The system according to Clause 36, wherein the plurality of heating elements along the longitudinal length of the syringe are individually adjustable to supply varying amounts of thermal energy to the syringe.

[0394] Clause 38. The system according to any one of Clauses 1 to 37, wherein the physical blowing agent port is in fluid communication with the physical blowing agent supply source.

[0395] Clause 39. The system according to any one of Clauses 1 to 38, further comprising a metering source fluidly coupled between the physical blowing agent port and the physical blowing agent supply source, wherein the metering source meters a supercritical fluid as a physical blowing agent into the injection barrel via the physical blowing agent port.

[0396] Clause 40. The system according to any one of Clauses 1 to 39, further comprising a gas backpressure source.

[0397] Clause 41. The system according to Clause 40, wherein the gas backpressure source is fluidly coupled to the press to provide backpressure to the mold prior to injection from the syringe.

[0398] Clause 42. The system according to Clause 41, wherein the gas backpressure source supplies nitrogen or carbon dioxide to the press.

[0399] Clause 43. The system according to any one of Clauses 1 to 42 further includes a gas back pressure regulator that maintains a constant back pressure of the mold in the press during injection of the material through the syringe.

[0400] Clause 44. The system according to any one of Clauses 1 to 43, wherein the physical blowing agent supply source comprises a gas, a liquid, or a supercritical fluid.

[0401] Clause 45. The system according to any one of Clauses 1 to 44, wherein the physical blowing agent supply source comprises compressed carbon dioxide gas or compressed nitrogen gas.

[0402] Clause 46. The system according to any one of Clauses 1 to 45 further includes a supply hopper configured to receive a polymer material, wherein the supply hopper is operatively coupled to the syringe to supply the polymer material to the syringe.

[0403] Clause 47. The system according to any one of Clauses 1 to 46, wherein the unloader includes an unloader lock that is convertible between an unlocked configuration and a locked configuration, wherein the unloader lock effectively secures the mold in the unloader when in the locked configuration.

[0404] Clause 48. The system according to Clause 47, wherein the unloader lock includes a first pair of fingers and a second pair of fingers that are slidably movable in a plane parallel to the top surface of the unloader plate when the unloader lock is converted between the unlocked configuration and the locked configuration.

[0405] Clause 49. The system according to any one of Clauses 1 to 48, wherein the unloader plate includes a top surface and a bottom surface, and the bottom surface of the unloader plate is supported by an unloader frame.

[0406] Clause 50. The system according to Clause 49, wherein the unloader plate includes an RFID reader.

[0407] Clause 51. The top surface of the unloader plate according to Clause 49 includes a first protrusion extending outwardly from the top surface of the unloader plate.

[0408] Clause 52. The top surface of the unloader plate according to Clause 51 includes a second protrusion extending outwardly from the top surface of the unloader plate and effectively received by the mold.

[0409] Clause 53. The first protrusion of the unloader plate is asymmetric with respect to the second protrusion of the unloader plate in one or more characteristics according to Clause 52.

[0410] Clause 54. The system according to Clause 53, wherein the one or more features include protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, or any combination thereof.

[0411] Clause 55. The system according to Clause 52, wherein the first protrusion on the top surface of the unloading machine plate is asymmetrically located on the top surface of the unloading machine plate and is configured to be received by the bottom plate of the mold to be aligned on the unloading machine plate.

[0412] Clause 56. The system according to any one of Clauses 1 to 55, wherein the unloading machine arm moves uniformly in the vertical direction and the unloading machine arm moves non-uniformly in the horizontal direction relative to the unloading machine frame.

[0413] Clause 57. The system according to any one of Clauses 1 to 56, wherein the unloading machine arm is slidably positioned between an open configuration and a closed configuration, the open configuration having a first distance between a first arm of the unloading machine arm and a second arm of the unloading machine arm, the closed configuration having a second distance between the first arm and the second arm, wherein the second distance is less than the first distance.

[0414] Clause 58. The system according to Clause 57, wherein the first unloading machine arm includes a first protrusion that is effectively received in the unloading machine interface of the mold.

[0415] Clause 59. The system according to Clause 58, wherein the first protrusion of the first unloading machine arm is asymmetric.

[0416] Clause 60. The system according to Clause 58, wherein the first unloading machine arm includes a second protrusion that is effectively received in the unloading machine interface of the mold.

[0417] Clause 61. The system according to Clause 60, wherein the first protrusion of the first unloading machine arm is asymmetric with respect to the second protrusion of the first unloading machine arm in one or more features.

[0418] Clause 62. The system according to Clause 61, wherein the one or more features include protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, or any combination thereof.

[0419] Clause 63. The system according to Clause 57, wherein the second unloading machine arm includes a third protrusion that is effectively received in the unloading machine interface of the mold.

[0420] Clause 64. The system according to Clause 63, wherein the second unloading machine arm includes a fourth protrusion that is effectively received in the unloading machine interface of the mold.

[0421] Clause 65. The system according to Clause 64, wherein the first protrusion of the first unloading arm is symmetric with respect to the third protrusion of the second unloading arm in one or more characteristics.

[0422] Clause 66. The system according to Clause 64, wherein the second protrusion of the first unloading arm is symmetric with respect to the fourth protrusion of the second unloading arm in one or more characteristics.

[0423] Clause 67. The system according to Clause 66, wherein the one or more characteristics include protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, or any combination thereof.

[0424] Clause 68. The system according to Clause 58, wherein the unloading arm includes a key extending in a direction parallel to the first protrusion of the first unloading arm, and the key effectively engages with the tool latch assembly to disengage the die fastening assembly.

[0425] Clause 69. The system according to any one of Clauses 1 to 68, wherein the first direction includes at least three positions: a first position where the die is closed, a second position where the die is partially open, and a third position where the die is more open, and the second position and the third position are different.

[0426] Clause 70. The system according to Clause 60, wherein the first protrusion of the first unloading arm has a linear segment in cross-section and the second protrusion has a curved segment in cross-section.

[0427] Clause 71. The system according to Clause 60, wherein the first protrusion of the first unloading arm is asymmetric with respect to the second protrusion of the first unloading arm in one or more characteristics.

[0428] Clause 72. The system according to Clause 71, wherein the one or more characteristics include protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, or any combination thereof.

[0429] Clause 73. The system according to Clause 72, wherein the second unloading arm includes a third protrusion that is effectively received in the unloading interface of the die.

[0430] Clause 74. The system according to Clause 1, wherein the robot rotates about at least one axis and moves along at least two other axes.

[0431] Clause 75. The system according to Clause 74, wherein the robot rotates about at least the Z axis and moves along at least the X and Y axes.

[0432] Clause 76. The system according to any one of Clauses 1 to 75, wherein the robot moves along at least the X, Y, and Z axes.

[0433] Clause 77. The system according to any one of Clauses 1 to 76, wherein the end effector includes a first side and a second side that is adjustably offset from the first side.

[0434] Clause 78. The system according to Clause 77, wherein the first side and the second side are slidably positioned on the end effector between an open configuration and a closed configuration, the open configuration having a first distance between the first side and the second side, the closed configuration having a second distance between the first side and the second side, and the second distance being less than the first distance.

[0435] Clause 79. The system according to any one of Clauses 1 to 78, wherein the end effector is a lifting device, and the lifting device includes a first protrusion that is effectively received in the lifting device interface of the mold.

[0436] Clause 80. The system according to Clause 79, wherein the first protrusion of the end effector is asymmetric.

[0437] Clause 81. The system according to Clause 79, wherein the end effector includes a second protrusion that is effectively received in the lifting device interface of the mold.

[0438] Clause 82. The system according to Clause 81, wherein the first protrusion of the end effector is asymmetric with respect to the second protrusion of the end effector in one or more characteristics.

[0439] Clause 83. The system according to Clause 82, wherein the one or more characteristics include protrusion length, protrusion cross-sectional shape, protrusion position, protrusion size, or any combination thereof.

[0440] Clause 84. The system according to Clause 83, wherein the end effector further includes an RFID reader.

[0441] Clause 85. The system according to any one of Clauses 1 to 84, further including a controller having a processor and a memory.

[0442] Clause 86. The system according to Clause 85, wherein the controller is logically coupled to at least one or more RFID readers of the system, the robot, and the press.

[0443] Clause 87. The system according to Clause 86, wherein the logical coupling is wired or wireless.

[0444] Clause 88. The system according to Clause 85, wherein the controller effectively stores the data retrieved from the RFID reader and provides an instruction to the robot to retrieve the mold in response to the data retrieved from the RFID reader.

[0445] Clause 89. The system according to any one of Clauses 1 to 88, wherein the temperature regulating bracket, the press, and the unloading machine are positioned within three meters of an arc centered at the robot.

[0446] Clause 90. The system according to any one of Clauses 1 to 88, wherein the temperature regulating bracket, the press, and the unloading machine are positioned within three meters of a line extending through at least two of the temperature regulating bracket, the press, and the unloading machine.

[0447] Clause 91. The system according to Clause 90, wherein the robot is movable along the line.

[0448] Clause 92. The system according to any one of Clauses 1 to 91, wherein the temperature regulating bracket is on a first side of the press and the unloading machine is on a second side of the press.

[0449] Clause 93. The system according to any one of Clauses 1 to 91, wherein the unloading machine is on a first side of the temperature regulating bracket and the press is on a second side of the temperature regulating bracket.

[0450] Clause 94. The system according to any one of Clauses 1 to 91, wherein the temperature regulating bracket is on a first side of the unloading machine and the press is on a second side of the unloading machine.

[0451] Clause 95. The system according to any one of Clauses 1 to 94, further comprising a second temperature regulating bracket, a third temperature regulating bracket, and a fourth temperature regulating bracket.

[0452] Clause 96. The system according to any one of Clauses 1 to 95, wherein the polymer composition comprises: a thermoplastic elastomer composition comprising a thermoplastic polyester homopolymer, a thermoplastic elastomer composition comprising a thermoplastic copolyester having two different types of polyester monomer segments, or a combination thereof.

[0453] Clause 97. The system according to any one of Clauses 1 to 96, wherein the syringe is located at a fixed position relative to the temperature regulating bracket by a plurality of consecutive injection operations.

[0454] Clause 98. A physical foaming injection molding system for a footwear component, the system comprising: a temperature regulating bracket, wherein the temperature regulating bracket is adapted to regulate the temperature of a mold maintained at the temperature regulating bracket; a press; an unloader, the unloader comprising a frame, an unloader plate, and a pair of unloader arms, wherein the unloader arms move uniformly in a first direction and non-uniformly in a second direction; and a robot, the robot comprising an end effector adapted to reversibly engage with the mold, wherein the robot is positioned relative to the temperature regulating bracket, the press, and the unloader to manipulate the end effector at the temperature regulating bracket, the press, and the unloader to reversibly engage with the mold.

[0455] Clause 99. A physical foaming injection molding system for a footwear component, the system comprising: a temperature regulating bracket, wherein the temperature regulating bracket is adapted to regulate the temperature of a mold maintained at the temperature regulating bracket; an unloader, the unloader comprising a frame, an unloader plate, and a pair of unloader arms, wherein the unloader arms move uniformly in a first direction and non-uniformly in a second direction; and a robot, the robot comprising an end effector adapted to reversibly engage with the mold, wherein the robot is positioned relative to the temperature regulating bracket and the unloader to manipulate the end effector at the temperature regulating bracket and the unloader to reversibly engage with the mold.

[0456] Clause 100. A physical foaming injection molding system for a footwear component, the system comprising: a temperature control unit; a syringe; and a press, the press comprising: (1) a support platform; and (2) a platen having a top surface and a bottom surface, wherein the bottom surface of the platen is supported by the support platform, wherein the platen comprises a temperature regulating fluid passage between the top surface of the platen and the bottom surface of the platen, and wherein the temperature regulating fluid passage of the platen is fluidly coupled to the temperature control unit.

[0457] Clause 101. An unloader for a physical foaming injection molding system for a footwear component, the unloader comprising: an unloader plate, wherein the unloader plate comprises a top surface, the top surface comprising a first protrusion extending outward from the top surface of the unloader plate; an unloader lock, the unloader lock comprising a first pair of fingers and a second pair of fingers, the first pair of fingers and the second pair of fingers being slidably movable in a plane parallel to the top surface of the unloader plate when the unloader lock transitions between an unlocked configuration and a locked configuration; and a pair of unloader arms, wherein the unloader arms move uniformly toward and away from the unloader plate in a first direction and non-uniformly parallel to the top surface of the unloader plate in a second direction.

[0458] Clause 102. A press in a physical foaming injection molding system for a footwear component, the press comprising: a common runner plate; an actuator; and a platen, the platen including a pressure lock, wherein the actuator adjustably positions the platen from a first configuration to a second configuration, the first configuration having a first distance between the common runner plate and the platen, the second configuration having a second distance between the common runner plate and the platen, and wherein the pressure lock includes a pair of sliding fingers that move between an unlocked configuration and a locked configuration in a lateral direction relative to the direction of movement of the platen, and the platen is adjustably positioned from the first configuration to the second configuration.

[0459] Clause 103. A method of physically foaming a footwear component formed from a polymer composition, the method comprising: adjusting the mold temperature to a temperature between 15 degrees Celsius and 90 degrees Celsius; engaging the mold with an end effector of a robot transfer adapted to reversibly engage with the mold; transferring the mold to a press with the end effector; applying a gas backpressure to a cavity of the mold; injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold; releasing the gas backpressure from the cavity of the mold; and removing the footwear component from the cavity of the mold.

[0460] Clause 104. The method according to Clause 103, wherein the footwear component is a footwear sole portion.

[0461] Clause 105. The method according to any one of Clauses 103 to 104, wherein the mold is temperature-adjusted at a temperature adjustment bracket.

[0462] Clause 106. The method according to Clause 105, wherein the mold is selected from a plurality of molds at the temperature adjustment bracket.

[0463] Clause 107. The method according to Clause 105, wherein the temperature adjustment bracket includes a temperature adjustment plate having a top surface and a bottom surface.

[0464] Clause 108. The method according to Clause 107, wherein the temperature adjustment plate includes a thermocouple.

[0465] Clause 109. The method according to Clause 108, wherein the thermocouple is a recess in the top surface of the temperature adjustment plate.

[0466] Clause 110. The method according to Clause 108, further comprising detecting the temperature with the thermocouple of the temperature adjustment plate.

[0467] Clause 111. The method according to Clause 107, wherein the temperature adjustment plate includes an RFID reader.

[0468] Clause 112. The method according to Clause 111 further comprises detecting an RFID tag of the mold with the RFID reader.

[0469] Clause 113. The method according to any one of Clauses 103 to 112, wherein the temperature is from 45 degrees Celsius to 80 degrees Celsius.

[0470] Clause 114. The method according to any one of Clauses 103 to 112, wherein the temperature is from 50 degrees Celsius to 70 degrees Celsius.

[0471] Clause 115. The method according to any one of Clauses 103 to 112, wherein the temperature is from 55 degrees Celsius to 65 degrees Celsius.

[0472] Clause 116. The method according to any one of Clauses 103 to 115 further comprises circulating a temperature regulating fluid between a temperature control unit and a temperature regulating bracket.

[0473] Clause 117. The method according to any one of Clauses 103 to 117, wherein engaging the mold comprises: positioning the end effector at the mold, wherein a first side of the end effector is on a first side of the mold and a second side of the end effector is on a second side of the mold; and positioning the first side of the end effector to the first side of the mold such that a first protrusion of the first side of the end effector is inserted into a first plate-manipulator keyway of the first side.

[0474] Clause 118. The method according to Clause 117, wherein engaging the mold further comprises positioning the second side of the end effector to the second side of the mold such that a first protrusion of the second side of the end effector is inserted into a first plate-manipulator keyway of the second side.

[0475] Clause 119. The method according to any one of Clauses 103 to 118, wherein engaging the mold further comprises reading an RFID tag of the mold with an RFID reader of the end effector.

[0476] Clause 120. The method according to any one of Clauses 103 to 119 further comprises selecting the mold with the end effector at least partially based on the mold reaching a defined temperature within a temperature regulating temperature range.

[0477] Clause 121. The method according to any one of Clauses 103 to 120, wherein transporting the mold comprises moving the mold in a non-linear path between the mold and the press.

[0478] Clause 122. The method according to any one of Clauses 103 to 120, wherein transporting the mold includes moving the mold in a linear path between the mold and the press.

[0479] Clause 123. The method according to any one of Clauses 103 to 122, further comprising positioning the mold on the platen of the press with the end effector.

[0480] Clause 124. The method according to Clause 123, wherein positioning the mold on the platen further includes inserting a first protrusion extending outward from the platen into a first plate alignment keyway.

[0481] Clause 125. The method according to Clause 123, further comprising circulating temperature regulating fluid through a temperature regulating channel extending through the platen.

[0482] Clause 126. The method according to Clause 123, further comprising: raising the platen supporting the mold within the press; engaging the mold with a common runner plate; aligning the runner outlet of the common runner plate with the runner of the mold; and aligning the gas port of the common runner plate with the gas port of the mold.

[0483] Clause 127. The method according to Clause 126, wherein the common runner plate is a hot runner plate, and the method further comprises circulating temperature regulating fluid through the channels of the common runner plate.

[0484] Clause 128. The method according to Clause 127, wherein the temperature regulating fluid circulating through the channels of the common runner plate is in the range from 20 degrees Celsius to 250 degrees Celsius.

[0485] Clause 129. The method according to any one of Clauses 103 to 128, wherein the gas back pressure is maintained at a pressure of 550 pounds per square inch (psi) to 1500 psi.

[0486] Clause 130. The method according to any one of Clauses 103 to 129, wherein the gas back pressure is supplied by a gas source including carbon dioxide, nitrogen, and / or ambient air.

[0487] Clause 131. The method according to any one of Clauses 103 to 130, wherein the gas back pressure is established before injecting the single-phase solution.

[0488] Clause 132. The method according to any one of Clauses 103 to 131, further comprising: dispensing polymer material formed from the polymer composition from a hopper into a syringe; and mixing the polymer material with a screw of the syringe while heating the polymer material.

[0489] Clause 133. The method according to Clause 132, wherein the polymeric material is in the form of beads, pellets, chips, and / or granules in the hopper.

[0490] Clause 134. The method according to Clause 132, wherein the polymer composition comprises a thermoplastic polyester composition.

[0491] Clause 135. The method according to Clause 132, further comprising heating the polymer composition in the syringe to a temperature of about the melting temperature of the polymer composition to about 50 degrees Celsius above the tail temperature of the thermoplastic elastomer composition.

[0492] Clause 136. The method according to any one of Clauses 103 to 135, further comprising rotating the screw in the syringe at a rate of 20 revolutions per minute (RPM) to 120 RPM.

[0493] Clause 137. The method according to Clause 103, wherein the polymer composition is a thermoplastic copolyester composition.

[0494] Clause 138. The method according to any one of Clauses 103 to 137, further comprising metering the supercritical fluid before introducing the supercritical fluid into the polymer composition.

[0495] Clause 139. The method according to any one of Clauses 103 to 138, further comprising impregnating the polymer composition with the supercritical fluid and using it as a single-phase solution in the syringe for injection into the cavity of the mold.

[0496] Clause 140. The method according to any one of Clauses 103 to 138, wherein the polymer composition is impregnated with the supercritical fluid before being dispensed into the syringe for injection into the cavity of the mold.

[0497] Clause 141. The method according to any one of Clauses 103 to 140, wherein the supercritical fluid is nitrogen in a supercritical fluid state or carbon dioxide in a supercritical fluid state.

[0498] Clause 142. The method according to any one of Clauses 103 to 141, wherein the footwear component has a relative density of 0.1 to 0.6.

[0499] Clause 143. The method according to any one of Clauses 103 to 141, wherein the footwear component has a relative density of 0.1 to 0.4.

[0500] Clause 144. The method according to any one of Clauses 103 to 141, wherein the footwear component has a relative density of 0.1 to 0.3.

[0501] Clause 145. The method according to any one of Clauses 103 to 144, wherein after injecting the single-phase solution, a gas backpressure is maintained in the cavity of the mold at a pressure effective to maintain the single-phase solution as a single-phase solution in the cavity of the mold for 0.5 seconds to 10.0 seconds.

[0502] Clause 146. The method according to any one of Clauses 103 to 144, wherein after injecting the single-phase solution, a gas backpressure is maintained in the cavity of the mold at a pressure effective to maintain the single-phase solution as a single-phase solution in the cavity of the mold for 1 second to 5.0 seconds.

[0503] Clause 147. The method according to any one of Clauses 103 to 146, further comprising: engaging the mold with the end effector at the press; and transferring the mold to the temperature conditioning bracket with the end effector.

[0504] Clause 148. The method according to any one of Clauses 103 to 148, further comprising: reading the RFID tag of the mold with the RFID reader of the end effector; and reading the RFID tag of the mold with the RFID reader of the temperature conditioning bracket.

[0505] Clause 149. The method according to any one of Clauses 103 to 148, further comprising temperature conditioning the mold at the temperature conditioning bracket after injecting the single-phase solution and before removing the footwear component from the cavity of the mold.

[0506] Clause 150. The method according to any one of Clauses 103 to 149, further comprising positioning the mold having the footwear component in the cavity of the mold at a location other than the press for 1 minute to 90 minutes before removing the footwear component from the cavity of the mold.

[0507] Clause 151. The method according to any one of Clauses 103 to 150, further comprising engaging the mold with the end effector at the press, and transferring the mold to an unloading machine with the end effector.

[0508] Clause 152. The method according to Clause 151, further comprising: reading the RFID tag of the mold with the RFID reader of the end effector; and reading the RFID tag of the mold with the RFID reader of the unloading machine.

[0509] Clause 153. The method according to any one of Clauses 103 to 152 further includes opening the mold at the unloading machine.

[0510] Clause 154. The method according to Clause 153, wherein opening the mold at the unloading machine includes causing a first pair of fingers to transition between an unlocked configuration and a locked configuration in a plane parallel to the top surface of the unloading machine plate to secure the mold to the unloading machine.

[0511] Clause 155. The method according to Clause 153, wherein opening the mold at the unloading machine includes inserting a pin into a tool latch assembly of the mold, wherein the pin disengages the tool latch assembly to allow the mold to open.

[0512] Clause 156. The method according to Clause 153, wherein opening the mold at the unloading machine includes lifting a first part of the mold from a second part of the mold, wherein the first part of the mold is secured by an unloading machine arm of the unloading machine and the second part of the mold is secured by at least a first pair of fingers of the unloading machine.

[0513] Clause 157. The method according to Clause 156, wherein opening the mold at the unloading machine includes lifting the first part a first distance, stopping the lifting of the first part for 1 second to 120 seconds, and then lifting the first part a second distance after stopping the lifting of the first part.

[0514] Clause 158. The method according to Clause 153 further includes reading an RFID tag of the mold by an RFID reader of the unloading machine.

[0515] Clause 159. The method according to any one of Clauses 103 to 158, wherein the polymer composition includes: a thermoplastic elastomer composition including a thermoplastic polyester homopolymer, a thermoplastic elastomer composition including a thermoplastic copolyester having two different types of polyester monomer segments, or a combination thereof.

[0516] Clause 160. The method according to any one of Clauses 103 to 159 further includes reducing the temperature of the single-phase solution in the cavity of the mold after injecting the single-phase solution and before reducing the gas back pressure below a pressure effective to maintain the supercritical fluid in a supercritical fluid state.

[0517] Clause 161. The method according to Clause 160, wherein the temperature reduction is in the range from 0.5 degrees Celsius to 50 degrees Celsius.

[0518] Clause 162. The method according to any one of Clauses 103 to 161 further includes, after removing the footwear component from the cavity of the mold, transferring the mold to the temperature conditioning bracket using the end effector.

[0519] Clause 163. The method according to Clause 160, wherein after removing the footwear component from the cavity of the mold, the mold is maintained at the temperature conditioning bracket until the mold is temperature-conditioned to a temperature within the range of 45 degrees Celsius to 80 degrees Celsius.

[0520] Clause 164. A method of physically foaming a footwear component, the method comprising: temperature-conditioning a mold to a temperature of 15 degrees Celsius to 90 degrees Celsius; applying a gas backpressure to the cavity of the mold; injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold; releasing the gas backpressure from the cavity of the mold; and removing the footwear component from the cavity of the mold.

[0521] Clause 165. A method of physically foaming a footwear component, the method comprising: temperature-conditioning a mold to a temperature of 15 degrees Celsius to 90 degrees Celsius at a temperature conditioning bracket; compressing the mold in a press; injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold; and removing the footwear component from the cavity of the mold.

[0522] Clause 166. A method of physically foaming a footwear component, the method comprising: temperature-conditioning a mold to a temperature of 15 degrees Celsius to 90 degrees Celsius at a temperature conditioning bracket; injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold at a press; maintaining the single-phase solution as a single-phase solution in the cavity of the mold for 0.5 seconds to 10.0 seconds before converting the supercritical fluid into a gas; and removing the footwear component from the cavity of the mold.

[0523] Clause 167. A method of physically foaming a footwear component, the method comprising: temperature-conditioning the temperature of a mold to a temperature of 15 degrees Celsius to 90 degrees Celsius at a temperature conditioning bracket; injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold at a press; transferring the mold from the press to a second temperature conditioning bracket; transferring the mold from the second temperature conditioning bracket to an unloading machine; and removing the footwear component from the cavity of the mold.

[0524] Clause 168. A method for physically foaming a footwear component, the method comprising: mating a mold with a hot runner plate and a platen at a press, wherein the hot runner plate is temperature-regulated and the platen is temperature-regulated; injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold at the press; and removing the footwear component from the cavity of the mold.

[0525] Clause 169. A method for physically foaming a footwear component, the method comprising: reading an RFID tag of a mold with an RFID reader of a temperature regulating plate; associating the temperature of the temperature regulating plate with the mold based on the RFID tag; selecting the mold based on the associated temperature; injecting a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the mold at the press; and removing the footwear component from the cavity of the mold.

[0526] Clause 170. A temperature regulating bracket for a physical foaming injection molding system for a footwear component, the temperature regulating bracket comprising: a temperature control unit; a plurality of compartments; a plurality of temperature regulating plates, wherein each of the plurality of compartments includes a temperature regulating plate from the plurality of temperature regulating plates; and a regulating fluid manifold fluidly coupled to the temperature regulating unit and the plurality of temperature regulating plates, wherein the temperature regulating bracket is adapted to regulate the temperature of a mold maintained at the temperature regulating bracket.

[0527] In addition to the specific clauses listed above, additional clause combinations are contemplated herein, and these combinations are part of the scope of the present disclosure. For convenience, each of the following combinations is provided in list format, but is intended to be the same as if written in sentence and / or paragraph form.

[0528] The following specifically listed clauses above may alternatively / additionally be used alone or in any combination depending on clause 98: Clauses 1 to 97.

[0529] The following specifically listed clauses above may alternatively / additionally be used alone or in any combination depending on clause 99: Clauses 1 to 97.

[0530] The following specifically listed cla...

Claims

1. A method for physically foaming a footwear component, the method comprising: At a temperature regulating support, regulate the temperature of a plurality of molds to a temperature between 15 degrees Celsius and 90 degrees Celsius; Select a mold from the plurality of molds at the temperature regulating support, the selection being at least partially based on the selected mold reaching a defined temperature within the temperature regulating temperature range; Engage the selected mold with an end effector of a robot transfer adapted to reversibly engage with the selected mold; Transfer the selected mold to a press with the end effector; Apply a gas back pressure to the cavity of the selected mold; Inject a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the selected mold; Release the gas back pressure from the cavity of the selected mold; And Remove the footwear component from the cavity of the selected mold.

2. The method according to claim 1, further comprising reading an RFID tag of the selected mold with an RFID reader.

3. The method according to claim 1, wherein engaging the selected mold comprises: Position the end effector at the selected mold, wherein a first side of the end effector is on a first side of the selected mold and a second side of the end effector is on a second side of the selected mold; and position the first side of the end effector to the first side of the selected mold such that a first protrusion of the first side of the end effector is inserted into a first plate-manipulator keyway of the first side of the selected mold.

4. The method according to claim 1, wherein engaging the selected mold further comprises reading an RFID tag of the selected mold with an RFID reader of the end effector.

5. The method according to claim 1, further comprising selecting the selected mold with the end effector at least partially based on the selected mold reaching a defined temperature within a temperature regulation temperature range.

6. The method according to claim 5, further comprising: Position the selected mold on a platen of the press with the end effector; Raise the platen supporting the selected mold within the press; Engage the selected mold with a common runner plate; align a runner outlet of the common runner plate with a runner of the selected mold; And align a gas port of the common runner plate with a gas port of the selected mold.

7. The method according to claim 6, wherein the common runner plate is a hot runner plate, and the method further comprises circulating a temperature regulating fluid through channels of the common runner plate.

8. The method according to claim 7, wherein the temperature regulating fluid circulating through the channels of the common runner plate is in a range from about 20 degrees Celsius to about 250 degrees Celsius.

9. The method according to claim 1, wherein the polymer composition is a thermoplastic polyester composition.

10. The method according to claim 1, wherein the footwear component has a relative density of 0.1 to 0.

6.

11. The method according to claim 1, wherein after injecting the single-phase solution, a gas backpressure is maintained in the cavity of the selected mold at a pressure effective to maintain the single-phase solution as a single-phase solution in the cavity of the selected mold for about 0.5 seconds to about 10.0 seconds.

12. The method according to claim 1, further comprising: Engage the selected mold with the end effector at the press;And transfer the selected mold to the temperature regulating support with the end effector.

13. The method according to claim 1 further comprises: Read an RFID tag of the selected mold with an RFID reader of the end effector; And read the RFID tag of the selected mold with an RFID reader of the temperature regulating support.

14. The method according to claim 1 further comprises thermally conditioning the selected mold at the temperature conditioning bracket after injecting the single-phase solution and before removing the footwear component from the cavity of the selected mold.

15. The method according to claim 1 further comprises positioning the selected mold having the footwear component in the cavity of the selected mold at a location other than the press for a duration of from about 1 minute to about 90 minutes before removing the footwear component from the cavity of the selected mold.

16. The method according to claim 1 further comprises reducing the temperature of the single-phase solution in the cavity of the selected mold after injecting the single-phase solution and before reducing the gas backpressure below a pressure effective to maintain the supercritical fluid in a supercritical fluid state.

17. The method according to claim 1 further comprises transferring the selected mold back to the temperature conditioning bracket using the end effector after removing the footwear component from the cavity of the selected mold.

18. A method of physically foaming a footwear component, the method comprising: At a temperature regulating support, regulate the temperature of a plurality of molds to a temperature of about 15 degrees Celsius to about 90 degrees Celsius; Select a mold from the plurality of molds at the temperature regulating support, the selection being at least partially based on the selected mold reaching a defined temperature within the temperature regulating temperature range; Apply a gas back pressure to the cavity of the selected mold; Inject a single-phase solution of a polymer composition and a supercritical fluid into the cavity of the selected mold; Release the gas back pressure from the cavity of the selected mold; And Remove the footwear component from the cavity of the selected mold.

19. The method according to claim 18 further comprises thermally conditioning the selected mold at the temperature conditioning bracket after injecting the single-phase solution and before removing the footwear component from the cavity of the selected mold.

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