System for manufacturing footwear components

Abstract

A system including a syringe, a press, and a robotic transfer device is used to form a physically foamed footwear article component from a single-phase solution of a polymeric composition and a supercritical fluid. Parameters and features of the system are configured for forming footwear components in an automated manner with increased throughput of the system.

Description

Technical Field

[0001] This article relates to systems and methods for forming physically foamed footwear or other clothing or equipment components. Background Technology

[0002] Injection molding is used to manufacture various components of footwear products, such as shoe soles, shoe uppers, and parts of shoe soles or uppers (e.g., cushioning elements, trimmings, etc.). For example, in some cases, the injection molding system is used to distribute a polymer melt into the cavity of a mold, after which the polymer melt solidifies into a polymer product having the shape of the mold cavity. In some cases, such as when manufacturing shoe soles (e.g., all or part of a shoe 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 that are different from those configured to mold non-foamed polymer products. For example, some injection molding systems both foam and mold polymer compositions. Summary of the Invention

[0003] The present invention is provided to introduce, in a simplified form, the selection of concepts further described below in the detailed description. The present 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, this disclosure relates to systems and methods for physically foaming using injection molding systems configured to mold various articles. Attached Figure Description

[0004] Some of the subjects described in this disclosure include systems, tools, and methods for injection molding systems for molding physically foamed parts. The subject matter is described in detail below with reference to the accompanying drawings, which are submitted with this specification and are incorporated herein by reference:

[0005] Figure 1 The components of footwear products are described according to various aspects of this article;

[0006] Figure 2 A schematic plan view of a footwear component manufacturing system in a first configuration, according to various aspects of this article, is depicted;

[0007] Figure 3 A schematic plan view of a footwear component manufacturing system in a second configuration, according to various aspects of this paper, is depicted;

[0008] Figure 4 A perspective view of the temperature regulating bracket and temperature control unit according to various aspects of this article is depicted;

[0009] Figure 5 This describes a multi-mold design based on various aspects of this article. Figure 4Temperature regulating bracket and temperature control unit;

[0010] Figure 6 Depicting various aspects based on this article Figure 5 Rear perspective view of the temperature regulating bracket;

[0011] Figure 7 An end effector in a first configuration is described according to various aspects of this paper;

[0012] Figure 8 Depicting the second configuration according to various aspects of this article Figure 7 The end effector;

[0013] Figure 9 A perspective view of the mold based on various aspects of this article is depicted;

[0014] Figure 10 Depicting various aspects based on this article Figure 9 Side view of the mold;

[0015] Figure 11 A perspective view of the press is depicted according to various aspects of this article;

[0016] Figure 12 Describing the first configuration based on various aspects of this article Figure 11 Front view of the press;

[0017] Figure 13 The second configuration of the mold, as described in this article, is depicted according to various aspects. Figure 11 Front view of the press;

[0018] Figure 14A A perspective view of a mold that connects with a hot runner plate to form a tool assembly, according to various aspects of this paper, is depicted.

[0019] Figure 14B Depicting various aspects based on this article Figure 14A A partial exploded view of the tool assembly, showing the second mold plate separated from the mold ring plate;

[0020] Figure 15A Depicting various aspects based on this article Figure 14A Front view of the mold and hot runner plate;

[0021] Figure 15B Depicting various aspects based on this article Figure 15A Internal components of the hot runner plate;

[0022] Figure 15C It describes the various aspects of this article. Figure 15B A cross-sectional view taken from line 15C-15C in the diagram;

[0023] Figure 16 Depicting various aspects based on this article Figure 14A Side view of the mold and hot runner plate;

[0024] Figure 17 Depicting various aspects based on this article Figure 14A A bottom view of the mold and hot runner plate;

[0025] Figure 18A The alignment with the syringe is described according to various aspects of this article. Figure 11 The press;

[0026] Figure 18B The injection manifold is described according to various aspects of this article;

[0027] Figure 19 The press and syringe of Figure 18a are depicted according to various aspects of this article;

[0028] Figure 20 A perspective view of the syringe shown in Figure 18 according to various aspects of this article is depicted;

[0029] Figure 21 Depicting various aspects based on this article Figure 20 A side view of the syringe;

[0030] Figure 22 The section cut along section line 22-22 is depicted based on various aspects of this paper. Figure 21 A cross-sectional view of the syringe;

[0031] Figure 23 A perspective view of the unloading machine based on various aspects of this article is depicted;

[0032] Figure 24 Depicting various aspects based on this article Figure 23 Side view of the unloading machine;

[0033] Figure 25 Depicting the first configuration according to various aspects of this article Figure 24 A cross-sectional view of the unloading machine;

[0034] Figure 26 The mold in the second configuration is described according to various aspects of this article. Figure 24 A cross-sectional view of the unloading machine;

[0035] Figure 27 A flowchart depicting a first method for physically foaming footwear components according to various aspects of this article is provided;

[0036] Figure 28 A flowchart is depicted representing a second method for physically foaming footwear components according to various aspects of this article;

[0037] Figure 29 A flowchart is depicted representing a third method for physically foaming footwear components according to various aspects of this article;

[0038] Figure 30 A flowchart illustrating a fourth method for physically foaming footwear components according to various aspects of this article is provided; and

[0039] Figure 31 A flowchart depicts a workflow process for manufacturing foamed polymer articles (such as segments of footwear) from virgin and recycled thermoplastic polymer elastomer compositions. Detailed Implementation

[0040] Footwear articles may include a variety of components formed from foamed polymer compositions. For example, soles, which may include insoles, midsoles, and / or outsoles, can be formed from foamed polymer compositions. Other components, such as inserts, padding, uppers, etc., are also envisioned components of footwear articles that can be formed from foamed polymer compositions. Depending on the polymer composition, how the polymer composition is foamed, and other process variables, foamed components may present challenges in terms of recycling or other sustainable disposal at the end of their service life or when scrapped during manufacturing. The systems and methods provided herein can form foamed polymer composition components that are more suitable for recycling, reuse, and / or reprocessing than conventionally formed foamed polymer compositions.

[0041] However, developing systems and methods for producing foamed polymer composition components suitable for footwear products while still providing improved sustainability is challenging. 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 of the foamed polymer components. This is achieved by manipulating the components of the system, the parameters of the system component operation, the foamed polymer composition, and the foaming process used to foam the polymer composition. As will be illustrated in detail below, combinations of two or more variables provide solutions for forming foamed polymer compositions that provide enhanced environmental sustainability results.

[0042] For example, the systems and methods provided herein envision physically foaming thermoplastic elastomer compositions, comprising thermoplastic polyester compositions (i.e., polymer compositions comprising one or more thermoplastic polyester elastomers), in a temperature-controlled mold. However, the process of physically foaming thermoplastic elastomer compositions is highly sensitive to manufacturing variables such as time, pressure, and temperature. Accordingly, the identification of various manufacturing processes and specific variables for producing parts with acceptable physical foaming has been developed through continuous investment in time, experimentation, and resources. The resulting tools, parts, processes, and manufacturing controls are provided below.

[0043] Physical foaming is a process of foaming a polymer composition using a physical foaming agent (as opposed to a chemical foaming agent). Inert compositions (such as nitrogen or carbon dioxide (CO2)) are examples of physical foaming agents contemplated herein. In these examples, unlike chemical foaming agents, which effectively foam polymer compositions through an outgassing effect (such as raising the temperature of a chemical foaming agent above its degradation temperature), physical foaming agents effectively foam polymer compositions by inducing pressure changes. In some examples, physical foaming agents can be in a gaseous, liquid, and / or supercritical fluid state. For example, a physical foaming agent can be a supercritical fluid that, when exposed to a reduced pressure (e.g., below the critical pressure of the physical foaming agent), releases from the solution, causing foaming to occur.

[0044] Supercritical fluids are fluids in a supercritical fluid phase, with temperatures and pressures above the critical point of the composition. For example, nitrogen has a critical point of -147°C and 34.0 bar, and carbon dioxide has a critical point of 31.2°C 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, causing the supercritical fluid to undergo a phase transition from a supercritical fluid state to a gaseous state as the pressure decreases below the critical pressure. The phase transition of the physical foaming agent causes it to be released from the solution containing the polymer composition. This creates a cell structure in the polymer composition that produces foamed polymer parts. It is conceivable that other phase transitions and / or pressure differences may also be combined with the physical foaming agent to foam the polymer composition.

[0045] This article includes aspects of a physical foaming injection molding system for footwear components. The envisioned system involves foaming a single-phase solution comprising a polymer composition and a supercritical fluid. The system includes an injector and a press paired with the injector. To achieve efficiency in the manufacturing process in an automated manner, the system also includes a robot comprising an end effector adapted for reversible engagement with a mold. The mold is configured to engage with the injector and press in such a way that the robot is positioned relative to the press to allow the end effector to reversibly engage with the mold.

[0046] This document also includes a physical foaming injection molding system for footwear components, comprising a temperature control unit and a temperature regulating bracket effectively coupled to the temperature control unit. The temperature regulating bracket is adapted to regulate and maintain the temperature of the mold at the temperature regulating bracket. The syringe includes a physical foaming agent port and a physical foaming agent supply source fluidly coupled to the physical foaming agent port of the syringe. The system also includes a press paired with the syringe. The system also includes an unloading machine having a frame, an unloading machine plate, and a pair of unloading machine arms that move co-located in a first direction and discontinuously in a second direction. The system also includes a robot with an end effector adapted for reversible engagement with the mold. The robot is positioned relative to the temperature regulating bracket, the press, and the unloading machine to manipulate the end effector at the temperature regulating bracket, the press, and the unloading machine to reversibly engage with the mold. As will be provided below, one or more of the listed components may be omitted, substituted, or added. Furthermore, the arrangement of various components of the system can be adjusted.

[0047] This paper also envisions a method for physically foaming footwear components, which involves conditioning a mold to a temperature between 15 and 90 degrees Celsius and then engaging the mold with an end effector suitable for reversible engagement with a robot. The method continues by conveying the mold to a press using the end effector and then applying a gas back pressure to the mold cavity to pressurize it. In an example, the gas back pressure is at or above the critical pressure of the physical foaming agent in a single-phase solution to be injected into the mold. The method continues, wherein a single-phase solution of a polymer composition and a supercritical fluid is injected into the mold cavity. The method then continues, wherein the gas back pressure is released from the mold cavity, and the footwear component is then finally removed from the mold cavity. Additional or alternative steps may be implemented, as will be provided in more detail below. Furthermore, one or more steps may be omitted in some examples.

[0048] One type of injection molding system for foamed and molded polymer compositions uses a microcellular injection molding process, in which one or more supercritical fluids (e.g., supercritical nitrogen, supercritical carbon dioxide, etc.) are used as physical foaming agents. For example, a supercritical fluid can be injected into the polymer melt contained in the injection barrel of the 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 allowed to flow into a mold cavity, where conditions are adjusted to cause the supercritical fluid to transform into a gas (e.g., nucleate into a gas) and 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, maintain the shape of the foamed polymer product.

[0049] These types of injection molding systems using microcellular injection molding processes are typically configured to control system parameters that can affect the properties of the foam 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 stages where the single-phase solution is formed, and between the stages where the single-phase solution is delivered to the mold. Additionally, parameters can be controlled between molds. These stages can independently and / or collectively influence the melting, mixing, and molding processes.

[0050] Conventional injection molding systems are configured to perform microcellular injection molding processes. However, the properties of parts molded using these systems are typically limited, meaning that the operating parameters and tooling of conventional systems are often not calibrated to mold parts with different properties. For example, parts molded in conventional systems may have relatively thin part thickness or wall thickness, preventing the conventional system from producing thicker parts with the desired characteristics.

[0051] Turn Figure 1 This describes a footwear article component 100 according to various aspects thereof. Footwear article component 100 is a sole. As previously discussed, any foamed component is contemplated to be manufactured using the systems and methods disclosed herein, but in this instance, footwear article component 100 is a footwear sole (e.g., a footwear midsole). Footwear component 100 has an upper surface 102, a lower surface 104, a toe cap 106, a heel cap 108, a lateral surface 110, and a medial surface 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, both of which are based on the conventional orientation of footwear articles during their intended use.

[0052] Footwear component 100 can be of any size, but includes shoe sizes where the length between at least the toe cap 106 and the heel cap 108 ranges from 127 mm to 342 mm. Footwear component 100 has a width that can be of any size (e.g., ranging from 70 mm to 135 mm), measured perpendicularly to a line extending between the extreme points at the toe cap 106 and the heel cap 108 on the widest portion of the footwear component between the inner side 112 and the outer side 110. Footwear component has a thickness that can be of any thickness, but in this example, the thickness at the thickest point between the upper surface 102 and the lower surface 104 is from 1 mm to 80 mm.

[0053] Accordingly, it is envisioned that the systems and methods provided herein effectively form foamed polymer parts with a relatively significant volume compared to articles formed by conventional physical foaming operations. Furthermore, the foamed parts produced by the systems and methods disclosed herein can have a high foaming ratio (e.g., the volume of non-polymer components relative to the volume of the polymer composition in the resulting foamed article) compared to articles formed by conventional physical foaming. For example, some foamed parts formed by the methods and systems provided herein have foaming ratios ranging 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 between them. In other words, it is envisioned that a footwear part with a foaming ratio of 80:20 has 20% of the part volume formed by the polymer composition, and the remaining 80% of the foamed part volume is the open volume of the cell structure formed as a result of the foaming process (e.g., the non-polymer composition). In another way of characterizing the foam composition, relative density can be expressed. The relative density of a foamed article (e.g., a foamed footwear component) is the density of the foamed article divided by the material forming the foamed article (e.g., a polymer composition). Therefore, it is envisioned that footwear components have a relative density in the range of 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 a relative density somewhere in between. This high foaming ratio produces foamed components suitable for use as footwear components.

[0054] It is envisioned that alternative sizes, shapes, and styles of soles can be formed using the provided systems and methods. It is also envisioned that alternative components can be formed using the provided systems and methods. For example, but not limited to, it is envisioned that insoles, midsoles, outsoles, inserts, or other foot support structures can be formed using the systems and methods provided herein. Additionally, footwear uppers, components of footwear uppers, or other components of footwear articles can also be formed using the methods and systems provided herein. Footwear component 100 is a non-limiting example of a footwear component that can be formed using the methods and systems provided herein.

[0055] Figure 2A schematic plan view of a footwear component manufacturing system 200 in a first configuration, according to various aspects of this document, is depicted. System 200 is configured to move tools (such as molds) through various system components (such as syringes 212). Moving a tool to a syringe, rather than moving a syringe to a tool, helps achieve a greater throughput in manufacturing footwear components. For example, by moving a tool to a syringe, the syringe can inject during the time it would take to move in an alternative configuration where the syringe is instead moved to a tool. Additionally, because various footwear component sizes (e.g., different sole sizes for different shoe sizes) can be manufactured within a common time period, the specific tool moving to the syringe can be adjusted to meet production demands. In an alternative configuration where the syringe is moved to a tool, travel time may increase when the syringe is forced to travel through tools that do not meet current production demands. Accordingly, moving a tool to a syringe (as provided in system 200) improves efficiency through flexible manufacturing. In alternative instances, it is envisioned that the syringe moves to two or more locations within the system, such as between two or more tool locations.

[0056] System 200 includes, in a clockwise order, a temperature regulating bracket 202, a temperature control unit 228, a temperature regulating bracket 204, a temperature regulating bracket 206, a temperature control unit 230, a temperature regulating bracket 208, a controller 216, a physical foaming 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 back pressure source 226, an unloader, a robot 232, and an end effector 234. Each component of system 200 will be discussed individually below.

[0057] The tool (mold 201) is depicted as a dashed line at various components of system 200 (e.g., temperature regulating bracket 202, press 210, unloading machine 214). The mold 201 is depicted as a dashed line to emphasize that it is momentary in system 200 and therefore can be positioned at or not positioned at one or more components at a specific time. The mold 201 is configured to receive an injection of a polymer composition from syringe 212 at press 210. The injected polymer composition is formed into a foamed article within the mold. Examples of molds 201 will be described and discussed in more detail below, such as... Figures 9 to 10 and Figures 14A to 17 Mold 900.

[0058] Combining Figures 4 to 6The temperature regulating bracket 202, discussed in more detail, is a temperature regulating bracket that effectively regulates the temperature of a mold. Temperature regulation is the process of influencing the temperature of a regulated article to a target temperature. Temperature regulation can raise or lower the temperature of the article to the target temperature. For example, before injecting the molten polymer composition into the cavity of a mold, temperature regulation can effectively raise the temperature of the mold (e.g., mold 201) from ambient conditions. Temperature regulation can also (or alternatively) effectively lower the temperature of mold 201 from the post-injection temperature caused by the injection of the molten polymer composition. This post-injection temperature regulation can reduce the time required for the cell structure of the foamed article to reach sufficient structural stability within the mold for removal from the mold cavity. Accordingly, it is envisioned that the temperature regulating bracket 202 can be used to regulate the temperature of mold 201 before injection and after injection. In the example, the ability to regulate the temperature of mold 201 with the temperature regulating bracket 202 before injecting a single-phase solution into the cavity of mold 201 results in the formation of a uniformly physically foamed article within mold 201.

[0059] The temperature regulating bracket 202 includes a radio frequency identification (RFID) reader 238. The RFID reader 238 is configured to transmit signals that can be emitted by RFID tags (such as...). Figure 17 The RFID tag 1708 receives an electromagnetic interrogation pulse. In response, the RFID tag responds with information received by the RFID reader 238. This information can be static information of a given RFID tag, or it can be dynamic information stored by the RFID tag and provided in response. In either case, it is assumed that the RFID reader 238 effectively receives information from the RFID tag. In use, the mold or other tool includes an RFID tag, which is interrogated by the RFID reader 238 to determine what associated tool is present at the temperature regulating bracket 202. As will be... Figure 4 As seen in the diagram, the envisioned temperature regulating bracket 202 comprises multiple compartments, and each compartment includes a unique RFID reader (e.g., RFID reader 438). Thus, each RFID reader effectively identifies a specific RFID tag present in each of the compartments of the temperature regulating bracket (and therefore identifies the associated mold with the specific RFID tag associated with it). Therefore, specific knowledge of the mold and its location within the temperature regulating bracket is obtained through the multiple RFID readers used in the temperature regulating bracket.

[0060] While various components / parts / systems of system 200 are discussed as including RFID readers (e.g., RFID reader 238 for temperature regulating bracket 202), one or more RFID readers from one or more of the components of system 200 can be completely omitted. For example, due to the automated nature of system 200, which limits or eliminates human intervention, system 200 effectively maintains knowledge of the tool positions within system 200 at all times, as the tool positions are controlled by components of system 200 (e.g., robot 232). In this example, system 200 can determine the tool position (even without relying on RFID verification) by recording changes in the tool position by system 200. However, it is also contemplated to use verification systems, such as RFID, visual codes (e.g., QR codes, barcodes), or other tracking technologies capable of using radio frequency, to ensure verification of the tool position, thereby further limiting potential manufacturing challenges.

[0061] The temperature regulating bracket 202 also includes a thermocouple 240 configured to measure temperature. In an example, the thermocouple 240 may be an electrical device that generates a temperature-related voltage or resistance (e.g., a resistance temperature detector (RTD)) that is interpreted as the measured temperature. The thermocouple 240 effectively measures the temperature of the mold within the temperature regulating bracket 202. Alternatively, and as will be... Figures 4 to 6 As discussed in more detail below, thermocouples can effectively measure the temperature of a temperature regulating plate on which a mold is placed. The temperature regulating plate 203 is a support structure for the temperature regulating bracket 202, configured to regulate the temperature of the tool (e.g., mold 201) supported by the temperature regulating plate 203. This will be discussed in more detail below. Figure 4 The temperature regulating plate 203 will be discussed in more detail as a temperature regulating plate 416, which is an example of a temperature regulating plate 203. As will be provided herein, it is envisioned that system 200 includes a plurality of temperature regulating plates 203. For example, each compartment of temperature regulating brackets 202, 204, 206 and 208 may include a temperature regulating plate, such as temperature regulating plate 203.

[0062] In this example, temperature regulating plate 203 is configured to regulate the temperature of the tool using heat conduction. Conduction allows heat energy to transfer between the tool (e.g., mold 201) and the temperature regulating plate (e.g., temperature regulating plate 203). Over time, the temperature of the tool converges to the temperature of the temperature regulating plate via conduction. Therefore, the temperature measurement of temperature regulating plate 203 is used as an approximation or representative value of the temperature of mold 201 maintained at temperature regulating plate 203. Thus, thermocouple 240 effectively measures or estimates the temperature of mold 201 (or any tool) maintained in the temperature regulating support 202 on temperature regulating plate 203. Based on the temperature measured by thermocouple 240, system 200 is able to determine whether the temperature of mold 201 is suitable for receiving injection or for removing foamed components from it.

[0063] The descriptions of temperature regulating brackets 204, 206, and 208 are similar to those of temperature regulating bracket 202. However, it is contemplated that each of the temperature regulating brackets 202, 204, 206, and 208 may vary in size, location, configuration, and components. In this example, each of the temperature regulating brackets 202, 204, 206, and 208 may regulate the temperature of a tool (such as mold 201) to different or similar temperatures. Furthermore, temperature regulating bracket 204 includes an RFID reader 242 and a thermocouple 244, temperature regulating bracket 206 includes an RFID reader 246 and a thermocouple 248, and temperature regulating bracket 208 includes an RFID reader 250 and a thermocouple 252.

[0064] Temperature control unit 228 effectively manipulates the temperature of the temperature-regulating fluid to a target temperature. Temperature control units (such as temperature control unit 228) effectively heat and / or cool the fluid circulating therethrough. Temperature control unit 228 may include a heat exchanger that effectively extracts or introduces heat energy to / from the temperature-regulating fluid. In some cases, temperature control unit 228 includes a refrigerant that effectively cools the temperature-regulating fluid. In some cases, temperature control unit 228 includes a heating element (e.g., a resistance heater, combustion chamber, induction coil) (not shown) that effectively heats the temperature-regulating fluid. It is also contemplated that temperature control unit 228 includes a circulation pump (not shown) that effectively circulates the temperature-regulating fluid (e.g., pumps the temperature-regulating fluid).

[0065] The temperature control unit 228 is fluidly connected to the temperature regulating bracket 202. Fluid connection (or fluid coupling) indicates a connection that effectively circulates or transfers fluid between at least two components. A fluid connection may include a hose, pipe, channel, conduit, or other conduit effectively used for fluid transfer between the components of the fluid connection. Figures 4 to 6 In more detail, the temperature control unit 228 may be fluidly connected to the temperature regulating bracket 202 via at least one manifold that effectively distributes circulating temperature regulating fluid among multiple compartments (or temperature regulating plates 203 in each compartment) to achieve the desired temperature at each of the targets (e.g., compartments, temperature regulating plates).

[0066] The descriptions of temperature control units 230 and 224 are similar to those of temperature control unit 228. However, it is envisioned that each of the temperature control units may have different configurations, settings, capacities, etc. For example, it is envisioned that temperature control units 228 and 230 circulate the temperature-regulating fluid at a first temperature (e.g., in the range of 15 degrees Celsius to 90 degrees Celsius), and temperature control unit 224, which is fluidly connected to compressor 210, operates at a second temperature. If temperature control unit 224 is connected to the hot runner plate of compressor 210 (e.g., Figure 11 If the hot runner plates 1116 and 1212 are fluidly connected, the second temperature can be higher than the first temperature, as will be discussed in more detail below. For example, although temperature control units 228 and 230 are configured to regulate the temperature-regulating fluid to a temperature ranging from 15 degrees Celsius to 90 degrees Celsius, in this example, temperature control unit 224 is configured to regulate the temperature-regulating fluid to a temperature ranging from 20 degrees Celsius to 250 degrees Celsius. In other words, depending on the component whose temperature is regulated by temperature control units 224, 228, and 230, temperature control units 224, 228, and 230 can provide temperature-regulating fluids of different temperatures to the corresponding connected components.

[0067] Each temperature control unit 224, 228, 230 may serve one or more components. For example, temperature control unit 228 is envisioned to be fluidly connected to temperature regulating brackets 202 and 204. Temperature control unit 230 is envisioned to be fluidly connected to temperature regulating brackets 206 and 208. Temperature control unit 224 is fluidly connected to compressor 210. (As will be...) Figures 11 to 1 As discussed in more detail in section 8, in this example, the temperature control unit 224 can serve the pressure plates of the press 210 (e.g., Figure 11 The pressure plate 1110) and / or the hot runner plate of the press 210 (e.g., Figure 12 Hot runner plates 1116 and 1212).

[0068] While system 200 is discussed as having a fluid connection between the 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 components. For example, induction heating, piezoelectric and thermoelectric effect devices, resistance heaters, etc., may alternatively be used for temperature regulation of one or more components of the system.

[0069] If in Figures 12 to 19As discussed in more detail below, the press 210 holds the mold 201 in place for receiving the injected polymer composition from the syringe 212. Additionally, the press 210 effectively serves as a conduit for gas back pressure from the gas back pressure source 226 to the mold 201. The press 210 also supports a manifold (e.g., Figure 13 The injection manifold 1120 is configured to distribute a polymer composition from the syringe 212 into a mold. Additionally, the press 210 supports one or more general-purpose flow channels that function as conduits (e.g., Figure 14A The hot runner plate 1116 and the second hot runner 1212), having a manifold of polymer composition (e.g., Figure 13 The injection manifold 1120 extends through these conduits and, in the case of a hot runner, is configured to regulate temperature during fluid communication from the syringe 212 to the mold. The press 210 also includes an RFID reader 254. The RFID reader 254 effectively identifies RFID tags associated with the mold 201 at the press 210. As with other components of the system 200, the identification of the mold 201 allows the controller 216 to monitor the production, tooling, and components used to efficiently manufacture the physically foamed footwear parts.

[0070] In Figures 19 to 22 The syringe 212, discussed in more detail herein, is configured to form a single-phase solution comprising a molten polymer composition and a physical foaming agent. As discussed herein, the physical foaming agent may be a supercritical fluid supplied from a metering feed source 220 and introduced into the polymer composition at the syringe 212. Additionally or alternatively, the physical foaming agent may impregnate the polymer composition supplied to the syringe 212. The hopper 222 is a device for supplying the polymer composition to the syringe 212. The polymer composition may be supplied from the hopper 222 in various media, such as granules, beads, fragments, regrinding waste, and / or particles. Example compositions for polymer materials are discussed below.

[0071] Injector 212 (also referred to as an injection barrel, injection system, and / or injection machine) melts and / or shears the polymer composition supplied by hopper 222 to produce a molten polymer composition by applying heat and / or pressure. In a contemplated example, injector 212 is also responsible for introducing a physical foaming agent (e.g., a supercritical fluid supplied from metering feed source 220) into the polymer composition to form a single-phase solution of the polymer composition and the physical foaming agent. In this example, the conditions within injector 212 must be able to support the supercritical fluid in a supercritical state. In other words, when the supercritical fluid is introduced, the conditions within injector 212 are at a temperature and pressure higher than the critical temperature and critical pressure of the introduced supercritical fluid. Injector 212 is then responsible for metering (e.g., metering) the single-phase solution to press 210. As previously described, injector 212 is contemplated via an injection manifold (e.g., Figure 11 The injection manifold 1120) and the hot runner plate (e.g., Figure 14A The hot runner plates 1116, 1212 are paired to ultimately form a fluid connection with the mold 201 held at the press 210, into which a metered single-phase solution is injected.

[0072] Metering source 220 effectively prepares and measures a physical foaming agent for introduction into syringe 212 and impregnation with a polymer composition. For example, metering source 220 is fluidly connected to physical foaming agent supply source 218 and prepares the physical foaming agent supplied by physical foaming agent supply source 218 for introduction into syringe 212 via a fluid connection between physical foaming agent supply source 218 and syringe 212. In an example, 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 physical foaming agent supply source 218 to a different state, such as a supercritical fluid. In an example, this phase transition is achieved through a pressure difference with a pressure above the critical pressure of the inert substance. Furthermore, metering source 220 also effectively measures (e.g., measures) a defined amount of physical foaming agent for use in the polymer composition prepared by syringe 212 for injection.

[0073] Specifically, for the manufacture of physically foamed footwear components, various sizes, volumes, and / or shapes will be formed by a series of injections using syringe 212. For example, the syringe will inject a single-phase solution into mold 201, which may be a first size of a first style at the first injection, and then the next and immediate injection will be for a second size and second style of footwear component. Thus, different volumes of single-phase solution will be metered by syringe 212 based on the footwear component to be formed at press 210 for a given mold. With each change in injection volume, a different metered amount of physical foaming agent is supplied to syringe 212 by metering source 220. This differs from conventional physically foaming injection operations, where a consistent injection volume is injected into a common mold in continuous injections. Because footwear components are formed in various sizes corresponding to various shoe sizes, a dynamic metering solution is incorporated in system 200 as metering source 220, in contrast to a static metering solution that is set and maintained.

[0074] The physical foaming agent supply source 218 may be a tank, cylinder, container, generator, or other component that effectively stores or generates a physical foaming agent effectively for use in system 200. The physical foaming agent supply source 218 is fluidly connected to a metering feed source 220; therefore, the physical foaming agent supply source 218 may be a supply line or other remote solution for storing, maintaining, and / or generating physical foaming agents.

[0075] Gas backpressure source 226 is fluidly connected to press 210 and effectively supplies backpressure to the mold positioned at press 210 before and / or during the injection of the polymer composition into the mold. Gas backpressure source 226 is configured to supply gas backpressure in the range of 500 pounds per square inch (psi) to 1,500 psi. However, it is contemplated that pressures above and below this range can be used to achieve foamed articles in system 200. In a first instance, gas backpressure source 226 is a compressor or other pressure generating device that effectively converts gas from a first pressure to a second, higher pressure. For example, the second pressure may be at or above the critical pressure of a supercritical fluid of a single-phase solution to be injected into mold 201. Gas backpressure source 226 effectively delivers backpressure via press 210 to a cavity (e.g., within the mold 201 positioned at press 210) Figure 14B The cavity 1420 is pressurized. When the single-phase solution is transferred from the syringe through the manifold to the mold, pressurizing the mold cavity with back pressure allows the single-phase solution in the volume injected into the cavity to remain a single-phase solution (e.g., to prevent foaming). In this way, the initiation of foaming can be controlled based on the release of back pressure, rather than being initiated immediately upon injection. This control over the initiation time of foaming (e.g., reducing the pressure below the critical pressure of the physical foaming agent) also allows system 200 to compensate the molten polymer to achieve the appropriate temperature before foaming. Accordingly, using gas back pressure allows system 200 to achieve the desired foaming time, the desired dispersion of the polymer material in the mold cavity before foaming, and the desired polymer temperature before foaming. In other words, the gas back pressure source 226 allows mold 201 to maintain the single-phase solution as single-phase until system 200 is ready to initiate foaming of the polymer material.

[0076] The gas backpressure source 226 includes a regulator 225 that effectively achieves and maintains a defined pressure within the mold cavity of the mold 201. The regulator 225 is effective in at least two phases. In the first phase, gas backpressure is introduced into the mold cavity before (or during) the injection of the single-phase solution into the cavity. Regardless of whether the gas pressure at the gas backpressure source 226 is at or above the set pressure, the regulator 225 effectively ensures that the pressure experienced within the mold cavity is the set pressure. The second phase occurs during the injection phase. When 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. Without the regulator 225, the volume consumption caused by the polymer composition could lead to an increase in pressure within the mold cavity. However, the regulator 225 effectively equalizes the cavity pressure with the volume change experienced during injection. Since some instances 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 achieving pressure control.

[0077] The gas back pressure source 226 can supply any suitable fluid as gas back pressure. In one example, the gas back pressure source 226 supplies a gas with a composition similar to that of the physical foaming agent. For example, if the physical foaming agent is nitrogen, the gas back pressure source 226 supplies nitrogen. If the physical foaming agent is carbon dioxide, the gas back pressure source 226 supplies carbon dioxide. It is also contemplated that the gas back pressure source 226 supplies air as back pressure to the mold cavity, which can be regulated to adjust humidity or temperature. Furthermore, it is contemplated that the gas back pressure source 226 supplies any inert gas, regardless of the composition of the physical foaming agent. In yet another contemplated example, the gas back pressure source 226 is fluidly connected to the physical foaming agent supply source 218 as a source of gas supplied by the gas back pressure source 226 to the press 210 holding the mold.

[0078] Unloader 214 (will be combined below) Figures 23 to 26 (Discussed in more detail) Effectively opens the mold 201 containing the foamed footwear component. The opening of the mold 201 allows the foamed footwear component to be removed from the mold 201. After the foamed component has reached a sufficient temperature to provide dimensional stability for the foamed component during and after removal, the unloading machine 214 receives the mold 201 with the foamed component in the cavity of the mold. The temperature may be indirectly determined based on the time elapsed after the injection of the polymer composition and / or based on the temperature regulation of the mold 201 at a temperature regulating bracket (e.g., temperature regulating bracket 2020) after the injection of the polymer composition. The unloading machine 214 effectively opens the mold 201 containing the foamed component in the first part of the mold (e.g., Figure 9 The first support plate 908) is engaged to secure the mold 201 to the unloading machine 214, while the unloading machine 214 is engaged with the second part of the mold 201 (e.g., Figure 9 The second support plate 906 engages with the mold 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 allow the foaming component to be removed from the cavity within the mold and to clear one or more runners of the mold. The unloading machine 214 also includes an RFID reader 256, which effectively reads the RFID tag (e.g., ...) of the mold 201 located at the unloading machine 214. Figure 17 (RFID tag 1708). Like other RFID readers in system 200, RFID reader 256 can be used to identify, verify, and locate tools during operation of system 200.

[0079] In this example, robot 232 is a multi-axis articulated robot manipulator that effectively positions end effector 234 at least at temperature regulating supports 202, 204, 206, 208, press 210, and / or unloader 214. 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 tamed assembly robot arm (SCARA) robot or a humanoid robot is a contemplated robot configuration. In some instances, robot 232 extends about the Z-axis of system 200 (extending to...). Figure 2 The robot 232 can rotate and move along the Z-axis (outside of the plan view), allowing the end effector 234 to be positioned at different heights within the system 200. In this example, the Z-axis defines the point of rotation of the robot 232 around it and defines an arcuate motion path 236. As the end effector 234 is positioned at or within various components of the system 200, the robot also moves in the X and Y-axis directions to pick up and place the mold 201. It is also envisioned that in some instances the robot 232 can also effectively rotate around the X-axis and / or Y-axis. Thus, the robot 232 can be articulated with at least six degrees of freedom.

[0080] The end effector 234 is the end-effector of the robot 232, and will be discussed in more detail with examples of end effectors 234, such as... Figures 7 to 8 The end effector 702. The end effector 234 is adapted to the mold 201 used in the specific manipulation system 200. (As if combined...) Figures 9 to 10 In more detail, the tool includes multiple keyways (e.g., Figure 9 The first plate-manipulator keyway 912 and the second plate-manipulator keyway 910 are used (e.g., from the end effector 234 and / or other components of the system 200) to receive one or more protrusions for positioning, locating and / or securing the tool.

[0081] When robot 232 positions end effector 234 at a tool (e.g., mold 201), end effector 234 engages with the tool to position the tool relative to and securely hold the tool at end effector 234, enabling robot 232 to precisely and intentionally position the tool at a component of system 200. End effector 234 and robot 232 may be jointly controlled by a controller, such as controller 216 or a similar controller.

[0082] System 200 provides a motion path 236 representing a circular or arc-shaped path, which allows primary transfers between components of system 200 to be performed in a rotational manner around the Z-axis of robot 232. In this example, at least temperature regulating bracket 202, press 210, and unloader 214 are positioned on an arc accessible to robot 232 (such as motion path 236), within a predetermined distance of the arc, or within the arc. It is envisioned that each of the temperature regulating 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 reasonably positioned at each of the components for the throughput purposes of system 200. In other words, it is envisioned that the components of system 200 are within a three-dimensional workspace accessible to robot 232 and end effector 234. In this way, robot 232 is able to pick up and place tools (e.g., mold 201) at components of system 200 via end effector 234. System 200 emphasizes this limitation on throughput, where syringe 212 remains stationary and robot 232 is responsible for supplying syringe 212 with tools (e.g., mold 201) for continuous injection. In an alternative arrangement where the syringe moves to the tool, the movement of the syringe may be a limiting factor for system throughput.

[0083] Controller 216 includes a processor and a memory, and is used to receive, store, process, and transmit 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. Accordingly, controller 216 is capable of receiving information from one or more components, storing that information, determining the processing steps to be performed by one or more components, and then transmitting instructions to one or more components to execute the production of components for footwear products.

[0084] The controller 216 is programmable to execute one or more instructions to cause the system 200 to manufacture foamed footwear components. These instructions include tool management via communication between one or more RFID readers of the system 200. For example, the RFID reader 238 of the temperature regulating bracket 202 queries and receives data from RFID tags (e.g., Figure 17The RFID reader 238 responds to an RFID tag 1708 associated with a mold 201 contained in a known compartment of a temperature-regulating bracket 202. The RFID reader 238 communicates with the controller 216 with information indicating the location of a specific RFID tag associated with the mold 201. The controller 216 also communicates with a thermocouple 240 to determine a measured temperature, such as that of a temperature-regulating plate 203 within the compartment that identifies the RFID tag of the mold 201. The controller 216 associates the measured temperature with the mold 201. Information is also provided to the controller 216 regarding what the mold 201 associated with the identified RFID tag is configured to form (such as a specific sole size for a particular footwear style).

[0085] In one example, a manufacturing objective is provided to controller 216 to produce a specified quantity of a particular footwear style and / or footwear component sizes. In this example, controller 216 is configured to determine which of a plurality of molds (e.g., mold 201) within system 200 are capable of achieving the objective. Controller 216 is also configured to determine the appropriate process to be executed and when to execute it for the molds capable of achieving the objective. For example, controller 216 knows one or more conditions of the mold (e.g., whether the mold contains foamed material that has not yet been removed, whether the mold has reached a sufficiently temperature-conditioned state, whether the mold has had sufficient time since a particular operation), and based on the mold conditions, the controller determines which mold should be transferred or otherwise used to achieve the manufacturing objective. In yet another example, controller 216 may be responsible for achieving a manufacturing objective that includes a plurality of footwear component sizes to be manufactured within a provided timeframe. In this example, controller 216 considers the conditions of various molds (e.g., mold 201) within system 200 and determines which mold should be transferred to which part of system 200 next. For example, when multiple temperature-regulating supports (e.g., 202, 204, 206, 208) exist in system 200, controller 216 can select one of the temperature-regulating supports 202, 204, 206, 208 based on the reduction in travel time of the robot 232 for that specific operation or via a series of transfers (e.g., considering what the next transfer will be after the current transfer; if the subsequent transfer reduces the total transfer time by an amount greater than the additional initial transfer time, the total transfer time can be reduced to allow the current transfer to have a longer initial transfer). In this way, controller 216 effectively and dynamically adjusts component selection, tool selection, transfer paths, etc., in an effort to increase the overall throughput of system 200. This contrasts with the linear determinism of conventional systems, which execute a first step and then a second step regardless of conditions within the system that may delay the execution of the first and / or second steps.

[0086] Continuing, controller 216 determines the next transfer instance and instructs robot 232 to position end effector 234 at mold 201, which is currently located in a known compartment of temperature regulating bracket 202. Then, end effector 234 grasps mold 201 and uses its RFID reader (e.g., ...) Figure 7 The RFID reader 713) queries the RFID tag of the mold 201 (e.g., Figure 17 The RFID tag 1708 is used to confirm that the correct mold has been selected. Then, the end effector 234 communicates with the controller 216 to instruct the mold 201 associated with the identified RFID tag to be conveyed to the press 210 as instructed.

[0087] Robot 232 places the mold at press 210 via end effector 234. RFID reader 254 of press 210 queries the RFID tag of the stored mold 201. RFID reader 254 then communicates with controller 216 to confirm that the RFID tag of mold 201 is located at press 210. Press 210 secures mold 201 and places mold 201 against a hot runner plate (e.g., Figure 2 1116, 1212) are paired to make the hot runner outlet (e.g., Figure 15C Hot runner outlet 1513) and hot runner plate (e.g., Figure 2 The back pressure outlet of 1116, 1212) (e.g., Figure 15B The gas back pressure outlet 1521 is aligned with the appropriate port on the mold 201. The controller 216 instructs the gas back pressure source 226 to pressurize the cavity of the mold 201 to the appropriate pressure through the interaction between the mold 201 and the press 210 (e.g., through the back pressure outlet on the hot runner plate).

[0088] As pre-guided by controller 216, syringe 212 meterly dispenses an appropriate single-phase solution and injects the metered single-phase solution into mold 201 via press 210. In this example, controller 216 anticipates that the specific mold to be injected will have a specific mold cavity volume. Based on this anticipated specific mold volume, controller 216 instructs syringe 212 to prepare an appropriate volume of single-phase solution for injection by controller 216. This anticipation may include controller 216 instructing metering source 220 to meterly dispense a specific amount of physical foaming agent into syringe 212, and instructing hopper 222 to dispense a specific amount of polymer material into syringe 212 based on the anticipated injection volume of the mold to be received and its associated cavity.

[0089] Controller 216 is notified that injection 212 has successfully entered the mold cavity. Then, according to programmed operating instructions, controller 216 instructs gas back pressure source 226 to release the gas back pressure at 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 gas back pressure in the mold cavity triggers foaming of the injected polymer composition and physical foaming agent. Controller 216 then instructs robot 232 to retrieve mold 201 (containing the injected material) from press 210 and place mold 201 at a temperature-regulating support (such as temperature-regulating support 204). Controller 216 can then access the mold from an RFID reader on end effector 234 (e.g., ...). Figure 7 The RFID reader 713 receives confirmation that the mold 201 has been retrieved and placed. Further confirmation can be received when the RFID reader (e.g., RFID reader 242) receiving the temperature-regulating bracket (e.g., temperature-regulating bracket 2020) of the mold 201 further queries the RFID tag from the mold 201. This confirmation is then relayed to the controller 216. Additionally, a thermocouple (e.g., thermocouple 244) associated with the compartment (in which the mold 201 is positioned after injection) provides a temperature reading of the mold 201 as the foamed, injected polymer composition cools and becomes more dimensionally stable. The temperature is reported to the controller 216, which can then correlate the temperature with the mold 201.

[0090] Once the mold 201 reaches the appropriate time or temperature after injection by syringe 212, controller 216 instructs robot 232 to retrieve the mold 201 to be positioned at unloading machine 214. Controller 216's determination regarding when the mold can be moved to unloading machine 214 is based in part on the time the injection into the mold cavity occurred, the time of release of back pressure, the temperature of the mold before receiving the injection (or an approximation of the temperature by inferring a reading from the temperature control plate from which the mold is selected), the temperature of the mold (or an approximation thereof) after injection at the temperature control bracket, the time the mold underwent temperature control at the temperature control bracket, and details of the mold (e.g., the size, style, and volume of the mold cavity forming the footwear component). Combined, controller 216 collects and stores information throughout the process to optimize the throughput of system 200.

[0091] At unloading machine 214, RFID reader 256 queries the RFID tag associated with mold 201. Figure 17The RFID tag 1708 is used to identify the mold 201 and transmit the identification to the controller 216. The controller 216 initiates the unloading process of the foamed part from the mold 201. At the end of the unloading process, the controller 216 guides the robot 232 to retrieve the mold 201 from the unloading machine 214 and store the mold 201 at a temperature-controlled support (e.g., temperature-controlled supports 202, 204, 206, 208). The controller 216 can then capture information about the processes performed on the mold 201 during the production of the foamed part. This data can be used for tooling management (e.g., cycle count) and quality control audits.

[0092] The use of System 200 enhances the quality control of the manufactured parts / products. System 200 is able to track and collect information associated with each product manufactured within System 200. For example, time, temperature, pressure, materials, machine parameters, environmental parameters, tooling parameters, etc., can all be captured, recorded, and associated with the specific part produced from System 200. If defects or other characteristics are identified in conjunction with the specific product formed by System 200, a review of the conditions, parameters, and other variables associated with the manufacture of that specific product can be completed. The ability to review information in conjunction with the specific products manufactured in System 200 is possible, in part, due to the autonomy of System 200. Because tools move autonomously through System 200 without human intervention, a chain of custody regarding the tools used to produce the specific product is maintained, and therefore, even before the specific product is formed, information captured related to the formation of the specific product can be tracked in conjunction with the specific tools. In other words, System 200 effectively captures and maintains information useful for quality control and the review of the manufacturing process of the specific products formed by System 200.

[0093] The above process is a non-limiting example of how a system 200 with controller 216 can operate. While a single controller 216 is depicted and described, in practice, multiple controllers can operate collaboratively to achieve the functions provided herein. For example, robot 232, press 210, syringe 212, and / or unloader 214 may have dedicated controllers that operate independently or under the guidance of controller 216. Accordingly, the use of controller 216 is a general indication of a computing device capable of controlling one or more aspects of system 200, which may be divided among multiple controllers that communicate logically via wired or wireless communication protocols.

[0094] System 200 is a non-limiting example of a system contemplated herein. It should be understood that any number of individual components can be incorporated into system 200. For example, four temperature-regulating supports 202, 204, 206, 208 are depicted, but it could be one temperature-regulating support, two temperature-regulating supports, three temperature-regulating supports, five temperature-regulating supports, or any suitable number of temperature-regulating supports. Similarly, examples of the positioning of various components are provided for illustrative purposes, but alternative positioning is also contemplated. For example, it is contemplated that press 210 or unloader 214 could be positioned between two or more temperature-regulating supports (e.g., 204, 206) to optimize the travel time of robot 232 between the various components by minimizing [the travel time]. Specifically, because the mold 201 travels sequentially from the temperature regulating brackets (e.g., temperature regulating brackets 202, 204, 206, 208) to the press 210, to the temperature regulating brackets (e.g., temperature regulating brackets 202, 204, 206, 208), to the unloading machine 214, and then back to the temperature regulating brackets (e.g., temperature regulating brackets 202, 204, 206, 208), in this example, providing a temperature regulating bracket at an intermediate position between the press 210 and the unloading machine 214 can reduce the travel time of the robot 232. Furthermore, Figure 2 The illustrations are for illustrative purposes only and do not limit the size, position, relative position, or scale. Furthermore, it is conceivable that one or more components can be omitted from the system and / or that one or more components can be introduced into the system.

[0095] Figure 3 A schematic plan view of a footwear component manufacturing system 300 in a second configuration, according to various aspects of this document, is depicted. Further details regarding... Figure 2 Those components with similar numbering in System 300, but from Figure 2 This is understood in conjunction with the discussion of similarly numbered components. However, the second configuration of system 300 demonstrates a non-arc / rotational motion path 304 provided by robot 302. In this example, robot 302 is a benchtop robot that effectively moves a tool (e.g., a mold) through system 300 in a linear manner. (As in conjunction with...) Figure 2 The system discussed in system 200, system 300 is based on the concept of moving a tool (e.g., mold 201) through the system, which is the opposite of the conventional injection molding operation of moving an syringe 212 to the tool. This alternative method is particularly suitable for manufacturing footwear parts with various injection volumes and significant foam volumes (e.g., part thickness), where the foam volume itself is insulating and thus slows down the cooling of the foamed part after foaming (e.g., the part itself is insulating due to the significant foam volume). Accordingly, with Figure 2 Similar to system 200, system 300 is configured to move mold 201 to syringe 212 instead of moving syringe 212 to mold 201.

[0096] Robot 302 in a similar combination Figure 2 The robot 232 operates in the manner described. However, instead... Figure 2 Based on the rotational primary motion path, robot 302 has the primary motion capability along motion path 304 in a linear manner. In addition to movement along motion path 304, robot 302 can also move along the Z and X axes when motion path 304 is in the Y-axis direction. This type of motion is sometimes referred to as Cartesian robot. Additional motion fields are envisioned to be possible, such as rotations about any of the X, Y, and / or Z axes.

[0097] In some instances, the linear (e.g., non-arc / rotational) primary motion path of system 300 can provide additional scalability to system 300 on an arcuate motion path system. For example, the linear distance can be extended indefinitely to incorporate additional components that can be approached by robot 302. This contrasts with the arcuate or rotational motion path of a robotic arm, which has a finite reach range based on arm configuration and therefore a finite circumferential length as the motion path along which the component is placed. Furthermore, although the component is depicted on one side of motion path 304, in some instances, it is envisioned that the component could be placed on both sides of the motion path, and two or more robots could operate in parallel motion paths or in a common motion path.

[0098] In this example, the arrangement of components in system 300 is provided to optimize the throughput of system 300. For example, temperature regulating supports (e.g., temperature regulating supports 202, 204, 206, 208) are positioned on either side of unloader 214 and press 210. However, it is envisioned that alternative arrangements of components, based on the configuration of the temperature regulating supports, process parameters, and robot priorities, result in optimized throughput of system 300. For example, it is envisioned that at least one temperature regulating support (e.g., temperature regulating supports 202, 204, 206, 208) could be positioned between press 210 and unloader 214 to provide optimized throughput on the system based on process parameters (e.g., injection time, rest time, robot speed). Furthermore, it is envisioned that temperature regulating supports 202, 204, 206, 208, unloader 214, and 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 approach each of the components without significantly sacrificing the throughput of the system 300 by excessive robot motion that would cause the components of the system to be misaligned with the motion paths of the robot 302.

[0099] System 300 is a non-limiting example of the system envisioned herein. It should be understood that any number of individual components can be combined within the system. For example, four temperature regulating supports 202, 204, 206, and 208 are depicted, but it could be one temperature regulating support, two temperature regulating supports, three temperature regulating supports, five temperature regulating supports, or any number of temperature regulating supports. Similarly, examples of the positioning of various components are provided for illustrative purposes, but alternative positioning is also envisioned. Furthermore, Figure 3 The illustrations are for illustrative purposes only and do not limit the size, position, relative position, or scale. Furthermore, it is conceivable that one or more components may be omitted from system 300 and / or one or more components may be introduced into system 300.

[0100] Figure 4 A perspective view 400 depicts a temperature regulating bracket 402 and a temperature control unit 428 according to various aspects herein. The temperature regulating bracket 402 is as previously discussed. Figure 2 Example embodiments of temperature regulating brackets 202, 204, 206, and 208. Temperature regulating bracket 402 includes multiple compartments 404, 406, 408, 410, 412, and 414. The multiple compartments can be any number, such as one, two, three, four, six, seven, eight, nine, or ten compartments. For example, in one instance, temperature regulating bracket 402 may include four to eight compartments. The number of compartments is chosen as an optimization for system throughput. The number of compartments is limited based on the minimum distance required to maintain tools and robot end effectors approaching, locating, and removing tools from the compartments. In some instances, the height of the temperature regulating bracket (e.g., mold 201) is also limited to the height accessible to robots (such as arm robots with limited reach). Furthermore, the number of compartments is partly limited by the ability of temperature control unit 428 to effectively regulate the temperature of multiple compartments. Accordingly, it is envisioned that a temperature regulating bracket 402 with four to eight compartments meets the identified conditions and provides effective throughput for the system. However, due to adjustments in process parameters, components, and / or conditions, this document envisions and provides alternative ranges of compartments.

[0101] Each of the six compartments of the temperature regulating bracket 402 is equipped with a temperature regulating plate, such as 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 within the compartment. Temperature regulating plate 416 effectively regulates the temperature of tools placed on it. For example, as... Figure 5 The mold 502 shown is positioned on a temperature regulating plate 416. In this example, the temperature regulating plate 416 includes a top surface 426, which, when the tool is positioned on the temperature regulating plate 416, is aligned with the tool (e.g., ...). Figure 5The mold 502 is connected, and the temperature regulating plate 416 includes a bottom surface, which in this example is supported by a compartment.

[0102] The temperature regulating plate 416 includes a fluid channel (not shown) extending between a top surface 426 and a bottom surface, the fluid channel beginning at a fluid inlet port (not shown) and terminating at a fluid outlet port (not shown). The fluid inlet port is fluidly connected to a temperature control unit 428, and the fluid outlet port is fluidly connected to the temperature control unit 428 to allow temperature regulating fluid to circulate between the temperature control unit 428 and the temperature regulating plate 416. The temperature regulating support 402 also includes a temperature regulating fluid manifold 436 serving 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 temperature regulating fluid from the temperature control unit 428 to the multiple compartments. In this example, this distribution of temperature regulating fluid controlled by the temperature regulating fluid manifold 436 provides a more equal temperature distribution of the temperature regulating fluid across the multiple compartments.

[0103] The temperature regulating fluid manifold 436 may have one or more valves that are dynamically or manually controlled to further control the distribution of the temperature regulating fluid in a uniform manner (e.g., consistent flow rate, consistent temperature). An example of a valve used in the temperature regulating fluid manifold 436 is valve 434. Valve 434 may be controlled by a controller (e.g., Figure 2 The controller 216 controls the flow of temperature-regulating fluid supplied to the temperature control plate 416. For example, if the temperature control plate 416 is not used, the valve 434 can restrict the flow of temperature-regulating fluid to conserve energy used for temperature regulation of the temperature control plate 416 when the tool is not being adjusted. The temperature control unit 428 is at least partially fluidly connected to the fluid inlet port via a supply line 432 and at least partially fluidly connected to the fluid outlet port via a return line 430. Each of the supply line 432 and the return line 430 may be fluidly connected to a corresponding manifold (e.g., temperature-regulating fluid manifold 436).

[0104] The temperature regulating plate 416 also includes a first protrusion 418 extending outwardly from the top surface 426. The size, shape, and position of the first protrusion 418 are configured on the top surface 426 to allow for... Figure 17 The first plate alignment keyway 1704 is received in the bottom surface of the tool, which will be combined below. Figure 17 To be discussed in more detail. The top surface 426 also includes a second protrusion 420 extending outwardly from the top surface 426. The size, shape, and position of the second protrusion 420 are set on the top surface 426 to be such that... Figure 17The second plate alignment keyway 1706 is received in the bottom surface of the tool. The first protrusion 418 is asymmetrical 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 of the protrusion (e.g., width), or any combination thereof.

[0105] The asymmetry between the first protrusion 418 and the second protrusion 420 effectively ensures the correct orientation and positioning of the tool within the compartment. This correct orientation and positioning ensures that the end effector (e.g., operating with very tight tolerances, e.g., less than 2 mm) can be positioned correctly. Figure 2 The end effector 234) enables the tool to be secured without human operator intervention. Proper orientation and positioning also ensure that the tool with the RFID tag is properly positioned relative to the RFID reader 438 for querying and confirmation within a specific compartment. Furthermore, the orientation and position confirmation provided by the asymmetry of the two protrusions also ensures that the tool is properly positioned relative to the thermocouple of the temperature control plate 416 (e.g., Figure 4 The thermocouple 424 is correctly aligned. In this example, the thermocouple 424 is placed in the recess 422 to prevent interference with the tool when it is positioned on and off 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.

[0106] Temperature control unit 428 is Figure 2 An example embodiment of temperature control unit 228. Temperature control unit 428 effectively regulates (e.g., heats or cools) the regulating fluid to temperatures of 15°C to 90°C, 50°C to 80°C, and / or 55°C to 70°C. It is envisioned that temperature control unit 428 serves two or more temperature regulating supports (e.g., Figure 2 Temperature regulating brackets 202 and 204). For example, temperature control unit 428 has multiple inlets and outlets for fluid connection to multiple components (such as two temperature regulating brackets) via supply line 432 and return line 430.

[0107] Figure 5 The present invention describes a plurality of molds 502 and 504 according to various aspects thereof. Figure 4 A temperature regulating bracket 402 and a temperature control unit 428 are configured 500. A first mold 502 is supported on a temperature regulating plate 416 in a compartment 408. A second mold 504, one of a plurality of molds, is depicted in a compartment 414.

[0108] Figure 6Depicting various aspects based on this article Figure 5 Rear perspective view 600 of the temperature regulating 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 Example temperature control bracket 402 is provided. It should be understood that a temperature control bracket of any size can be implemented with any number of compartments, temperature control panels, and configuration. Therefore, although... Figures 4 to 6 Specific temperature regulation brackets are provided and described, but are not intended to limit the systems and methods presented herein.

[0109] Figure 7 An end effector 702 in a first configuration 700 is depicted according to various aspects of this document. The end effector 702 is as previously discussed. Figure 2 An example embodiment of the end effector 234. 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... Figure 8 The depicted first distance 718 and second distance 802 are movable. This slidable movement allows the first arm 704 and the second arm 706 to move respectively within the tool (e.g., Figure 9 The mold 900 and the tool converge on the first side and the second side of the tool to engage the end effector 702 with the tool. The tool will be referred to below relative to... Figure 9 Describe it.

[0110] The first arm 704 and the second arm 706 are configured in parallel such that when the first arm 704 and the second arm 706 are positioned between a first distance and a second distance, they converge on the tool and align with the tool to control the robot's end effector 702 (e.g., Figure 2 The robot (232) operates within strict tolerances. 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, they will engage with the sides. The parallel arrangement allows for robust engagement and operation within strict tolerances.

[0111] 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 outward from the first arm 704 toward the second arm 706. Similarly, the second arm 706 includes a third protrusion 714 and a fourth protrusion 716 extending outward from the second arm 706 toward the first arm 704. The first protrusion 708 is asymmetrical 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 location, protrusion size, and any combination thereof. Similarly, the third protrusion 714 is asymmetrical 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 location, protrusion size, and any combination thereof. It is conceivable that the first protrusion 708 and the third protrusion 714 are symmetrical with respect to one or more characteristics, and that the second protrusion 710 and the fourth protrusion 716 are symmetrical with respect to one or more characteristics. For example, the first protrusion 708 may have a cylindrical volume, while the second protrusion 710 may have a linear volume. In this example, the second protrusion 710 with a linear volume will not engage with a keyway configured to receive the cylindrical volume of the first protrusion 708.

[0112] Each protrusion is designed to be received in and thus engaged with a corresponding keyway in a tool such as a die. This coordination between the protrusion features and the associated keyway allows the end effector 702 to securely engage the tool in a known position and orientation, similarly positioning the tool in a known position and orientation.

[0113] The end effector 702 includes an RFID reader 713 received in a recess 712 of the first arm 704. The location of the recess 712 is selected such that the RFID reader 713 can interrogate the engaged mold (e.g., Figure 9 RFID tags (e.g., on specific locations of mold 900) Figure 17 The close proximity between the RFID reader 913 and the RFID tag limits the possibility of querying the RFID tag for identification errors or failures. As previously provided, the RFID reader 913 of the end effector 702 effectively reports RFID tag identification to the controller (e.g., RFID tag 1708). Figure 2 The controller 216 is used for process management and system coordination. The end effector 702 also includes a moving mechanism, such as an electric linear actuator, pneumatic actuator, hydraulic actuator, or other drive system (not shown). The moving mechanism responds to commands to adjust the distance between the first arm 704 and the second arm 706. In other words, the moving mechanism is mechanically connected to the first arm 704 and / or the second arm 706 to adjust the relative position of the first arm 704 and / or the second arm 706, thereby adjusting the distance between the mold (e.g., [missing information]) between the first arm 704 and the second arm 706. Figure 9The mold 900) engages and disengages.

[0114] Figure 8 The second configuration 800 is described according to various aspects of this article. Figure 7 The end effector 702. For example... Figure 8 As depicted, the first arm 704 and the second arm 706 converge with a sliding motion as indicated by direction indicator 804. This convergence results in a distance 802 extending between the first arm 704 and the second arm 706. In an example, this second configuration 800 is adapted to work with a mold (e.g., Figure 9 The mold 900) is joined and fixed.

[0115] Figure 7 and Figure 8 The end effector 702 is a non-limiting example of an end effector contemplated herein. While specific structures, configurations, and elements are depicted and described, additional or alternative structures, configurations, and / or elements are contemplated to form an effective end effector in the systems and methods contemplated herein.

[0116] Figure 9 A perspective view of mold 900 according to various aspects of this document is depicted. Mold 900 is a specific form of tool generally referenced herein. In the systems provided herein (e.g., Figure 2 In the system 200) and method, it is envisioned that an alternative tool (such as an alternative mold) is used and that the alternative tool is effective. Mold 900 includes a first mold portion 903 and a second mold portion 905. It is envisioned that each of the mold portions 903, 905 includes a mold cavity (e.g., mold cavity 1420 of FIG. 14) for effectively forming a component (e.g., a footwear sole component) using the system and method provided herein. For example, the first mold portion 903 effectively forms a right sole portion and a left sole portion of a pair of shoes. Similarly, the second mold portion 905 effectively forms a right sole portion and a left sole portion to form a second pair of shoes. 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 envisioned 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 volume allows for the formation of a manifold (e.g., Figure 18B The injection manifold 1811) has a uniformly distributed injection volume and is used as a syringe (e.g., Figure 2 The conduit between 212) and the mold cavity. In this example, maintaining consistency between the mold volumes injected with a common injection material from the syringe provides greater control over the resulting product.

[0117] The mold 900 includes a first top mold plate 902 and a second top mold plate 904. The mold 900 includes a first support plate 908 and a second support 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 support plate 908 toward the second support plate 906 and a second portion 919 extending from the second support plate 906 toward the first support plate 908. The first portion 917 and the second portion 919 of the tool latch assembly 918 are offset and parallelly positioned to interface and engage when a biasing pin 922 extends from the first portion 917 toward the second portion 919, and to extend into an orifice 920 of the second portion 919 in the biased position. The biasing pin 922 may be derived from an unloading machine (e.g., Figure 24 The key of the uninstaller 2300 (e.g., Figure 24 The key 2606 is operated to cause the biasing pin 922 to retract from the orifice 920, thereby allowing the first portion 917 and the second portion 919 to slidably disengage, and the first support plate 908 to space itself from the second support 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.

[0118] Each of the support plates 906 and 908 includes a keyway intended to engage with protrusions from different components of the system, as will be discussed in more detail below. The first support plate 908 includes a first plate-operator keyway 912 and a second plate-operator keyway 910. The second support plate 906 includes a first plate-opening keyway 914 and a second plate-opening keyway 916. The first plate-operator keyway 912 and the second plate-operator keyway 910 are asymmetrical in at least one characteristic. One or more characteristics include keyway depth, cross-sectional shape, location, size, or any combination thereof. For example, the first plate-operator keyway 912 has a cylindrical volume, and the second plate-operator keyway 910 has a linear volume.

[0119] In fact, the first plate-operator keyway 912 is adapted to receive from Figure 7 The third protrusion 714 of the end effector 702, and the second plate-manipulator keyway 910 are adapted to receive from Figure 7 The fourth protrusion 716 of the end effector 702. Similarly, the first plate-opening keyway 914 is adapted to receive the first protrusion 2320 from the unloader 2300, which will combine Figure 25 Discussions were held, and the second plate - open keyway 916 is adapted to receive from Figure 25The second protrusion 2322 of the unloading machine 2300. It is envisioned that the tool side, opposite to the positions of the first plate-operator keyway 912, the second plate-operator keyway 910, the first plate-opening keyway 914, and the second plate-opening keyway 916, has a similar keyway. A similar keyway can be... Figure 9 The corresponding keyways on the depicted sides are symmetrical. Alternatively, imagine that in relation to... Figure 9 The keyways on the sides of the mold 900 depicted opposite sides are in one or more features relative to them. Figure 9 The corresponding keyways on the side of the mold 900 depicted in the image are asymmetrical.

[0120] Figure 10 It describes the combination of various aspects based on this article. Figure 9 A side view of the mold 900 discussed. The mold 900 is provided as a non-limiting example of a tool that can be implemented in the systems and methods contemplated herein. This tool can produce alternative foamed parts; having alternative elements, alternative configurations, alternative sizes, and alternative arrangements. Accordingly, the systems and methods contemplated herein can implement alternative tools within the contemplated coping methods.

[0121] Figure 11 A perspective view of the press 1100 according to various aspects of this document is depicted. The press 1100 is a previously combined... Figure 2 An example embodiment of the press 210 discussed. Figure 2 The disclosure of press 210 is applied herein to press 1100. Press 1100 has a frame 1102, and frame 1102 has a movable support platform 1104. The movable support platform 1104 can be moved by one or more actuators, such as... Figure 12 The first actuator 1202 and Figure 12 The second actuator 1204. The press 1100 also includes a pressure plate 1110 having a top surface 1111 and an opposing bottom surface 1113. The bottom surface 1113 of the pressure plate is positioned on a movable support platform 1104, and the top surface 1111 of the pressure plate is positioned to receive and support tools, such as those from… Figure 9 The mold 900. The press 1100 also includes a pressure lock 1115 that can move between a locked configuration and an unlocked configuration. In the locked configuration, the pressure lock 1115, for example, by means of... Figure 9 The first support plate 908 of the mold 900 engages to secure the tool (e.g., Figure 13The mold 900 is depicted. The pressure 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. This 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 pressure plate 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 inconsistent with the pair of sliding fingers 1106, 1108. The pair of fingers 1106, 1108 and the second pair of fingers work together to engage the tool (e.g., as shown in the image). Figure 13 The mold 900 depicted is fixed to the pressure plate 1110. The pressure plate 1110 also includes a first protrusion 1112 extending from the top surface 1111 toward the hot runner plate 1116 and the second hot runner plate 1212. The pressure plate 1110 also includes a second protrusion 1114 extending from the top surface 1111 toward the hot runner plate 1116 and the second hot runner plate 1212.

[0122] The first protrusion 1112 is asymmetrical relative 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 pressure plate 1110, the cross-section of the protrusion taken in a plane parallel to the top surface of the pressure plate 1110, the position of the protrusion on the top surface of the pressure plate 1110, the size (e.g., width) of the protrusion, or any combination thereof.

[0123] The asymmetry between the first protrusion 1112 and the second protrusion 1114 effectively ensures that the tool (e.g., as Figure 13 The depicted mold 900 is positioned correctly in orientation and location within the press 1100. This correct orientation and positioning ensures that the tool is aligned with the hot runner plate 1116 and, by extension, with the injection manifold 1120, which serves as a conduit for injecting the polymer composition into the tool. Correct orientation and positioning also ensure that the tool with the RFID tag is properly positioned relative to the RFID reader 1118 for querying and verification within the press 1100. Furthermore, the orientation and position verification provided by the asymmetry of the two protrusions 1112, 1114 also ensures that the tool is correctly aligned with the thermocouple of the pressure plate 1110, if present.

[0124] The first protrusion 1112 and the second protrusion 1114 are joined in a manner similar to that of a joint. Figure 4 The first protrusion 418 and the second protrusion 420 of the temperature regulating bracket 402 under discussion operate in a manner that allows for effective alignment of the tool with common alignment keyways in at least two components of the system, such as the temperature regulating bracket 402 and the press 1100.

[0125] In this example, the pressure plate 1110 includes an regulating fluid channel (not shown) extending between a top surface 1111 and a bottom surface 1113. The regulating fluid channel allows the pressure plate 1110 to communicate with a temperature control unit (e.g., Figure 2 The temperature control unit 204 has an inlet (not shown) and an outlet (not shown) that are fluidly connected. Thus, the pressure plate 1110 can be partially connected with... Figure 4 The temperature adjustment plate 416 of the temperature adjustment bracket 402 is used in a similar manner to that described for adjusting the tool during and / or after injection.

[0126] Figure 12 The first configuration 1200 is described according to various aspects of this article. Figure 11 Front view of press 1100. Press 1100 is Figure 2 An example embodiment of the press 210. A first configuration 1200 positions the movable support platform 1104 in the 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 place tools (e.g., such as...) Figure 13 The depicted mold 900 is fixed against the hot runner plates 1116 and 1212 to form an effective seal, thereby allowing the single-phase solution to be fluidly transferred from the press 1100 to the tool, and to maintain gas back pressure in the tool cavity during transfer from the press 1100. A first configuration 1200, placing the movable support platform 1104 in the retracted platform position, allows the tool (such as...) Figure 9 The mold 900 is positioned on the pressure plate 1110 and can be fixed by the pressure lock 1115.

[0127] Hot runner plates 1116, 1212 are statically positioned to the press, for example by bolts, latches, or other fasteners. Thus, when the movable support platform 1104 moves from the first configuration 1200... Figure 13 In the second configuration 1300 depicted, the distance between the movable support platform 1104 and the hot runner plates 1116 and 1212 is reduced, making the distance in the first configuration 1200 greater than the distance in the second configuration 1300.

[0128] A hot runner plate (such as hot runner plate 1116) provides a mechanism for holding the molten polymer composition within the injection manifold 1120 in a molten state. To achieve this, the hot runner plate 1116 includes channels (not shown) within it that effectively circulate a conditioning fluid at a controlled 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, which are fluidly connected by channels extending through the hot runner plate 1116 for circulating the conditioning fluid.

[0129] 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, the hot runner plate 1212 includes channels (not shown) within it that effectively circulate a conditioning fluid at a controlled 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, which are fluidly connected by channels extending through the hot runner plate 1212 for circulating the conditioning fluid.

[0130] The use of hot runner plates (e.g., hot runner plate 1116, second hot runner plate 1212) in this physical foaming operation reduces the amount of foam produced by the foaming process. Figure 2 The waste generated by the extended cold runner between the syringe 212 and the tool. By keeping a portion of the conduit between the syringe and the tool as a hot runner, the polymer composition does not solidify between injections in those portions heated by the hot runner plates 1116, 1212. Additionally, as previously discussed, in this 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 dispenses a metered amount of material for subsequent injections, the time interval between injections may vary, and therefore... Figure 2 The flow channel system or manifold of syringe 212 (e.g., Figure 18B The molten polymer composition in the manifold 1811 or other locations may experience temperature drops at different levels without a hot runner plate (e.g., hot runner plate 1116, second hot runner plate 1212). Therefore, in this example, a hot runner plate (e.g., hot runner plate 1116, second hot runner plate 1212) is applied to the system to achieve a consistent foaming component, regardless of the time between injections or other variables during continuous injection.

[0131] Figure 13 The second configuration 1300 with mold 900 is described according to various aspects of this article. Figure 11 A front view of the press 1100. As depicted, the movable support platform 1104 is raised, thereby enabling fluid communication between the mold 900 and the hot runner plates 1116, 1212. As previously discussed, this fluid communication allows a single-phase solution to flow from... Figure 2 The syringe 212 transfers the solution through the injection manifold 1120 through the hot runner plates 1116, 2121 into the cavity of the mold 900, while maintaining it as a single-phase solution. Similarly, the fluid communication between the hot runner plates 1116, 1212 and the mold 900 allows for the supply of gas from a backpressure source (such as...) Figure 2 The gas back pressure source 226 supplies back pressure to the mold 900.

[0132] Injection manifold 1120 delivers single-phase solution from hot runner plates 1116 and 1212. Figure 2 The syringe 212 is distributed to the mold 900. The injection manifold 1120 also maintains the single-phase solution as a single-phase solution between continuous injection or injection into the tool. In this example, the injection manifold 1120 achieves this partially via a valve when it contacts the mold 900 through a hot runner plate (e.g., hot runner plate 1116, second hot runner plate 1212), which opens when the press 1100 establishes fluid communication between the mold 900 and the hot runner plates 1116, 1212.

[0133] The press 1100 is described as having a specific configuration, structure, and arrangement; however, the press 1100 is a non-limiting example of the press contemplated herein. Alternative arrangements (such as omitting the hot runner plate, pressure plate), alternative actuators, alternative press locking mechanisms, etc., are contemplated within the scope of the systems and methods provided herein.

[0134] Figure 14A A perspective view of a mold 900 according to various aspects herein is depicted, the mold 900 having a first mold portion 1401 and a second mold portion 1403 in fluid communication with hot runner plates 1116 and 1212 of a forming tool assembly 1400. A gas backpressure port 1404 is depicted extending from one side of the hot runner plate 1212. The gas backpressure port 1404 provides a conduit through the hot runner plate 1212 for connecting a gas backpressure supply source to a cavity of the mold 900 (e.g., ...) in the second portion associated with the hot runner plate 1212. Figure 14B The mold cavity 1420 is fluid-connected. A similar gas backpressure port is located in... Figure 14AAn invisible portion extends through the hot runner plate 1116 on the opposite side. The gas back pressure port (not shown) of the hot runner plate 1116 also provides a conduit through the hot runner plate 1116 for supplying a gas back pressure source (e.g., ...) within a portion of the mold 900 associated with the hot runner plate 1116. Figure 2 The gas back pressure source 226) is fluidly connected to the cavity of the mold 900.

[0135] 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 nozzle receiving opening 1402a to 1402h and 1404a to 1404h effectively receives a nozzle (e.g., from a manifold) from the nozzle. Figure 18B Nozzle 1807), such as in Figure 15B and Figure 15C As shown in more detail below. Nozzle (e.g., Figure 18B The nozzle 1807 effectively directs the gate of the mold 900 (e.g., Figure 14B The gate 1422) is fluidly connected to the syringe 212, thereby allowing the molten composition to flow from the syringe 212 to the mold cavity (e.g., Figure 14B The fluid communication between the mold cavity 1420 and the ...

[0136] Figure 14B Depicting various aspects based on this article Figure 14A A partially exploded view of the tool assembly 1400 shows a second mold plate 1406 separate from the mold annular plate 1408. The second mold plate 1406 includes a peripheral wall 1410 forming a boundary along the side of the mold cavity wall 1412. Additionally, the mold annular plate 1408 includes a mold cavity wall 1414 that at least partially closes the mold annular cavity 1416, and the mold cavity wall 1414 includes a first peripheral ridge 1418 traversing the periphery of the mold annular cavity 1416. When the second mold plate 1406 is layered adjacent to or abutting the mold annular plate 1408, such as when assembling the first mold portion 1401, the peripheral wall 1410 is nested within the mold cavity wall 1414 to at least partially close a portion of the mold annular cavity 1416. Furthermore, the peripheral wall 1410 abuts the first peripheral ridge 1418 to at least partially seal and form the mold cavity 1420.

[0137] One aspect of this disclosure includes a mold system having a universal runner plate (e.g., a universal hot runner plate or a universal 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 universal runner plate and including a three-dimensional mold cavity size. Furthermore, the three-dimensional mold cavity size of the first mold in 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 in the array is for a footwear component of a second shoe size. In one aspect, the first and second shoe sizes are each within the range of U.S. Men 3.5 to U.S. Men 15, or U.S. Men 5 to U.S. Men 12, or U.S. Men 6 to U.S. Men 11, or U.S. Men 7 to U.S. Men 10. For example, the first shoe size can be in the range of US Men 3.5 to US Men 8, or US Men 5 to US Men 7.5, or US Men 6 to US Men 7; and the second shoe size can be in the range of US Men 8.5 to US Men 15, or US Men 9 to US Men 12, or US Men 9 to US Men 10.

[0138] Figure 15A Depicting various aspects based on this article Figure 14A Front view 1500 of mold 900 and hot runner plates 1116 and 1212. (Reference) Figure 15B and Figure 15C Some parts of the walls of the hot runner plate 1212 are omitted to illustrate some internal components of the hot runner plate 1212 in more detail. For example, the hot runner plate 1212 includes eight nozzle receiving sleeves 1505a to 1505h, each of which receives a corresponding nozzle of the injection manifold 1120 (e.g., Figure 18B Nozzle 1807). Each nozzle receiving sleeve 1505a to 1505h includes a nozzle receiving opening 1402a (see...). Figure 14A ) and sleeve outlet 1507. Sleeve outlet 1507 includes a peripheral outer edge 1515 forming a nozzle seat 1517, when the nozzle (e.g., Figure 18B When the nozzle 1807 is fully inserted into the nozzle receiving sleeve, the tip of the nozzle is biased against the nozzle seat 1517.

[0139] The hot runner plate 1116 also includes hot runners (e.g., 1509) that flow from each nozzle (e.g., after material is dispensed). Figure 18B The nozzle 1807 delivers material. For example, each hot runner (e.g., 1509) includes a sleeve outlet (e.g., Figure 15CThe hot runner inlet (e.g., 1511) is fluidly connected to the nozzle (e.g., 1507) in the cross-sectional view, and includes a hot runner outlet 1513. In one aspect of this disclosure, the hot runner inlet (e.g., 1511) and the hot runner outlet (e.g., 1513) are spaced apart by a distance ranging from about 1 cm to about 3 cm. Accordingly, when material flows from the nozzle (e.g., 1507), the hot runner outlet (e.g., 1513) is fluidly connected to the nozzle (e.g., 1507). Figure 18B When the nozzle (1807) disperses, an injection port is formed in a hot runner (e.g., 1509), the injection port having a length ranging from about 1 cm to about 3 cm. In one aspect of this disclosure, this injection port length provides a gripping area where a tool can grasp the injection port to extract it from a mold (e.g., Figure 9 Remove the cured material from the flow channel in the mold (900).

[0140] The hot runner plate 1116 includes various components that help control conditions related to the injection molding system. For example, the hot runner plate 1116 includes a conditioned fluid line 1519 for conveying conditioned fluid through the hot runner plate 1116. The conditioned fluid can be conditioned to include temperatures for maintaining, raising, or lowering the temperature of the components of the hot runner plate, which include hot runners (e.g., 1509), nozzle receiving sleeves 1505a to 1505h, and nozzles (e.g., when inserted into the sleeves) that are then positioned within the sleeves. Figure 18B Nozzle 1807 (see also) Figure 12 It depicts an inlet 1208 and an outlet 1210 positioned on the outer wall of a hot runner plate 1116. Accordingly, when a thermoplastic elastomer composition (e.g., a single-phase solution having a supercritical fluid as a physical foaming agent) is dispensed from a nozzle (e.g., Figure 18B When the nozzle 1807 is dispensed, the temperature in the hot runner plate 1116 can be maintained at a sufficiently high level to delay the conversion of the supercritical fluid to gas and / or to keep the polymer composition in a molten state.

[0141] In another aspect, the hot runner plate 1116 includes a gas conduit 1501 for passing through... Figure 14A Gas back pressure port 1404 and Figure 2 The gas back pressure source 226 is fluidly connected to the gas back pressure outlet 1521, which is effectively connected to the mold (e.g., Figure 9 The mold (900) is fluid connected.

[0142] In one aspect of this disclosure, hot runner plates 1116 and 1212 are directly connected to Figure 18AA universal hot runner plate for the injection manifold 1120. For example, one or more fasteners can connect the hot runner plates 1116, 1212 to the injection manifold 1120. In contrast to this disclosure, some conventional injection molding systems may have individual hot runner plates, each interfaced with a different cold runner plate (or other untemperature-controlled plates), and connected and disconnected with a manifold or nozzle in each injection cycle. This aspect of the 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 different mold cavities, different gating schemes, or any combination thereof. For example, mold cavities for molding parts for shoes of different sizes may differ in volume and / or shape, and gating schemes may differ by including different gating locations and / or numbers of gatings. In all respects, a single gating can serve a mold cavity, contrary to multiple gatings serving a single mold cavity. Additionally, the hot runner plate 1116 is connected to all components (including via the regulating fluid line 1519 and gas conduit 1501) used to control various aspects of the molding process. Hot runner plates are generally associated with higher costs (e.g., the addition of piping for temperature control elements). A universal hot runner plate can particularly reduce the cost of multiple mold sets because, instead of having to manufacture a hot runner plate for each mold set, only a single common hot runner plate can be used in multiple mold sets. Furthermore, costs can be reduced over time due to fewer parts to store, maintain, repair, move, handle, etc. Although the accompanying drawings of this disclosure illustrate hot runner plates 1116 and 1212 (which provide an interface between the syringe nozzle 1807 and the tool), in other aspects of this disclosure, a universal cold runner plate or other types of universal runner plates can provide an interface between the syringe nozzle 1807 and the tool.

[0143] Figure 16 Depicting various aspects based on this article Figure 14A Side view 1600 of mold 900 and hot runner 1212. Figure 17 Depicting various aspects based on this article Figure 14A The bottom plan view 1700 of the mold 900. A first plate alignment keyway 1704 and a second plate alignment keyway 1706 are depicted on the bottom surface 1702 of the first support plate 908. As previously discussed, the first plate alignment keyway 1704 and the second plate alignment keyway 1706 are effectively used to receive components from system parts (such as…) Figure 2 Temperature regulating bracket 402 Figure 11 The 1100 press and Figure 23 Alignment protrusions of the unloader 2300. These keyways 1704, 1706 ensure alignment, position, and orientation during various processes and in anticipated future processes (e.g., when preparing to be picked up by the end effector with tight dimensional tolerances).

[0144] The RFID tag 1708 is also depicted. The RFID tag 1708 is recessed into the bottom surface 1702 to prevent contact with... Figure 2 The system 200 is protected against interference or collisions from other surfaces. RFID tag 1708 is provided with a mold (e.g., Figure 5 The unique identifier associated with the mold 502 is such that when the RFID tag 1708 is queried, this unique identifier causes the system 200 to know the location of the mold and / or the RFID reader (e.g., when the RFID tag 1708 is queried, the system 200 knows ... RFID tag 1708 in the system 200). Figure 4 The RFID reader 438 thereby identifies the RFID tag 1708.

[0145] Figure 18A The image depicts the alignment with syringe 1806 according to various aspects of this text. Figure 11 Perspective view 1800 of press 1100. Injector 1806, which can be referred to as an injection cartridge, terminates at nozzle 1804. Injector 1806 is... Figure 2 An example embodiment of syringe 212. Nozzle 1804 effectively engages with syringe port 1802 of injection manifold 1120. The syringe port 1802 is sized and configured to engage with nozzle 1804 to form a fluid connection that allows the single-phase solution to remain a single-phase solution as it is transferred from syringe 1806 to injection manifold 1120. Syringe port 1802 provides access through injection manifold 1120 to manifold nozzle (e.g., Figure 18B The nozzle 1807) and the conduit 1803, these manifold nozzles extend through the hot runner plates 1116, 1212 and connect with Figure 13 The mold 900 forms a fluid connection, and the mold 900 is fixed and compressed in the press 1100.

[0146] refer to Figure 18BAn 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 connected 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 from the thermoplastic elastomer composition of the syringe 1806 and divide the injections into multiple deposits for individual 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 control unit 1811 for maintaining, increasing, or decreasing the temperature of the injection manifold 1120. For example, the manifold temperature control unit 1811 may include a regulated fluid line 1805 for maintaining and delivering a regulated fluid for cooling or heating. Accordingly, as 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 can maintain the thermoplastic elastomer composition under conditions that are beneficial for maintaining the foaming agent in a supercritical fluid phase and reducing the possibility of it turning into a gas. In another aspect, the injection manifold 1120 includes a syringe-pin assembly (e.g., 1809) for each nozzle (e.g., 1807), which can selectively insert a pin (or other obstruction) into the tip of each nozzle to prevent material flow.

[0147] In another aspect of this disclosure, nozzles 1807 are arranged as nozzle groups comprising two to six nozzles. For example, in FIG18b, nozzles 1807 are arranged in four groups of four linearly aligned nozzles, and in other aspects, these groups may include two, three, five, or six linearly aligned nozzles. Each group of nozzles is positioned to inject material collectively into a single mold cavity. For example, in one aspect of this disclosure, each group of four nozzles is configured to inject material into a single mold cavity having a three-dimensional shape of a footwear component (e.g., a footwear sole). In one aspect, the four nozzles optimize the available footprint and the space operable to distribute material into the mold cavity having a 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 this length to uniformly distribute the injected material into the mold cavity, such that each injected material foams and cures in a desired manner.

[0148] exist Figure 18B In the middle, the injection manifold 1120 includes sixteen nozzles 1807, each nozzle capable of being inserted into Figure 14AIn the corresponding nozzle receiving openings (e.g., 1402) of the depicted hot runner plates 1116 and 1212.

[0149] Figure 19 Depicting paired and fluidly connected aspects according to the various aspects of this paper. Figure 18A A perspective view 1900 of the press 1100 and syringe 1806. Syringe 1806 includes physical foaming agent ports 1902 and 1904. Physical foaming agent ports 1902 and 1904 provide for connecting syringe 1806 to a metering feed source (e.g., for providing a physical foaming agent, such as a supercritical fluid)... Figure 2 The syringe 1806 also includes a polymer composition hopper 1906 for supplying the polymer composition to the syringe 1806 to convert it into a single-phase solution. The syringe may include one or more physical foaming agent ports. 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).

[0150] Figure 20 A perspective view of syringe 1806 2000, as shown in Figure 18 according to various aspects of this document, is depicted. Figure 20 Section line 22-22 is provided, which will be defined below. Figure 22 The cross-section. Figure 21 Depicting various aspects based on this article Figure 20 Side view 2100 of syringe 1806.

[0151] Figure 22 The section cut along section line 22-22 is depicted based on various aspects of this paper. Figure 21 A cross-sectional view 2200 of the syringe 1806 is shown. 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. Accordingly, the screw rotates at 20 rpm to 120 rpm. The screw 2202 is used to deliver and compress the polymer composition through the syringe 1806, which increases the pressure experienced by the polymer composition within the syringe. The syringe also includes a plurality of heating elements extending along the length of the syringe 1806. The heating elements are selected and labeled as heating elements 2210, 2212, 2214, and 2216. The heating elements effectively heat the polymer composition to a molten state. The frictional / shear-induced heat generated by the screw 2202 propelling the polymer composition through the syringe 1806 can also contribute to the melting of the polymer composition. The heating elements can use induction heating, resistance heating, regulating fluid, etc.

[0152] The syringe 1806 is depicted as having at least three general regions. A first region 2204 represents a portion of syringe 1806 in which the polymer composition is heated and compressed. A second region 2206 represents a portion of syringe 1806 in which a physical foaming agent is introduced together with the molten polymer composition. A third region 2208 represents a portion of syringe 1806 in which the physical foaming agent and the molten polymer composition combine to form a single-phase solution. In this example, the third region 2208 is also effectively used to meter the volume of the single-phase solution for subsequent injection of the propellant, which will be fluidly transmitted through nozzle 1804 to the manifold, as previously described.

[0153] 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 contemplated while remaining within the scope of these contemplations.

[0154] Figure 23 A perspective view of the unloader 2300 according to various aspects of this document is depicted. The unloader 2300 is a combination of... Figure 2 An example embodiment of the unloading machine 214 is described. 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, and 2316, and an unloading machine plate 2304. The unloading machine plate includes a first protrusion 2308, a second protrusion 2306, and a recess 2310 containing an RFID reader 2311.

[0155] Uninstaller 2300 effectively opens the tool (e.g., Figure 26 The mold 900 shown is used for unloading the cavity contained in the tool (e.g., Figure 14B Foamed articles (e.g., footwear component 100) in cavity 1420). Unloading machine 2300 slides unloading machine lock 2313 having fingers 2312, 2314, 2316 onto a part of the tool (such as Figure 9 The tool is secured to the unloading plate 2304 by sliding fingers 2312, 2314, 2316 in a plane parallel to the top surface 2315 of the unloading plate 2304. After the tool is secured to the unloading plate 2304, the first unloading arm 2318 and the second unloading arm 2324 can be engaged with another part of the tool (such as...). Figure 9The mold 900's second support plate 906 engages with the mold 900. Engagement is achieved by a first protrusion 2320 extending outward from the first unloading arm 2318 toward the second unloading arm 2324 and a second protrusion 2322 extending outward from the first unloading arm 2318 toward the second unloading arm 2324. The first protrusion 2320 is configured to receive in a keyway (such as...). Figure 10 In the first plate-open keyway 914), and the second protrusion 2322 is configured to receive in the keyway (such as Figure 10 In the second plate - open keyway 916).

[0156] The first protrusion 2320 is asymmetrical 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 location, protrusion size, and any combination thereof. Similarly, the third protrusion extending from the second unloading arm 2324 is asymmetrical with respect to the 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 location, protrusion size, and any combination thereof. In some examples, the first and third protrusions are symmetrical in at least one characteristic. In some examples, the second and fourth protrusions are symmetrical in at least one characteristic.

[0157] The first unloading arm 2318 and the second unloading arm 2324 are slidably positioned between an open configuration and a closed configuration, wherein 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, performed horizontally as depicted, is not consistent. For example, when the first unloading arm 2318 moves to the left, the second unloading arm 2324 moves to the right, representing the open configuration. Similarly, when the first unloading arm 2318 moves to the right, the second unloading arm 2324 moves to the left, representing the closed configuration. The slidable movement can be achieved by a power actuator, such as an electric linear actuator, a pneumatic actuator, a hydraulic actuator, or other moving mechanism (not shown).

[0158] The first unloading arm 2318 and the second unloading arm 2324 are also configured to be in an alternative direction (such as...) Figure 23The movements are synchronized in the vertical direction (as depicted). For example, when the first unloading arm 2318 moves upward, the second unloading arm 2324 also moves upward, representing a lifting configuration. Similarly, when the first unloading arm 2318 moves downward, the second unloading arm 2324 also moves downward, representing a closing configuration. This synchronized movement can be achieved by a power actuator, such as an electric linear actuator, a pneumatic actuator, a hydraulic actuator, or other moving mechanism. Thus, the first unloading arm 2318 and the second unloading arm 2324 effectively move synchronizedly with each other in the first direction and inconsistently with each other in the lateral direction.

[0159] Figure 24 Depicting various aspects based on this article Figure 23 Side view of the unloader 2300 2400. Figure 25 The first configuration 2500 is described according to various aspects of this article. Figure 24 Cross-sectional view of the unloader 2300.

[0160] Figure 25 The diagram depicts a first vertical distance 2502 between the first unloading arm 2318 and the unloading plate 2304, and a first horizontal distance 2504 between a pair of fingers 2312, 2316. This first configuration 2500 represents a lifting configuration of the unloading arm and an opening configuration of the unloading lock. Figure 26 The second configuration 2600 with mold 900 is described according to various aspects of this article. Figure 24 Cross-sectional view of the unloader 2300. Figure 26A 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 are depicted. This second configuration 2600 represents a closed configuration of the first unloading arm 2318 and the second unloading arm 2324, and a locking configuration of the unloading lock 2313. In the locking configuration, the pair of fingers 2312, 2316 engage and secure the first support plate 908 of the mold 900. The engagement of the pair of fingers 2312, 2316 secures the first support 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 support plate 906, and lifts the second support plate 906. This lifting action separates the second support plate 906 from the first support plate 908, which allows access to the internal volume of the mold cavity, enabling the removal of the foamed article. Therefore, 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 open to remove waste material from the mold's runner system, and the third position is when the mold is opened to a greater extent so that the foamed article can be removed from the mold cavity. It is envisioned that a fixed-time delay or stop of movement of 1 to 120 seconds is provided between the transitions between the second and third positions. In an example, this intentional delay allows for automated removal of waste, such as by an auxiliary robot.

[0161] The first unloading arm 2318 also includes a key 2606 extending outward from the first unloading arm 2318 toward the second unloading arm 2324. The key 2606 is... Figure 10 The biasing pin 922 engages with a protrusion, and the biasing pin 922 is biased into a locking configuration. The second unloading arm 2324 also includes a key 2607 extending outward from the second unloading arm 2324 toward the first unloading arm 2318 (e.g., ...). Figure 24 (As best shown in the image). Key 2607 is related to... Figure 10 The biasing pin 922 engages with the protrusion, and the biasing pin 922 is biased into a locking configuration.

[0162] When the first unloading arm 2318 and the second unloading arm 2324 move asynchronously with each other, each of the first unloading arm 2318 and the second unloading arm 2324 includes a key (such as key 2606 and key 2607) that engages with a corresponding tool latch assembly (e.g., Figure 10 The corresponding biasing pin in the tool latch assembly 918 (e.g., Figure 10The biasing pin 922 engages. When the first unloading arm 2318 and the second unloading arm 2324 converge, their respective keys (i.e., keys 2606 and 2607) engage with the tool latch assembly to release the mechanical lock caused by the biasing pin. The tool latch assembly is then unlocked via the unloading machine 2300 (e.g., ...). Figure 10 During the tool latch assembly 918, it is envisioned that the unloader 2300 (such as via unloader arms 2318, 2324) compresses the tool to relieve shear stress, which is applied by a second portion of the tool latch assembly interacting with the biasing pin (e.g., ...). Figure 10 On 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, so as to allow the converging force of the unloader arm to compress the biasing pin inward and push it out from the second part of the tool latch assembly.

[0163] While a specific unloading machine has been depicted and described, unloading machine 2300 is a non-limiting example. Within the scope of the systems and methods provided herein, alternative unloading machine configurations, arrangements, and / or structures are contemplated while remaining within the scope of the contemplation herein.

[0164] Figure 27 A flowchart 2700 depicts a first method for physically foaming footwear components according to various aspects of this document. At block 2702, a step of temperature conditioning the mold is performed. Temperature conditioning can be performed at a temperature conditioning bracket, and the temperature conditioning causes the mold to reach a temperature of 15 degrees Celsius to 90 degrees Celsius. In an alternative range, the mold temperature is conditioned to a temperature of 50 degrees Celsius to 70 degrees Celsius. In an additional alternative range, the mold temperature is conditioned to a temperature of 55 degrees Celsius to 65 degrees Celsius.

[0165] At block 2704, the method continues, wherein the end effector engages with the mold. This engagement may be achieved due to one or more protrusions of the end effector receiving one or more keyways in the mold. The protrusions may 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 reversibly engages with the mold, such that the end effector engages with the mold to deliver the mold and disengages from the mold to place and store the mold.

[0166] At block 2706, a step of transferring the mold by an end effector is provided. The transfer is performed by manipulating the position of the end effector in macroscopic space using a robot. The mold is transferred by the end effector to the press. This transfer can be in a generally arc-shaped manner caused by the robot's rotation about a major axis. In an example, the transfer can be in a generally non-arc-shaped manner, such as a linear motion patch provided by a Cartesian or benchtop robot.

[0167] At block 2708, the method continues, wherein a gas back pressure is applied to the mold. This gas back pressure can be supplied via a hot runner fixed to the press and in fluid communication with the mold. This gas back pressure can pressurize the cavity of the mold to at least the critical pressure of the physical foaming agent used in the method. The gas supplied for the gas back pressure can be any material, such as nitrogen, carbon dioxide, or air. In this example, the material of the gas back pressure is similar to the composition of the physical foaming agent (e.g., the physical foaming agent is supercritical fluid nitrogen; the gas back pressure is supplied by nitrogen gas).

[0168] At block 2710, the method continues, wherein a single-phase solution comprising a polymer composition and a physical foaming agent is injected into the cavity of a mold. The single-phase solution comprises a polymer composition and a supercritical fluid in a ratio of X:Y, or X1:Y1, or X2:Y2. The injected single-phase solution is allowed to remain single-phase for a period of time without any supercritical fluid exiting the solution. In the example, this 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 process, which can produce more consistent foamed articles.

[0169] At block 2712, the method continues, wherein the gas back pressure is released from the mold cavity to below the critical pressure of the supercritical fluid, which acts as a physical foaming agent. When the pressure drops below the critical pressure, the supercritical fluid undergoes a gas phase change, causing the foaming agent to escape from the solution and form bubbles, which create the cell structure of the resulting foamed article. It is envisioned that the regulator continuously releases the gas back pressure during the injection process, but the release of the regulator is intended to maintain a consistent pressure within the mold cavity. Block 2712 indicates a pressure reduction to a level sufficient to activate the physical foaming agent.

[0170] Imagine that the mold can be transferred to a temperature-controlled support after the foaming process is initiated. This allows the mold and the foamed article to undergo temperature conditioning at the support. The conditioning time can vary, but in this example, it ranges from 1 minute to 90 minutes. This conditioning time allows the foamed article to cure within the mold and achieve dimensional stability before being removed from the mold.

[0171] At block 2714, the method continues by removing the footwear component from the mold. This removal can occur at an unloading machine to which the mold is conveyed. The removal of the footwear component formed in the mold can be done manually by a human operator, or it can be done automatically, such as by an end-arm tool for an assistive robot that effectively holds and removes the foamed product / component from the mold cavity.

[0172] Figure 28A flowchart 2800 depicts a second method for physically foaming footwear components according to various aspects thereof. At block 2802, the method includes temperature conditioning of a mold. At block 2804, the method includes applying a gas back pressure to a cavity in 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 back pressure to a pressure that causes the physical foaming agent to escape from the solution and foam the polymer composition. At block 2810, the method includes removing the foamed footwear component from the mold.

[0173] Figure 29 A flowchart 2900 depicts a third method for physically foaming footwear components according to various aspects thereof. At block 2902, the method includes engaging a mold with a hot runner plate and a pressure plate at a press. For example, the press compresses the mold between the pressure plate 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 it as a single-phase solution. At block 2904, the method includes injecting the single-phase solution into a cavity of the mold. The single-phase solution, comprising a physical foaming 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.

[0174] Figure 30 A flowchart 3000 depicts a fourth method for physically foaming footwear components according to various aspects thereof. At block 3002, the method includes reading an RFID tag associated with a mold by an RFID reader of a temperature-regulating bracket. At block 3004, the method includes associating temperature with the mold based on the RFID tag. For example, a thermocouple effectively measures the temperature of a temperature-regulating plate on which the mold may be located, and the RFID reader is also associated with the temperature-regulating plate. Therefore, a controller is able to associate the temperature of the temperature-regulating plate with the mold based on the determined mold position determined by querying the RFID reader of the RFID tag. At block 3006, the method continues, wherein 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 adequately adjusted for use in a system for forming physically foamed articles. 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.

[0175] Material

[0176] Foamed thermoplastic elastomer composition

[0177] This disclosure relates to articles comprising foam components, the foam components comprising foamed thermoplastic elastomer compositions. The foam components comprise foamed thermoplastic elastomer compositions having a multi-celled foam structure (e.g., multi-cell open-cell or closed-cell foam structure). Foam components may include foamed thermoplastic elastomer compositions having a multi-celled open-cell structure. The articles may be components for footwear, apparel, or sports equipment articles, such as cushioning elements. In one example, the article is a cushioning element for footwear articles (such as midsoles or midsole components).

[0178] It has been found that thermoplastic elastomer compositions (i.e., polymer compositions comprising one or more thermoplastic elastomers) (including thermoplastic polyester compositions (i.e., polymer compositions comprising one or more thermoplastic polyester elastomers)) can be used to form multi-celled foams with advantageous properties for consumer articles, such as cushioning elements. As used herein and discussed further below, the term polyester can refer to a polyester homopolymer and / or copolyester polymer having at least one polyester monomer segment. When foamed as described herein, these multi-celled foams retain thermoplastic properties, making the thermoplastic elastomer compositions of the foam readily recyclable and reusable. For example, once foamed, the thermoplastic elastomer composition can be milled, melted to eliminate its foam structure and foamed again, or it can be milled, melted to eliminate its foam structure and molded into articles having a non-foamed structure (i.e., solid articles).

[0179] The foam components disclosed herein are formed by foaming a thermoplastic elastomer composition into a multi-celled foam having an open-cell or closed-cell foam structure. The thermoplastic elastomer composition may be a thermoplastic polyester composition comprising one or more thermoplastic polyester elastomers. Examples of thermoplastic polyesters include polymers having one or more carboxylic acid functional groups, which are present in the polymer backbone, on one or more side chains, or simultaneously in the polymer backbone and on one or more side chains. The one or more carboxylic acid functional groups of the thermoplastic polyester may include free carboxylic acid, a salt of carboxylic acid, or an anhydride of carboxylic acid. The carboxylic acid functional groups of the thermoplastic polyester may be acrylic acid functional groups or methacrylic acid functional groups.

[0180] Based on the total weight of the thermoplastic elastomer composition, the thermoplastic elastomer composition may include at least 90% by weight, or at least 95% by weight, or at least 99% by weight of a polymer component, which includes all 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 includes at least 90% by weight, or at least 95% by weight, or at least 99% by weight of a polymer component, which includes all 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. Non-polymer components may include all non-polymer compositions present in the thermoplastic elastomer composition or the thermoplastic polyester composition, or may include specific types of non-polymer compositions present in the thermoplastic elastomer composition or the thermoplastic polyester composition. Examples of non-polymer components may include one or more of nucleating agents, non-polymer fillers, chemical foaming agents, colorants such as pigments and / or dyes, processing aids, etc. In some instances, the thermoplastic elastomer compositions (or thermoplastic polyester compositions) are 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 with low levels of non-polymer components (such as nucleating agents, fillers, and colorants) increases the likelihood of reusing and recycling these compositions, as they can be used for applications where the presence of one or more of these components is undesirable or would require dilution by adding virgin polymers. Furthermore, the absence of high levels of fillers or colorants in the polymer composition, compared to compositions with high levels of non-polymer components, can reduce the specific gravity of the foam and can allow the formation of foams with open-cell structures, which can further reduce the specific gravity of the foam.

[0181] Articles or foam parts comprising thermoplastic elastomer foams can be formed by injection molding and foaming thermoplastic elastomer polymer compositions as described herein to form articles or foam parts that can be directly incorporated into footwear, apparel, or sports equipment without any additional processing; that is, the dimensions and / or outer surface of the injection-molded foam may not require any modification. When using physical foaming agents, it has been found that injection-molded foams formed from thermoplastic elastomer compositions (including thermoplastic polyester compositions) are highly dimensionally stable because the foam articles or parts shrink very little after release from the mold and require no additional processing to stabilize the foam, thus allowing for the use of a “one-to-one” injection molding process, in which the size of the resulting molded foam article or part is substantially the same as the size of the mold used in the injection molding process. Alternatively, the injection-molded foam articles or parts may be further processed, such as by stabilizing the foam through an annealing process, by compressing the injection-molded foam articles or parts into finished foams, and / or by applying coatings or decorative elements to the injection-molded foam articles or parts.

[0182] Features of thermoplastic elastomer foam parts

[0183] The disclosed thermoplastic elastomer foams (i.e., foams formed by expanding thermoplastic elastomer compositions as disclosed herein) (including thermoplastic polyester foams) can exhibit a variety of beneficial properties. For example, thermoplastic elastomer foams can exhibit beneficial tear resistance, such as high tear resistance values ​​for sole components in footwear articles. In some aspects, when determined using the tear resistance test methods described herein, thermoplastic elastomer foams can have tear resistance values ​​greater than about 1.5 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 tear resistance test methods described herein, thermoplastic elastomer foams can have tear resistance values ​​from 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. Thermoplastic elastomer foams can have a tear strength 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 foam is injection molded and has a tear strength 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. Thermoplastic elastomer foams can have an open-cell foam structure. Thermoplastic elastomer foams can be the product of physical foaming of thermoplastic elastomer compositions as disclosed herein, i.e., foams formed using a physical foaming agent (i.e., a physical blowing agent). As used herein, thermoplastic elastomer foam should be understood to refer to a foamed material having both thermoplastic and elastomer properties. A thermoplastic elastomer foam can be a foamed product of a thermoplastic elastomer composition comprising less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymeric components based on the total weight of the thermoplastic elastomer composition. In some aspects, the thermoplastic elastomer foam is 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 foam is injection molded and subsequently compression molded in a separate compression mold, which has a different dimension from the mold used in the injection molding step.

[0184] The density or specific gravity of the disclosed thermoplastic elastomer foams (including thermoplastic polyester foams) is also an important physical property to consider when using the foams in clothing, footwear, or sports equipment. As discussed above, the thermoplastic elastomer foams of this disclosure exhibit low density or specific gravity, which advantageously reduces the weight of midsoles or other components containing thermoplastic elastomer foams.

[0185] When determined using the specific gravity testing methods described herein, the thermoplastic elastomer foams (including thermoplastic polyester foams) of this disclosure may have a specific gravity of 0.02 to 0.22, or 0.03 to 0.12, or 0.04 to 0.10, or 0.11 to 0.12, or 0.10 to 0.12, or 0.15 to 0.20, or 0.15 to 0.30. In some aspects, when determined using the specific gravity testing methods described herein, the thermoplastic elastomer foams may have a specific gravity of 0.15 to 0.22, such as 0.17 to 0.22 or 0.18 to 0.21. Alternatively or additionally, when determined using the specific gravity test method described herein, the thermoplastic elastomer foam may have a specific gravity of 0.01 to 0.10, or 0.02 to 0.08, or 0.03 to 0.06, or 0.08 to 0.15, or 0.10 to 0.12. For example, the specific gravity of the thermoplastic elastomer foam may be 0.15 to 0.2, or 0.10 to 0.12. The thermoplastic elastomer foam may be injection molded, or it may be injection molded and subsequently compression molded. In some aspects, when determined using the specific gravity test 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 methods described herein, thermoplastic elastomer foams (including thermoplastic elastomer foams present in midsoles and midsole components) may have a specific gravity of 0.05 to 0.25, or 0.05 to 0.2, or 0.05 to 0.15, or 0.08 to 0.15, or 0.08 to 0.20, or 0.08 to 0.25, or 0.1 to 0.15. In some aspects, when determined using the specific gravity testing methods described herein, thermoplastic elastomer foams have a specific gravity of about 0.15 to about 0.3, or about 0.2 to about 0.35, or about 0.15 to about 0.25. Thermoplastic elastomer foam articles or article parts may be formed by injection molding without a subsequent compression molding step. Thermoplastic elastomer foams may have an open-cell foam structure. Thermoplastic elastomer foam can be a foaming product that foams a thermoplastic elastomer composition, wherein the thermoplastic elastomer composition comprises less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymer components based on the total weight of the thermoplastic elastomer composition.

[0186] When determined using the density testing methods described herein, the thermoplastic elastomer foams (including thermoplastic polyester foams) of this disclosure can have densities ranging from 0.02 g / cc to 0.22 g / cc, or 0.03 g / cc to 0.12 g / cc, or 0.04 g / cc to 0.10 g / cc, or 0.11 g / cc to 0.12 g / cc, or 0.10 g / cc to 0.12 g / cc, or 0.15 g / cc to 0.2 g / cc, or 0.15 g / cc to 0.30 g / cc. In some aspects, when determined using the density testing methods described herein, the thermoplastic elastomer foams can have densities ranging from 0.15 g / cc to 0.22 g / cc, such as 0.17 g / cc to 0.22 g / cc or 0.18 g / cc to 0.21 g / cc. Alternatively or additionally, when determined using the density testing methods described herein, the thermoplastic elastomer foam may have a density of 0.01 g / cc to 0.10 g / cc, or 0.02 g / cc to 0.08 g / cc, or 0.03 g / cc to 0.06 g / cc, or 0.08 g / cc to 0.15 g / cc, or 0.10 g / cc to 0.12 g / cc. For example, the density of the thermoplastic elastomer foam may be 0.15 g / cc to 0.2 g / cc, or 0.10 g / cc to 0.12 g / cc. The thermoplastic elastomer foam may be injection molded, or it may be injection molded and subsequently compression molded. In some aspects, when determined using the density testing methods 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 methods described herein, the thermoplastic elastomer foam (including thermoplastic elastomer foam present in the midsole and midsole components) can have a density of 0.05 g / cc to 0.25 g / cc, or 0.05 g / cc to 0.2 g / cc, or 0.05 g / cc to 0.15 g / cc, or 0.08 g / cc to 0.15 g / cc, or 0.08 g / cc to 0.20 g / cc, or 0.08 g / cc to 0.25 g / cc, or 0.10 g / cc to 0.15 g / cc. In some respects, when determined using the density testing methods 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. Thermoplastic elastomer foam articles or article parts can be formed by injection molding without a subsequent compression molding step. Thermoplastic elastomer foams can have an open-cell foam structure.Thermoplastic elastomer foam can be a foaming product that foams a thermoplastic elastomer composition, wherein the thermoplastic elastomer composition comprises less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymer components based on the total weight of the thermoplastic elastomer composition.

[0187] When determined using a 45 mm diameter cylindrical sample for cyclic compression testing, 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 cyclic compression testing, 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. Thermoplastic elastomer foam articles or article components can be formed by injection molding without a subsequent compression molding step. Thermoplastic elastomer foams can have an open-cell foam structure. Thermoplastic elastomer foam can be a foaming product that foams a thermoplastic elastomer composition, wherein the thermoplastic elastomer composition comprises less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymer components based on the total weight of the thermoplastic elastomer composition.

[0188] When determined using the hardness tester described herein, the thermoplastic elastomer foam portion (including the thermoplastic polyester portion) of an article or article component may have an Asker C 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. Thermoplastic elastomer foam articles or article components may be formed by injection molding without a subsequent compression molding step. Thermoplastic elastomer foams may have an open-cell foam structure. Thermoplastic elastomer foams may be foamed products that foam a thermoplastic elastomer composition comprising less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymer components based on the total weight of the thermoplastic elastomer composition.

[0189] The energy input of the foam is the integral of the force-displacement curve during the loading phase of the foam in a cyclic compression test. The energy return of the foam is the integral of the force-displacement curve during the unloading phase of the foam in a cyclic compression test. When determined using a 45 mm diameter cylindrical sample for cyclic compression testing, the thermoplastic elastomer foam portion (including the thermoplastic polyester foam portion) of the article or article part may have an energy return of about 200 mJ to about 1200 mJ, or about 400 mJ to about 1000 mJ, or about 600 mJ to about 800 mJ. When determined using a foot-shaped sample for cyclic compression testing, the thermoplastic elastomer foam portion of the article or article part (e.g., for a footwear sole for a US men's size 10) may have an energy input of about 2000 mJ to about 9000 mJ, or about 3000 mJ to about 8000 mJ, or about 4500 mJ to about 6500 mJ. Thermoplastic elastomer foam articles or parts thereof can be formed by injection molding without a subsequent compression molding step. Thermoplastic elastomer foams can have an open-cell foam structure. Thermoplastic elastomer foams can be foamed products that foam a thermoplastic elastomer composition comprising less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymer components based on the total weight of the thermoplastic elastomer composition.

[0190] Energy efficiency (EE) is a measure of the percentage of energy in the thermoplastic elastomer foam portion (including thermoplastic polyester foam portion) of an article or component that is returned when it is released after being compressed under load. This can provide improved performance for athletic footwear, for example, to reduce energy loss or dissipation during running. This is especially true for running and other athletic footwear. In some respects, when determined using a 45 mm diameter cylindrical sample in a sample cyclic compression test, the thermoplastic elastomer foam portion of the articles and components provided herein has 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 cyclic compression testing, the thermoplastic elastomer foam portion of the articles and parts provided herein can have an energy efficiency of about 50% to about 97%, or about 60% to about 95%, or about 60% to about 90%, or about 60% to about 85%, or about 65% to about 85%, or about 70% to about 85%, or about 70% to about 90%, or about 70% to about 95%. Thermoplastic elastomer foam articles or article parts can be formed by injection molding without a subsequent compression molding step. Thermoplastic elastomer foams can have an open-cell foam structure. Thermoplastic elastomer foams can be foamed products that foam a thermoplastic elastomer composition comprising less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymer components based on the total weight of the thermoplastic elastomer composition.

[0191] The resulting foam can have a multi-cell closed-cell or open-cell foam structure. A cell is a hollow structure formed during the foaming process, in which air bubbles are formed in the thermoplastic elastomer composition by a foaming agent. The cell walls are largely defined by the thermoplastic elastomer composition. "Closed-cell" refers to a completely enclosed individual volume that is not in fluid communication with adjacent individual volumes. A "closed-cell structure" refers to a foam structure in which at least 50% or more of the cells are closed-cell, or at least 60% or more of the cells are closed-cell, or at least 80% or at least 90% of the cells are closed-cell, or at least 95% of the cells are closed-cell. 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-cell.

[0192] 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 the cell to the opposite side. For example, in some aspects of this disclosure, the open-cell and closed-cell thermoplastic elastomer foams can have an average cell size of about 50 micrometers to about 1000 micrometers, or about 80 micrometers to about 800 micrometers, or about 100 micrometers to about 500 micrometers. These are example cell sizes in one aspect of this disclosure, where the foam forms part of a footwear article, and in other aspects, the cell size can be larger or smaller when the foam forms other footwear articles. Additionally, the open-cell and closed-cell thermoplastic elastomer foams can form all or part of non-footwear articles, and in those cases, the foam can have a cell diameter including, smaller than, larger than, or any combination thereof, these example cell sizes.

[0193] For both open-cell and closed-cell structures, the cell proportion in a thermoplastic elastomer foam having a cell diameter of approximately 50 micrometers to approximately 1000 micrometers is preferably not less than 40% of all cells, or not less than 50% or not less than 60% of all cells. If the cell proportion is less than 40%, the cell structure will tend to be non-uniform and / or have a coarse cell structure. As used herein, a “coarse cell structure” refers to a foam structure in which the average cell diameter is greater than 1 millimeter, and / or for more than 20% of cells, a 1-millimeter line drawn across the largest cell size will not pass through the cell wall or strut (i.e., open cell wall or part thereof).

[0194] The number of open and / or closed cells in a foam and the cell diameter can be determined visually, for example by capturing an image of the cut surface with a camera or digital microscope, to determine the number of cells, the number of open cells and / or the number of closed cells, and to determine the cell area and convert it into the equivalent circle diameter.

[0195] Methods for manufacturing disclosed foam

[0196] In some instances, 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 parts (such as insoles, insole parts, inserts, and insert parts) can be prepared by injection molding a melt composition comprising a polymer composition (such as a thermoplastic elastomer composition) using a physical foaming agent, a combination of a physical foaming agent and a chemical foaming agent, or only a chemical foaming agent as described herein. The disclosed foam parts (e.g., the disclosed foam articles or parts) can be prepared by the methods disclosed below.

[0197] This document discloses a method for manufacturing foam articles or parts, the method 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; foaming the thermoplastic elastomer composition to form a foamed thermoplastic elastomer composition; curing the foamed thermoplastic elastomer composition to form a foam article having a multi-celled foam structure; and removing the foam article from the mold cavity. In some aspects, the mixture of the thermoplastic elastomer composition and the blowing agent comprises a single-phase solution of a liquid, gaseous, 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 a polymer composition. In a specific example, the mixture is a single-phase solution of supercritical nitrogen in a thermoplastic polyester composition. In some aspects, the thermoplastic elastomer composition comprises less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymer components based on the total weight of the thermoplastic elastomer composition. In this respect, injecting the mixture into the mold cavity may include injecting a single-phase solution into the mold cavity, then cooling the single-phase solution in the mold cavity before reducing the pressure in the mold cavity to a level where the supercritical fluid phase transforms into gas, and allowing gas to drip from the solution in the molten polymer, forming gas bubbles in the molten polymer and causing the molten polymer to foam. In some aspects, the foaming forms a foam with an open-cell foam structure.

[0198] A method for manufacturing foam articles or parts is also disclosed, the method comprising: forming a mixture of a molten thermoplastic elastomer composition and a foaming agent; injecting the mixture into a mold cavity; foaming the molten thermoplastic elastomer composition 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-celled 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 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 other aspects, the melt temperature of the thermoplastic elastomer present in the thermoplastic elastomer composition is the melt temperature of the thermoplastic elastomer having the highest melt temperature of all polymers present in the polymer component of the thermoplastic elastomer composition. In other aspects, the melt temperature is the melt temperature of the thermoplastic polyester (such as a polyester elastomer) present in the thermoplastic elastomer composition. Foaming can occur when the mixture is at a foaming temperature, wherein the foaming temperature is about the melt temperature of the thermoplastic elastomer to about 50°C above the tail temperature of the thermoplastic elastomer. In some aspects, the mixture forming the thermoplastic elastomer composition and the foaming agent comprises a single-phase solution forming a supercritical fluid and a molten thermoplastic elastomer composition. The thermoplastic elastomer composition may include less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymer 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 melt temperature may be the highest melt temperature of the thermoplastic elastomer present in the composition. In this respect, injecting the mixture into a mold cavity may include injecting a single-phase solution into the mold cavity, then cooling the single-phase solution in the mold cavity before reducing the pressure in the mold cavity to a level where the supercritical fluid phase transforms into a gas, and allowing gas to drip from the solution in the thermoplastic elastomer composition, forming gas bubbles in the thermoplastic elastomer composition and causing the thermoplastic elastomer to foam. Foaming can form a foam with an open-cell foam structure.

[0199] Dynamic scanning calorimetry (DSC) is used to determine the melt temperature and tail temperature of a thermoplastic elastomer composition, or the polymer component of a thermoplastic elastomer composition, or a separate thermoplastic elastomer present in a thermoplastic elastomer composition, and exemplary methods are described below. Briefly, 10 to 30 mg of undried resin granules 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 hot-cold-hot profile, where the heating / cooling rate is 10°C / min, the lowest temperature is 0°C, and the highest temperature is 250°C. Analysis should be performed in duplicate. The melt temperature and glass transition temperature values ​​are recorded from the second cycle. The melt “peak” is identified as the local maximum value of the second heating cycle. If more than one peak exists in the DSC profile, 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 and the extrapolated baseline.

[0200] The disclosed foamed thermoplastic elastomer compositions can be prepared using a suitable syringe. The syringe may have a motor to rotate a screw within the syringe. The syringe may include a single screw or a twin screw and may include individual elements of various sizes and pitches suitable for mixing or kneading the specific materials used.

[0201] 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 appropriately sized solid particles (e.g., fragments or granules), which can melt when mixed in the syringe barrel. The contents of the syringe can be heated to melt the composition. While the melt is present in the syringe barrel, a physical foaming 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 foaming agent that causes the composition to foam in a mold cavity, and the resulting thermoplastic elastomer foam is therefore substantially free of unreacted chemical foaming agents or decomposition or degradation products of chemical foaming agents. The thermoplastic elastomer composition can be added to the syringe as a melt at a temperature close to the melting temperature of the polymer components of the composition.

[0202] If a chemical blowing agent is used, the processing (melting) temperature can be sufficiently lower than 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 near or at the trigger temperature of the chemical blowing agent, thereby generating a chemically foamed thermoplastic polyester foam when the composition leaves the syringe (e.g., when the composition is injected 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 trigger temperature of the chemical blowing agent, thereby generating a chemically foamed thermoplastic elastomer foam within the runner and / or the mold cavity.

[0203] Alternatively or additionally, physical foaming agents can be used to foam the thermoplastic elastomer composition to form physically foamed thermoplastic elastomer foams, or physically and chemically foamed thermoplastic elastomer foams. For example, supercritical fluids (such as supercritical carbon dioxide or supercritical nitrogen) can be mixed with the molten thermoplastic elastomer composition in the barrel of a syringe to form a single-phase solution. Pressure drop can be used to convert the supercritical fluid into a gas phase and to foam the thermoplastic elastomer composition. In one aspect, gas back pressure can be applied to the mold cavity and the flow channels leading to the mold cavity. The back pressure can be high enough to hold the supercritical fluid in the solution within the flow channels and the mold cavity. Once a single-phase solution is in the mold cavity, the back pressure within the mold cavity can be reduced to a level at which the supercritical fluid phase converts into a gas and drips from the solution in the molten thermoplastic elastomer composition, forming gas bubbles in the thermoplastic elastomer composition and causing the thermoplastic elastomer composition to foam in the mold cavity. In one aspect, the thermoplastic elastomer composition comprises less than 10% by weight, or less than 5% by weight, or less than 1% by weight of nonpolymeric components based on the total weight of the thermoplastic elastomer composition, and the multicellular foam has an open-cell structure.

[0204] Articles, cushioning elements, or article components (such as insoles, insole components, inserts, and insert components) can be prepared by injection molding the thermoplastic elastomer compositions described herein using a physical foaming agent. The injection molding process can utilize a screw-type injector, which allows for maintaining and controlling the pressure within the injector barrel. The injection molding machine can allow for the metering and delivery of 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 cause the molten thermoplastic elastomer composition to expand (foam) when the temperature and / or pressure change to the point where the solubility of the supercritical fluid in the molten thermoplastic elastomer composition changes and the supercritical fluid transitions to the gas phase. The injection molding process can include using injection molding processes that form multi-celled foam structures, such as the “MUCELL” process (Trexel Inc., Wilmington, MA, USA), to physically foam the compositions described herein.

[0205] The thermoplastic elastomer foams described herein can be produced using a process involving impregnating a thermoplastic elastomer composition with a physical blowing agent at a first concentration or a first pressure (e.g., at or above the softening temperature of the composition). As used herein, the term "impregnation" generally refers to dissolving or suspending a physical blowing agent in the composition. The impregnated composition can then be foamed, or it can be cooled (where applicable) and re-softened (where applicable) to foam at a later time. In some aspects, the impregnated molten thermoplastic elastomer composition forms a single-phase solution comprising a supercritical fluid (e.g., carbon dioxide or nitrogen) dissolved in the molten thermoplastic elastomer composition. In one aspect, the thermoplastic elastomer composition comprises less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymer components based on the total weight of the thermoplastic elastomer composition.

[0206] Foaming of an impregnated thermoplastic elastomer composition (e.g., a single-phase solution) is achieved by reducing the solubility of a physical foaming agent in the thermoplastic elastomer composition through pressure and / or temperature changes. These pressure and / or temperature changes can occur immediately after the impregnated composition leaves the syringe or injection barrel, or in the runner leading to the mold cavity, or within the mold cavity itself. For example, the system may include a hot runner or gas backpressure, or both, which controls and maintains 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 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 a supercritical fluid in the molten thermoplastic elastomer composition, thereby causing the molten thermoplastic elastomer composition to expand into a foam, including a foam with an open-cell structure. The decrease in the solubility of a physical foaming agent can release additional amounts of gas (e.g., to produce secondary expansion of the partially foamed thermoplastic elastomer composition) to further expand the composition and form a foam structure (e.g., a foam with a multi-celled structure). Alternatively or additionally, a chemical foaming agent can be activated in the thermoplastic elastomer composition in the mold cavity to produce secondary expansion of the partially foamed thermoplastic elastomer composition.

[0207] Chemical foaming agents can be endothermic or exothermic, referring to the type of decomposition or degradation they undergo that produces gases (used to generate foam). Decomposition or degradation can be triggered by thermal energy present in the molding system. Endothermic foaming agents absorb energy and typically release gases, such as carbon dioxide, upon decomposition. Exothermic foaming agents release energy and generate gases, such as nitrogen, upon decomposition. Regardless of the chemical foaming agent used, the thermal variables of the foamed thermoplastic elastomer composition and the thermal variables of the foaming agent to be decomposed or degraded are combined to allow for the selection of process parameters so that the thermoplastic elastomer composition can be foamed and molded, and the foaming agent can be decomposed or degraded at appropriate stages of the foaming and molding process.

[0208] Thermoplastic elastomer compositions

[0209] The thermoplastic elastomer compositions disclosed herein include one or more thermoplastic elastomers. These one or more thermoplastic elastomers may be one or more thermoplastic polyester elastomers. In some aspects, based on the total weight of the thermoplastic elastomer composition, the thermoplastic elastomer composition includes at least 90% by weight, or at least 95% by weight, or at least 99% by weight of a thermoplastic resin component, wherein the thermoplastic resin component includes all polymers present in the composition. The thermoplastic resin component includes one or more thermoplastic elastomers. The thermoplastic resin component may include at least one thermoplastic polyester elastomer. The thermoplastic resin component may include more than one thermoplastic polyester elastomer. The thermoplastic resin component may include one or more thermoplastic polyester elastomers and one or more thermoplastic polyesters that are not elastomers. In some aspects, the thermoplastic resin component includes one or more thermoplastic polyesters and also includes 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, may each be a thermoplastic elastomer. Alternatively, in other aspects, the thermoplastic resin component consists substantially of one or more thermoplastic elastomers. Optionally, the thermoplastic resin component may consist substantially of one or more thermoplastic polyester elastomers. In some aspects, the thermoplastic elastomer composition comprises less than 10% by weight, or less than 5% by weight, or less than 1% by weight of non-polymeric components, based on the total weight of the thermoplastic elastomer composition. 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, the thermoplastic elastomer composition comprises less than 10% by weight, or less than 5% by weight, or less than 1% by weight of solid colorants, based on the total weight of the thermoplastic elastomer composition. In one aspect, the thermoplastic elastomer composition consists substantially of one or more thermoplastic elastomers. In another aspect, the thermoplastic elastomer composition consists substantially 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 respects, thermoplastic copolyester elastomers can include copolyesters having two or more types of polyester monomer segments, or copolyesters including polyester monomer segments and one or more non-polyester monomer segments.

[0210] In some aspects, the resin component of a thermoplastic elastomer composition, including all polymer compositions present in a thermoplastic polyester composition, is substantially composed of one or more thermoplastic elastomers or substantially composed 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 olefinic unsaturated acid groups.

[0211] 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, determined by using 2.16 kg weight at 210°C. 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, determined by using 2.16 kg weight at 220°C. 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, determined by using 2.16 kg weight at 230°C.

[0212] Thermoplastic elastomers (including thermoplastic polyesters) may have the following weight-average molecular weights: 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.

[0213] Thermoplastic elastomers (including thermoplastic copolyesters) can be terpolymers. In some aspects, the thermoplastic copolyester can be a terpolymer derived from ethylene, acrylic acid, and portions of methyl acrylate or butyl acrylate. In some aspects, the ratio of the total weight parts of acrylic acid 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.

[0214] Thermoplastic elastomers can be terpolymers comprising 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 comprising: (a) a plurality of first segments, each derived from a dihydroxy-terminated polydiol; (b) a plurality of second segments, each derived from a diol; and (c) a plurality of third segments, each derived from an aromatic dicarboxylic acid. In various aspects, the thermoplastic copolyester is a block copolymer. In some aspects, the thermoplastic copolyester is a multiblock copolymer. In other aspects, the thermoplastic copolyester is a random copolymer. In still other aspects, the thermoplastic copolyester is a condensation copolymer.

[0215] Thermoplastic elastomers (including thermoplastic copolyesters) may have the following ratio of first segment to third segment: from about 1:1 to about 1:5 by weight of each of the first and third segments; or from about 1:1 to about 1:4 by weight of each of the first and third segments; or from about 1:1 to about 1:2 by weight of each of the first and third segments; or from about 1:1 to about 1:3 by weight of each of the first and third segments.

[0216] Thermoplastic elastomers (including thermoplastic copolyesters) may have the following ratio of second to third segments: from about 1:1 to about 1:2 by weight of each of the first and third segments; or from about 1:1 to about 1:1.52 by weight of each of the first and third segments.

[0217] Thermoplastic elastomers (including thermoplastic copolyesters) may have a first segment derived from a poly(epoxy)diol having the following number average molecular weights: about 250 Daltons to about 6,000 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.

[0218] Thermoplastic elastomers (including thermoplastic copolyesters) may have a first segment derived from a poly(epoxide) glycol, such as poly(vinyl ether) glycol; poly(propylene ether) glycol; poly(tetramethylene ether) glycol; poly(pentamethylene ether) glycol; poly(hexamethylene ether) glycol; poly(heptamethylene ether) glycol; poly(octamethylene ether) glycol; poly(nonamethylene ether) glycol; poly(decamethylene ether) glycol; or mixtures thereof. In another aspect, the thermoplastic copolyester may have a first segment derived from a poly(epoxide) glycol, such as poly(vinyl ether) glycol; poly(propylene ether) glycol; poly(tetramethylene ether) glycol; poly(pentamethylene ether) glycol; poly(hexamethylene ether) glycol. In yet another aspect, the thermoplastic copolyester may have a first segment derived from a poly(tetramethylene ether) glycol.

[0219] Thermoplastic elastomers (including thermoplastic copolyesters) may have a second segment derived from a diol with a molecular weight of less than about 250. The diol from which the second segment is derived may be a C2 to C8 diol. In another aspect, the second segment may be derived from ethylene glycol; propylene glycol; butanediol; pentanediol; 2-methylpropanediol; 2,2-dimethylpropanediol; hexanediol; 1,2-dihydroxycyclohexane; 1,3-dihydroxycyclohexane; 1,4-dihydroxycyclohexane; and mixtures thereof. In yet another aspect, the second segment may be derived from 1,2-ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,6-hexanediol, and mixtures thereof. In yet another aspect, the second segment may be derived from 1,2-ethylene glycol. In yet another aspect, the second segment may be derived from 1,4-butanediol.

[0220] Thermoplastic elastomers (including copolyesters) may have a third segment derived from aromatic C5 to C16 dicarboxylic acids. Aromatic C5 to C16 dicarboxylic acids may have the following molecular weights: less than about 300 Daltons; about 120 Daltons to about 200 Daltons; or one or more values ​​of molecular weight within any of the foregoing ranges, or a molecular weight range covering any subrange of the foregoing ranges. In some cases, aromatic C5 to C16 dicarboxylic acids are terephthalic acid, phthalic acid, isophthalic acid, or derivatives thereof. In another aspect, aromatic C5 to C16 dicarboxylic acids are diester derivatives of terephthalic acid, phthalic acid, or isophthalic acid. In yet another aspect, aromatic C5 to C16 dicarboxylic acids are terephthalic acid or a dimethyl ester derivative thereof.

[0221] The thermoplastic copolyester may include: (a) a plurality of first copolyester units, each of the plurality of first copolyester units comprising a first segment derived from a dihydroxyl-terminated polydiol and a third segment derived from an aromatic dicarboxylic acid, wherein the first copolyester unit has a structure represented by Formula 1:

[0222]

[0223] Wherein R1 is the group remaining after removing the terminal hydroxyl group from the poly(epoxy)diol of the first segment, wherein the poly(epoxy)diol of the first segment is a poly(epoxy)diol with 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 comprising a second segment derived from the diol and a third segment derived from the aromatic dicarboxylic acid, wherein the second copolyester unit has a structure represented by Formula 2:

[0224] R3 is the group remaining after removing the hydroxyl group from the diol derived from the second segment of the diol, wherein the diol is a diol with a molecular weight of less than about 250; and R2 is the group remaining after removing the carboxyl group from the aromatic dicarboxylic acid of the third segment.

[0225] Thermoplastic copolyesters may include a plurality of first copolyester units having a structure represented by Formula 3:

[0226]

[0227] Wherein R is H or methyl; where y is an integer having a value from 1 to 10; where z is an integer having a value from 2 to 60; and where 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 other 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.

[0228] Thermoplastic copolyesters may include a plurality of first copolyester units having a structure represented by Formula 4:

[0229]

[0230] Where z is an integer having a value from 2 to 60; and each of the plurality of first copolyester units has a weight-average molecular weight of 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 from 5 to 60; or an integer having a value from 5 to 50; or an integer having a value from 5 to 40; or an integer having a value from 4 to 30; or an integer having a value from 4 to 20; or an integer having a value from 2 to 10.

[0231] The thermoplastic copolyester may include a plurality of first copolyester units having the following weight-average molecular weights: about 400 Daltons to about 6,000 Daltons; or about 400 Daltons to about 5,000 Daltons; or about 400 Daltons to about 4,000 Daltons; or about 400 Daltons to about 3,000 Daltons; or about 500 Daltons to about 6,000 Daltons; or about 500 Daltons to about 5,000 Daltons; or about 500 Daltons to about 4,000 Daltons; or about 500 Daltons to about 3,000 Daltons; or about 600 Daltons to about 6,000 Daltons; or about 600 Daltons to about 5,000 Daltons; or about 600 Daltons to about 4,000 Daltons; or about 600 Daltons to about 3,000 Daltons; or about 2,000 Daltons to about 3,000 Daltons.

[0232] Thermoplastic copolyesters may include a plurality of second copolyester units, each of which has a structure represented by Equation 5:

[0233]

[0234] Where x is an integer having a value from 1 to 20; wherein the foamed article has a multi-cell 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 range or values, or any range of integer values ​​covering a subrange of the foregoing range of integer values. In other aspects, x is an integer having a value of 2, 3, or 4.

[0235] Thermoplastic copolyesters may include a plurality of second copolyester units, each of which has a structure represented by Equation 6:

[0236]

[0237] Based on the total weight of the thermoplastic copolyester, the thermoplastic copolyester may include a plurality of first copolyester units in a weight percentage range such that the weight percentage ranges from about 30 wt% to about 80 wt%; or about 40 wt% to about 80 wt%; or about 50 wt% to about 80 wt%; or about 30 wt% to about 70 wt%; or about 40 wt% to about 70 wt%; or about 50 wt% to about 70 wt%; or about 40 wt% to about 65 wt%; or about 45 wt% to about 65 wt%; or about 50 wt% to about 65 wt%; or about 55 wt% to about 65 wt%; or about 40 wt% to about 60 wt%; or about 45 wt% to about 60 wt%; or about 50 wt% to about 60 wt%; or about 55 wt% to about 60 wt%.

[0238] In some aspects, thermoplastic elastomers (including thermoplastic copolyesters) may include phase-separated structural domains. For example, a plurality of first segments derived from dihydroxyl-terminated polydiols may be phase-separated into structural domains primarily comprising the first segments. Furthermore, a plurality of second segments derived from diols may be phase-separated into structural domains primarily comprising the second segments. In other aspects, thermoplastic copolyesters may include phase-separated structural domains primarily comprising a plurality of first copolyester units, each of which includes a first segment derived from a dihydroxyl-terminated polydiol and a third segment derived from an aromatic dicarboxylic acid, wherein the first copolyester unit has a structure represented by Formula 1:

[0239]

[0240] Wherein R1 is the group remaining after removing the terminal hydroxyl group from the poly(epoxy)diol of the first segment, wherein the poly(epoxy)diol of the first segment is a poly(epoxy)diol with 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 other phase-separated structural domains mainly comprising a plurality of second copolyester units, each of the plurality of second copolyester units comprising a second segment derived from the diol and a third segment derived from the aromatic dicarboxylic acid, wherein the second copolyester unit has a structure represented by Formula 2:

[0241]

[0242] R3 is the group remaining after removing the hydroxyl group from the diol derived from the second segment of the diol, wherein the diol is a diol with a molecular weight of less than about 250; and R2 is the group remaining after removing the carboxyl group from the aromatic dicarboxylic acid of the third segment.

[0243] In other respects, the thermoplastic copolyester may include a phase-separated structural domain primarily comprising a plurality of first copolyester units, each of which has a structure represented by Equation 3:

[0244]

[0245] Wherein R is H or methyl; where y is an integer having a value from 1 to 10; where z is an integer having a value from 2 to 60; and where 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 other 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.

[0246] In other respects, the thermoplastic copolyester may include a phase-separated structural domain primarily comprising a plurality of first copolyester units, each of which has a structure represented by Equation 4:

[0247]

[0248] Where z is an integer having a value from 2 to 60; and 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 from 5 to 60; or an integer having a value from 5 to 50; or an integer having a value from 5 to 40; or an integer having a value from 4 to 30; or an integer having a value from 4 to 20; or an integer having a value from 2 to 10.

[0249] The thermoplastic copolyester may include a phase-separated domain comprising a plurality of first copolyester units having the following molecular weights: about 400 Daltons to about 6,000 Daltons; or about 400 Daltons to about 5,000 Daltons; or about 400 Daltons to about 4,000 Daltons; or about 400 Daltons to about 3,000 Daltons; or about 500 Daltons to about 6,000 Daltons; or about 500 Daltons to about 5,000 Daltons; or about 500 Daltons to about 4,000 Daltons; or about 500 Daltons to about 3,000 Daltons; or about 600 Daltons to about 6,000 Daltons; or about 600 Daltons to about 5,000 Daltons; or about 600 Daltons to about 4,000 Daltons; or about 600 Daltons to about 3,000 Daltons; or about 2,000 Daltons to about 3,000 Daltons.

[0250] In other respects, the thermoplastic copolyester may include a phase-separated structural domain comprising a plurality of second copolyester units, each of which has a structure represented by Equation 5:

[0251]

[0252] Where x is an integer having a value from 1 to 20; wherein the foamed product has a multi-cell 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.

[0253] In other respects, the thermoplastic copolyester may include a phase-separated structural domain comprising a plurality of second copolyester units, each of which has a structure represented by Equation 6:

[0254]

[0255] The thermoplastic copolyester may include phase-separated structural domains, wherein, based on the total weight of the thermoplastic copolyester, the weight percentage of the phase-separated structural domains comprising a plurality of first copolyester units ranges from about 30 wt% to about 80 wt%; or about 40 wt% to about 80 wt%; or about 50 wt% to about 80 wt%; or about 30 wt% to about 70 wt%; or about 40 wt% to about 70 wt%; or about 50 wt% to about 70 wt%; or about 40 wt% to about 65 wt%; or about 45 wt% to about 65 wt%; or about 50 wt% to about 65 wt%; or about 55 wt% to about 65 wt%; or about 40 wt% to about 60 wt%; or about 50 wt% to about 60 wt%; or about 55 wt% to about 60 wt%.

[0256] In all respects, the thermoplastic elastomer composition may include one or more thermoplastic polyester homopolymers, wherein the thermoplastic polyester homopolymer includes any of the polyester monomer segments or units or modifications thereof disclosed herein. In the same or alternative respects, the thermoplastic elastomer composition may include one or more thermoplastic polyester homopolymers, wherein the thermoplastic polyester homopolymer includes any polyester homopolymer exhibiting any or all of the properties and parameters discussed herein with respect to thermoplastic elastomers and / or thermoplastic elastomer compositions.

[0257] The disclosed thermoplastic elastomer compositions, polymeric components of the compositions, or individual thermoplastic elastomers in their pure form may be characterized by one or more properties. In some aspects, when determined using the cyclic tensile testing method described herein, the thermoplastic elastomer composition or polymeric component or polymer has a maximum load of about 10 Newtons to about 100 Newtons, or about 15 Newtons to about 50 Newtons, or about 20 Newtons to about 40 Newtons.

[0258] Tensile strength of the thermoplastic elastomer composition or the polymer component of the thermoplastic elastomer composition or the pure form of the thermoplastic elastomer is another important physical characteristic. When determined using the cyclic tensile testing method described herein, the thermoplastic elastomer composition or polymer component or elastomer can have tensile strengths ranging 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.

[0259] When determined using the cyclic tensile testing method described herein, the thermoplastic elastomer composition or the polymer component of the thermoplastic elastomer composition or the pure form of the thermoplastic elastomer can have a tensile modulus of about 2 MPa to about 20 MPa or about 5 MPa to about 15 MPa.

[0260] Exemplary but non-limiting thermoplastic elastomers (including thermoplastic polyesters) that may 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 City, NY, USA); “TRIEL” 5300, “TRIEL” 5400, and blends thereof (Samyang Corporation, South Korea); and “KEYFLEX” BT1028D, BT1033D, BT1035D, BT1040D, BT1045D, and BT1047D (LG Chem, LG Chem). Chem (Korea); and "KOPEL" KP3340, KP3346, KP3347 (Kolon Plastics, Inc., Korea).

[0261] The disclosed thermoplastic elastomer compositions may also include one or more ionomers, such as any of the “SURLYN” polymers (DuPont, Wilmington, Delaware, USA). The foams described herein can be prepared by a process / method comprising receiving the compositions described herein and physically foaming the compositions to form thermoplastic elastomer foams having the following densities: about 0.7 g / cm³ or less, or 0.5 g / cm³ or less, or 0.4 g / cm³ or less, or 0.3 g / cm³ or less.

[0262] The disclosed thermoplastic elastomer compositions may 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., Brexville, Ohio, USA).

[0263] The disclosed thermoplastic elastomer compositions may further comprise 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 polymers are ethylene-based copolymers, such as styrene-ethylene / butene-styrene (SEBS) copolymers; ethylene-propylene diene monomer (EPDM) copolymers; ethylene-vinyl acetate (EVA) copolymers; ethylene-alkyl acrylate (EAA) copolymers; ethylene-alkyl methacrylate (EAMA) copolymers; any copolymers thereof, and any blends thereof. In some aspects, the ratio V of the total weight parts of the olefin polymers present in the composition to the total weight parts of the thermoplastic polyesters in the composition is about 0.0 to about 0.6, or about 0.0 to about 0.4, or about 0.01 to about 0.4, or about 0.01 to about 0.6, or about 0.1 to about 0.4.

[0264] The disclosed thermoplastic elastomer compositions may also include ethylene-vinyl acetate (EVA) copolymers. The ethylene-vinyl acetate (EVA) copolymers may have a range of vinyl acetate contents based on the weight of the copolymer, for example, 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%.

[0265] Characterization of thermoplastic elastomer compositions

[0266] Component sampling procedure

[0267] This procedure can be used to obtain samples of the foam composition or material when the composition or material is incorporated into a component (such as the sole structure, midsole, or outsole of a footwear article). Samples of the component including the composition or material are obtained during the component's formation or by cutting it from the footwear article using a blade. The 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 may be peeled, abraded, scraped, or otherwise cleaned to remove any upper adhesives, yarns, fibers, foam, etc., that may potentially interfere with test results.

[0268] The resulting component samples comprise compositions or materials. Accordingly, any test using the component sampling procedure can simulate how the composition or material would function as part of a footwear article. As specified in the test method, the component can be tested as a complete component (e.g., a complete midsole component), or it can be removed as a sample with a specific geometry. Samples of the component are taken at locations along the component where it is provided at a substantially constant thickness (within plus or minus 10% of the average thickness), such as in the forefoot, midfoot, or heel region of the article. Unless otherwise specified, the desired geometry of the harvested component is a cylindrical disc with a diameter of 45 mm and a cylindrical height of at least about 10 mm, preferably about 20 to 25 mm.

[0269] Density test

[0270] The density of samples obtained using the component sampling procedure was measured using a digital balance or a Densicom tester (Qualitest Corporation, Plantesham, Florida, USA). For each sample, the sample volume was determined in cubic centimeters, and then each sample was weighed (g). The sample density is given as mass divided by the sample volume, expressed in grams per cubic centimeter.

[0271] Specific gravity test

[0272] This test is applicable to both closed-cell foam and open-cell foam samples with a substantially uniform closed skin. The specific gravity (SG) of the samples obtained using the component sampling procedure is measured using a digital balance or a Densicom tester (Gordon Corporation, Plantesham, Florida, USA). Each sample is weighed (g) and then immersed in a distilled water bath (22°C ± 2°C). To avoid error, air bubbles are removed from the sample surface, for example by wiping the sample with isopropyl alcohol before immersion in water, or by using a brush after immersion. The weight of the sample in distilled water is recorded. The specific gravity is calculated using the following formula:

[0273]

[0274] Force / displacement test (foot-shaped cyclic compression test)

[0275] Force / displacement behavior of foams and foamed products can be measured using complete midsole samples, complete outsole samples, separate midsoles, and / or separate midsoles, with foot-shaped samples used to test impacts to accurately simulate full-open loads. For these tests, a cyclic compression testing apparatus such as the Instron Electropuls E10000 (Instron Corporation, Norwood, MA, USA) was used to apply a 2000 N load at a load rate of 5 Hz to midsoles with foot-shaped samples, testing US Men's Size 10 midsoles and Men's Size 9 foot-shaped samples for impact. Each sample was compressed to 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) were measured from the generated force-displacement curves. The stiffness of a specific foam sample is the maximum load divided by the displacement under the maximum load, given as a value in N / mm. The reported value for each metric is the average of the metrics from the 60th, 70th, 80th, and 90th cycles.

[0276] Sample Cyclic Compression Test

[0277] The force / displacement behavior of foams and foamed articles can also be measured, or alternatively, using samples harvested from larger parts (e.g., cylindrical discs harvested from footwear midsoles), and methods for obtaining samples are described in the “Part Sampling Procedure” section of this disclosure. In one testing method, when testing a sample (e.g., a cylindrical disc harvested from a larger part), the sample is tested along the length axis of the part using a compression plate at least twice the diameter (e.g., the diameter of the cylindrical disc). Furthermore, the sample is compressed to a 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 in such a way that example characteristic ranges (which may depend on the sample geometry) are provided in parentheses. Stiffness is the stress at 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 load 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).

[0278] Cyclic tensile test

[0279] Cyclic tensile tests were performed on solid specimens prepared using a component sampling procedure. These specimens were 2 mm thick and dog-bone shaped as described in ASTM D638. During testing, the specimens were placed under a preload of 5 N. Strain was controlled to elongate the specimens to 6% at a strain rate of 5 Hz. Stiffness was calculated by dividing the load at 6% strain by the elongation at 6% strain, given in N / mm. The maximum load (N) observed over 500 test cycles was also recorded.

[0280] Hardness tester hardness test - Shore A

[0281] The following tests are used to obtain the hardness values ​​of foam products. A flat foam sample is prepared using a component sampling procedure, with the sample having a minimum thickness of 6 mm for Shore A hardness testing. Samples may be stacked to achieve the minimum thickness if necessary. The sample is 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 test area is flat and parallel, with an area of ​​at least 6 mm in diameter. At least five hardness measurements and tests are performed using a head weight of 1 kg.

[0282] Transverse tear test

[0283] The split tear test determines the internal tear strength of foam materials. Samples can be provided using a component sampling procedure. The sample is punched into a rectangular shape 1.54 cm wide, 15.24 cm long (1 inch × 6 inches), and 10 mm (±1 mm) thick. At one end, a slit is made in the sample, bisecting the thickness, extending across the entire width of the sample and 3 cm from the end of the sample. Starting from the end of the slit, five marks are placed at 2 cm intervals along the length of the sample. The cut end of the sample is placed in the clamps of a tensile testing machine. Each segment of the sample is held in the clamps in such a way that the original adjacent cut edges form a straight line connecting the center of the clamps. The crosshead speed is set to 50 mm / min. The tear strength is measured throughout the entire splitting process of the crosshead. If necessary, a sharp blade can be used to hold the foam at the center of the separated sample, discarding any readings caused by the blade's cutting. Record the lowest split tear strength value for each of the five marked segments of the sample (between each of the 2 cm marks). Record the average split tear strength value for each sample. If a segment of the sample has an air bubble larger than 2 mm, the tear strength of that segment is discarded, and the air bubble is recorded as a test defect. If more than one segment of the sample has an air bubble larger than 2 mm, the entire sample is discarded.

[0284] Energy intensity

[0285] Energy intensity is used for formation specificThe energy of foam products is measured in kilowatt-hours (kW-h). To obtain energy intensity, the energy required (in kW-H) to produce a batch or lot of products, such as cushioning elements (e.g., paired insoles 122), is first calculated, determined, or measured (from granules to finished parts). For example, for physical foaming processes, the measured energy may include the energy required for all energy-consuming steps such as: preheating the mold and hot runner (if used), melting the granules, generating gas back pressure, injecting molten plastic, introducing supercritical fluid, cooling the mold and / or the workpiece, and removing the workpiece from the mold. The total energy required to produce this batch of cushioning element pairs is then divided by the number of cushioning element pairs produced in that batch.

[0286] Zero shear viscosity

[0287] The zero-shear viscosity was determined using flow profiles obtained on a rotational rheometer. The zero-shear viscosity was defined as the viscosity at 1 x 10⁻⁶ when the polymer was heated to 10°C above its melt temperature. -2 The apparent viscosity of the polymer melt was measured at a shear rate of 1 / s. The apparent viscosity was measured in continuous flow using a cone-plate rotating holder. The temperature of the rotating holder was maintained at the polymer melt temperature. The voids and geometry of the cone were selected such that the measured torque was entirely within the measurement limits of the rheometer.

[0288] Melt flow index test

[0289] According to the test method detailed in ASTM D1238-13, "Standard Test Method for Measuring Melt Flow Rate of Thermoplastic Plastics by Extrusion Plasticity Tester," the melt flow index is determined using a sample prepared using the part sampling procedure described therein, with procedure A described therein. In short, the melt flow index measures the extrusion rate of a thermoplastic plastic through an orifice at a specified temperature and load. In the test method, approximately 7 grams of sample are loaded into the barrel of a melt flow apparatus heated to a specified temperature of 210°C, 220°C, or 230°C. A weight of 2.16 kg is applied to the plunger, forcing the molten sample through the die. The extrudate is collected at time and weighed. The melt flow rate value is calculated (in g / 10 min) and reported at the specified temperature (i.e., 210, 220, or 230°C) and the weight applied to the plunger (i.e., 2.15 kg).

[0290] Recyclables

[0291] Next reference Figure 20 The flowchart, in accordance with various aspects of this disclosure, substantially describes at point 2000 the process for manufacturing foamed polymer articles (such as...). Figure 1 An improved method or control strategy for the midsole (122). Figure 20Some or all of the operations illustrated and further described in detail below may represent algorithms corresponding to processor-executable instructions, which may be stored in, for example, main memory, 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 or all of the functions described above or below associated with the disclosed concepts. One or more of the illustrated operations may be performed manually or with manual assistance by a field technician. It should be understood that the execution order 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.

[0292] Figure 31 Method 3100 is initialized at block 3101, for example, in response to an input activation command signal received from a human-machine interface (HMI) of a central control terminal. The initial phase of the manufacturing process may include supplying, acquiring, and / or utilizing (collectively, “receiving”) various materials, tools, and machines required to manufacture foamed polymer articles. For example, at process block 2003, a batch of recycled plastic material is acquired from an available repository of polymer recyclables. As used herein, the term “recycled plastic” can encompass used, excess, or scrapped plastics entering the recycling stream, including wholesale recycling of entire products, dismantling of products and recycling only selected parts, and recycling of manufacturing byproducts, all of which may require sorting and cleaning of any collected material. For at least some embodiments, waste and scrap thermoplastic polyester elastomer (TPE-E) compositions (e.g., regenerated from foamed or unfoamed virgin TPE-E material and / or virgin TPE-E compositions) can be recycled and then incorporated into foamed articles produced using at least some virgin TPE-E and / or virgin TPE-E compositions. The recycled TPE-E compositions can be derived from one or more reactants, such as poly(epoxy)diol materials and / or aromatic dicarboxylic acid materials. The recycled thermoplastic polyester elastomer compositions can have a weight-average molecular weight in the range of about 50,000 Daltons to about 200,000 Daltons.

[0293] Once the batch of recycled plastic is received and any incidental sorting, cleaning, and other pretreatments are completed at process block 3103, method 3100 shreds, chips, cuts, and / or grinds (collectively, “grinding”) the batch of recycled plastic at process block 3105. As a non-limiting example, a dedicated recycling station may be responsible for grinding the recycled TPE-E into granules or pellets; the ground recycled material may be produced in real-time or stored in stock for reuse when desired. Alternatively, “grinding” may include feeding the hot compound of the recycled material into an extruder equipped with a perforated die; a cutter immediately in front of the die cutter extrudes the compound line into granular pellets. The cut pellets are then cooled while being conveyed to a screening machine to separate irregularly sized pellets. The “re-ground material” thermoplastic polymer composition may be derived from re-extruded material, such as unfoamed TPE-E composition waste from the die runner, which is extruded, granulated, and returned to the resin. Re-grinding material can also originate from injection-molded foam materials, such as virgin TPE-E composition resins, which are injected and foamed during normal processing, discarded, then shredded and reintroduced as re-grinding material. The shredded recycled material can have irregular shapes, with a main length size of about 1 to 10 mm and virgin polymer material having a particle size of about 1 to 10 mm.

[0294] At process block 3107, the shredded recycled material is mixed with a composition of virgin polymer material. As used herein, the terms “mixing” and “blending” are used interchangeably and synonymously mean combination or blending, wherein the resulting mixed batch may or may not be homogeneous throughout the mixture. The recycled material can contrast with the virgin material because the original “virgin” material was neither injected into the mold assembly nor expanded by activation with a mixed foaming agent to form the final product. The virgin polymer composition may be a general polymer composition that is the same as or similar to the recycled material, or alternatively, it may be a polymer composition that is distinguishable from the recycled material. To properly calibrate the operating parameters of the injection molding system and control the functional properties of the resulting foamed polymer article, a metered amount of shredded 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 about 10 to about 50 parts of recycled TPE-E composition or about 80 to about 100 parts of virgin TPE-E composition into newly foamed TPE-E articles by means of the methods described herein.

[0295] Continue to refer to Figure 31Method 3100 continues to process block 3109, which has instructions for treating the recycled material before, during, or after mixing with virgin material. Processing the recycled material may include the addition of foaming agents / blowing agents, fillers, pigments, and / or processing aids. In at least some embodiments, a foaming agent is incorporated as a separate component into the mixture of recycled and virgin polymeric materials to induce expansion of the mixture during molding. The foaming agent may include a suitable stimulant that, alone or in combination with other substances, is capable of creating a cell structure in the plastic. The foaming agent may include a fluid that expands upon pressure release.

[0296] For at least some applications, it may be desirable to add a physical foaming agent to the mixture of recycled and virgin materials during or after the melting of the mixture. When injection molding the midsole, it may be desirable to inject the physical foaming agent into the polymer melt composition. The physical foaming agent may consist of one or more supercritical fluids (SCFs), such as supercritical nitrogen or carbon dioxide, which dissolve under pressure in the polymer melt composition to form a single-phase solution (SPS). As yet another option, method 3100 may be characterized by the absence of a chemical foaming agent for forming the foamed polymer article. The SCF concentration may be specified, in particular, by the desired solubility and desired density. In some embodiments, chemical foaming agents may be used in addition to or as a substitute for physical foaming agents.

[0297] Many other additives can be incorporated into the recycled batch before it is introduced into the final mold used to form the foamed polymer article, including fillers, activators, homogenizers, pigments, flame retardants, lubricants, and other suitable additives. Non-limiting examples of filler materials include talc, mica silicates, sulfates, 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 may 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 as a lubricant, dicumyl peroxide as a polymerization initiator, zinc oxide as an activator of the foaming agent, and titanium dioxide as a white pigment or carbon black as a black pigment.

[0298] Figure 31Process block 3111 includes memory-stored, processor-executable instructions for melting the ground recycled material and virgin polymer material into a polymer melt composition. It should be understood that the ground recycled material and virgin polymer material can be melted separately and then flowed into the mixed polymer melt composition. Alternatively, the mixed batch of recycled and virgin polymer material generated at process block 3107 can be heated into a polymer melt composition. For at least some embodiments, the mixture of ground recycled and virgin polymer material has a setpoint temperature ranging from about 190°C to about 215°C. Furthermore, the mixed batch of ground recycled and virgin polymer material can have an average peak crystallization temperature ranging from about 135°C to about 165°C.

[0299] Once the polymer composition is complete and ready for molding, processed recycled and virgin materials are pressurized and injected (commonly "injected") into one or more cavities of the mold assembly to form a foamed polymer article, as indicated at process block 3113. After SCF is injected into the polymer melt composition (where SCF dissolves in the melt to form molten SPS), the molten SPS flows into the inner mold cavity. SCF acts as a physical foaming agent to cause the molten TPE-E composition to expand and thereby fill the mold cavity. The pressure within the mold cavity is reduced or eliminated to release SCF from the SPS and to allow the expanded melt to cool and solidify. To provide a circularly sustainable "closed-loop" molding system that eliminates most (if not all) of manufacturing waste and scrap, the mass of recycled thermoplastic resin within the inner mold cavity can be greater than or equal to the mass of mixed thermoplastic resin within any filler portion fluidly connected to the cavity.

[0300] To ensure the integrity and desired performance characteristics of the resulting foamed polymer articles, 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 blend. For example, the injection molding system can be set to a molding melt temperature of approximately 210°C to approximately 215°C, where the batch melt temperature is approximately 190°C and the crystallization temperature is approximately 147°C. In addition to selective control of the mold temperature, the gas backpressure release rate and holding time can be recalibrated for a TPE-E polymer melt composition with approximately 20% by mass of recycled TPE-E composition to, for example, adjust the cooling rate within the mold cavity (e.g., a higher pressure drop results in a faster cooling rate and a shorter cooling time). System operating parameters can be selectively modified to ensure that the polymer melt composition remains within a pre-calculated optimal melt temperature-crystallization temperature range within a selected timeframe during the processing cycle.

[0301] At process block 3115, the foamed polymer article is discharged 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., by volume of the longest cell size). For at least some embodiments, the foamed polymer article may exhibit some and / or all of the following characteristics: (1) an energy efficiency of about 55% to about 95%, or in some preferred configurations, a target efficiency of 70% to 85%; (2) an energy return of about 1000 millijoules (mJ) to about 7000 mJ, or in some preferred configurations, a target return of 4500 mJ to 5500 mJ (e.g., with a standard midsole geometry); and / or (3) a density of about 0.15 g / cm³ (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.

[0302] Alternatively, the resulting foamed polymer article may exhibit an energy efficiency to energy intensity ratio (EE / EI) greater than about 1.125, or greater than about 1.35 for some embodiments, or greater than about 1.5 for some desired embodiments, or optionally about 1.6 to 2.1. Similarly, the resulting foamed polymer article may exhibit an energy efficiency to energy intensity to density product ratio (EE / (EI*ρ)) greater than about 5.25, or greater than about 6.3 for some embodiments, or greater than about 7.0 for some desired embodiments, or optionally about 8.8 to 11.2. Furthermore, the resulting foamed polymer article may exhibit an energy return to energy intensity ratio (ER / EI) greater than about 6,375, or greater than about 7,650 for some embodiments, or greater than about 8,500 for some desired embodiments, or optionally about 9,900 to 11,300. The resulting foamed polymer articles can exhibit the following ratio of energy return to the product of energy intensity and density (ER / (EI*ρ)): greater than about 33,750, or greater than about 40,500 for some embodiments, or greater than about 45,000 for some desired embodiments, or optionally about 55,400 to 62,500.

[0303] For at least some embodiments, the 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 solely from virgin thermoplastic materials. This predefined tolerance can be approximately 75% to approximately 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 operate in a repeatable or continuous cycle.

[0304] It is foreseeable 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 in hopes of achieving a “circular economy.” In this regard, aspects of this disclosure relate to a “closed-loop” manufacturing process that limits available sources of recyclables to manufacturing byproducts (e.g., gate or runner trimmings) and refurbished defective articles (e.g., visually or mechanically defective foamed polymer footwear sole components). Implementing such a “closed-loop” manufacturing process can ideally optimize material utilization efficiency by achieving, for example, zero or near-zero waste of polymer materials in the manufacture of foamed polymer articles.

[0305] As Figure 31 Method 3100, as an extension, modification, or standalone process, describes a method for producing foamed polymer articles that 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 / hour) of a specified design / model with pre-defined 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 on a particular production line. Individual batches may exhibit different quantifiable production variables, including: the average article mass m of the foamed polymer articles. AA (e.g., average total mass of all products / lot or average individual product mass or all products / lot), and average product defect rate. (For example, the ratio of total defective products to total products / batch). Because the process can produce multiple product packages (e.g., their quantity and geometry are distinguishable from each other), the tools used for each geometry may consume different volumes of raw materials and generate different volumes of manufacturing byproducts.

[0306] As will be explained in further detail below, a production line can generate a baseline average by-product value (e.g., generating unfoamed by-products upstream of the tooling and / or foamed by-products downstream of the tooling). For a given production batch, the amount of average by-product mass can be calculated as the sum of: (1) the amount of by-products generated for each geometry produced in a batch divided by the quantity of each geometry in that batch; and (2) the residual upstream by-product mass / batch. As a non-limiting example, the batch size of a production batch may include a total of 100 articles, comprising 20 first geometries, 20 second geometries, and 60 third geometries. In this case, the by-product mass can be calculated as: (total by-product mass of the first geometry) / 20 + (total by-product mass of the second geometry) / 20 + (total by-product mass of the third geometry) / 60 + upstream and / or downstream by-product mass.

[0307] For at least some implementations, a production batch may be limited to a single batch used to manufacture a pre-defined quantity of individual article designs having a predefined shape and size. Alternatively, a mass production batch may comprise multiple batches of different types of polymer articles, each type having its own shape and size. These batches may be executed simultaneously or sequentially, with each batch producing the same number of articles or different numbers of articles. When multiple batches are performed as part of a larger mass production batch, the average article quality m of that mass production batch... AA It can be calculated as the arithmetic sum of the average product masses of all discrete batches, i.e.: m AA-1 +m AA-2 +…+m AA-n Similarly, the average defect rate of large-scale batches It can be calculated as the arithmetic mean of the average product defect rates for all discrete batches, i.e.:

[0308] After completing a single production batch or a set of discrete batches of foamed polymer articles, the method may include regenerating and recycling one or more batches of manufacturing byproducts accompanying that batch or batches. Recycled byproduct material may be recovered from upstream molding system sections (e.g., from hot or cold runner plates), downstream molding system sections (e.g., mold overflow and trimming), and / or from within the mold itself (e.g., inlet and outlet gates of the mold annular cavity). In this example, the manufacturing byproducts may have an average byproduct mass m. AB (For example, average total by-product mass / lot or average by-product mass per finished product / lot). When multiple batches are produced, the average by-product mass for the entire large-scale production batch can be calculated as the arithmetic sum of the individual average by-product masses, i.e.: m AB-1 +mAB-2 +…+m AB-n Alternatively, the average by-product mass can be calculated as the arithmetic sum of the following: (1) the mass of the first by-product accompanying the first batch divided by the first quantity of the first polymer articles in that batch; (2) the mass of the second by-product accompanying the second batch divided by the second quantity of the second polymer articles in that batch; ... and (n) the mass of the nth by-product accompanying the nth batch divided by the nth quantity of the polymer articles in that batch.

[0309] Before, during, or after the retrieval of the batch of manufacturing by-products, the method may also include the recycling and recovery of one or more batches of defective articles accompanying the production batch. Based on the footwear example above, the recovered defective materials can be recycled from pre-consumer footwear and, if desired, from post-consumer footwear. For pre-consumer products, defective foamed articles can be identified using any commercially available technology for identifying manufacturing defects. For example, injection molding systems can... Figure 9 or Figure 14A The tooling components downstream combine a system-automated visual inspection station and a system-automated mechanical testing station. The visual inspection station can utilize high-definition digital cameras and machine learning algorithms to search for and mark any one of several predefined visual defects (e.g., dimensional defects, surface contamination, shape defects, etc.). Furthermore, the mechanical testing station can be an impact testing machine with a linear force sensor operatively coupled to a motor-driven, final-formed plunger. The plunger and sensor together measure the stiffness, energy efficiency, energy return, etc., of each foam product, and if any of these measurements fall outside the corresponding manufacturing tolerance, the product is marked as defective.

[0310] Continuing the discussion on defective products before consumption, the manufacturing system will have an associated average defect quality m. AD (per batch). The average defect quality m AD It can be calculated as the product defect rate. and average product quality m AA The arithmetic product, or For implementation schemes that execute multiple batches as part of a larger mass production batch, the average defect quality m AD It can be the arithmetic mean of the average defect quality of each production batch, that is: (m AD-1 +m AD-2 +…+m AD-n To achieve a "closed-loop" manufacturing process, the system can be constrained as follows:

[0311] (m AB +m AD ) / m AA ≤0.2

[0312] During closed-loop manufacturing processes, foamed polymer waste (manufacturing byproducts and defective articles) can be added directly to the injection barrel for subsequent injection into the mold cavity. The foamed 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 "filler" feeder can be used to push the waste material back into the tooling assembly. Before refeeding, the foamed polymer waste can be shredded at least once, or in at least some applications, twice or more, to ensure that the discrete waste elements are substantially uniform in shape and size. If it is determined that the foamed polymer waste cannot be added directly to the injection barrel, it may be necessary to process, melt, and regranulate the foamed waste. In this case, the waste material will be shredded once or more, fed into a separate extrusion line, where it is melted and extruded, and then granulated to form pellets with a geometry and density similar to the virgin pellets. These "new" waste material pellets can then be combined with the virgin pellets in the injection barrel.

[0313] 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 be increased (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, production variables per batch may be based on the following parameters: approximately 0.2 kg / pair, approximately 2 pairs (4 midsoles) / minute, 8-hour shift, and runner waste of approximately 10% to approximately 15% of the weight of each pair of midsoles.

[0314] definition

[0315] 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 pertains. It should be further understood that terms as defined in commonly used dictionaries should be interpreted as having the same meaning as they have in the context of this specification and the relevant field, and should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0316] The terms “comprises”, “comprising”, “including”, and “having” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof.

[0317] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural indicators unless the context clearly indicates otherwise. Thus, for example, references to “foam particles,” “midsole,” or “adhesive” include, but are not limited to, two or more such foam particles, midsoles, or adhesives.

[0318] As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0319] As used herein, “in substance or substantially” means at least 80%, 85%, 90%, 95% or more, as determined based on weight, volume or unit.

[0320] 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 used only to distinguish one element, component, region, layer, or section from another. Terms such as “first,” “second,” and other numerical terms do not imply order or sequence unless explicitly indicated by the context. Therefore, the first element, component, region, layer, or section discussed below may be referred to as the second element, component, region, layer, or section without departing from the teachings of the example configuration.

[0321] As used herein, the modifiers “upper,” “lower,” “top,” “bottom,” “upward,” “downward,” “vertical,” “horizontal,” “longitudinal,” “lateral,” “front,” “back,” etc., are relative terms unless otherwise defined or become clear under this disclosure, and are intended to place the various structures or orientations of footwear articles in the context of footwear articles worn by a user standing on a flat, horizontal surface.

[0322] When listed in the claims, the term "receive," such as "receive uppers for footwear articles," is not intended to require any particular delivery or receipt of the received articles. Rather, for clarity and readability, the term "receive" is used only to list articles that will be referred to in subsequent elements of the claims.

[0323] The terms “at least one” and “one or more” are used interchangeably and have the same meaning, including both single and multiple elements, and can also be indicated by the suffix “(s)” at the end of the element. For example, “at least one polyamide,” “one or more polyamides,” and “polyamide” are used interchangeably and have the same meaning.

[0324] It should be noted that ratios, concentrations, amounts, and other numerical data may be expressed in range format herein. When a range includes one or two boundaries, the range excluding any one or both of those included boundaries is also included in this disclosure; for example, the phrase “x to y” includes the range from 'x' to 'y' as well as the range 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'. Furthermore, the phrase “about 'x' to 'y'” (where 'x' and 'y' are numerical values) includes “about 'x' to about 'y'”. It should be understood that this range format is used for convenience and brevity, and therefore should be interpreted flexibly to include not only the values ​​explicitly listed as range boundaries, but also all individual values ​​or subranges covered within that range, as if each value and subrange were explicitly listed. For example, the range “about 0.1% to 5%” should be interpreted to include not only the explicitly listed values ​​of about 0.1% to about 5%, but also individual values ​​(e.g., 1%, 2%, 3%, and 4%) and subranges (e.g., 0.5%, 1.1%, 2.4%, 3.2%, and 4.4%) within the indicated range.

[0325] Due to expected variations known to those skilled in the art (e.g., limitations and variability in measurement), the terms “about” and “substantially” are used herein in relation to measurable values ​​and ranges.

[0326] As used herein, the terms “optional” or “optionally” mean that a component, event, or condition described below may or may not occur, and the description includes both the occurrence and non-occurrence of said component, event, or condition.

[0327] Unless otherwise specified, the temperatures mentioned herein are based on atmospheric pressure (i.e., one atmosphere).

[0328] Before providing examples, it should be understood that this disclosure is not limited to the specific aspects described, and variations are naturally possible. Other systems, methods, features, and advantages of foam compositions and components thereof will be, or will become apparent to those skilled in the art, upon studying the following figures and detailed description. All such additional systems, methods, features, and advantages are intended to be included in this specification, within the scope of this disclosure, and protected by the appended claims. It should also be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Those skilled in the art will recognize many variations and modifications to the aspects described herein. These variations and modifications are intended to be included in the teachings of this disclosure and are covered by the claims herein.

[0329] While specific elements and steps are discussed in conjunction with each other, it should be understood that any element and / or step provided herein is contemplated as being able to be combined with any other element and / or step, regardless of its express provision, while still remaining within the scope provided herein. Because many possible embodiments of this disclosure can be made without departing from its scope, it should be understood that everything set forth herein or shown in the accompanying drawings should be interpreted as illustrative rather than restrictive.

[0330] As used herein and in conjunction with the claims listed below, the term "any one of the clauses" or similar variations thereof are intended to be interpreted as allowing the features of the claim / clause to be combined in any combination. For example, exemplary clause 4 may indicate a method / apparatus according to any one of clauses 1 to 3, which is intended to be interpreted as allowing the features of clauses 1 and 4 to be combined, the elements of clauses 2 and 4 to be combined, the elements of clauses 3 and 4 to be combined, the elements of clauses 1, 2, and 4 to be combined, the elements of clauses 2, 3, and 4 to be combined, the elements of clauses 1, 2, 3, and 4 to be combined, and / or other variations. Furthermore, the term "any one of the clauses" or similar variations thereof are intended to include "any one of the clauses" or other variations of such terms, as indicated by some of the examples provided above.

[0331] The following terms are the aspects envisioned in this document.

[0332] Clause 1. A physical foaming injection molding system for footwear components formed from a polymer composition, the system comprising: a temperature control unit; a temperature regulating bracket 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; an syringe including a physical foaming agent port; a physical foaming agent supply source fluidly coupled to the physical foaming agent port of the syringe; a press paired with the syringe; an unloading machine including a frame, an unloading machine plate, and a pair of unloading machine arms, wherein the unloading machine arms move co-currently in a first direction and unco-currently in a second direction; and a robot including 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 unloading machine to manipulate the end effector at the temperature regulating bracket, the press, and the unloading machine to reversibly engage with the mold.

[0333] Clause 2. The system according to Clause 1, wherein the temperature regulating bracket includes multiple compartments.

[0334] Clause 3. The system according to any one of Clauses 1 to 2, wherein the temperature regulating bracket includes a temperature regulating inlet fluidly connected to a temperature regulating outlet, wherein the temperature control unit is fluidly connected to the temperature regulating bracket via the temperature regulating inlet and the temperature regulating outlet.

[0335] Clause 4. The system according to any one of Clauses 1 to 3, wherein the temperature regulating bracket includes an RFID reader.

[0336] Clause 5. The system according to any one of Clauses 1 to 4, wherein the temperature regulating bracket includes a temperature regulating plate.

[0337] Clause 6. The system according to Clause 5, wherein the temperature control panel includes an RFID reader.

[0338] Clause 7. The system according to Clause 5, wherein the temperature regulating plate includes a thermocouple.

[0339] 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.

[0340] 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 top surface of the temperature regulating plate.

[0341] Clause 10. The system according to Clause 9, wherein the top surface of the temperature regulating plate includes a second protrusion extending outward from the temperature regulating top surface and effectively received by the mold.

[0342] Clause 11. The system according to Clause 10, wherein the first protrusion of the temperature regulating plate is asymmetrical relative to the second protrusion of the temperature regulating plate in one or more features.

[0343] Clause 12. The system according to Clause 11, wherein said one or more features include protrusion length, protrusion cross-sectional shape, protrusion location, protrusion size, or any combination thereof.

[0344] Clause 13. The system according to Clause 9, wherein a first protrusion on the top surface of the temperature regulating plate is asymmetrically located on the top surface of the temperature regulating plate and is configured to be received by the base plate of the mold for alignment on the temperature regulating plate.

[0345] Clause 14. The system according to Clause 8, wherein the temperature regulating plate includes a fluid channel extending between the top surface of the temperature regulating plate and the bottom surface of the temperature regulating plate.

[0346] Clause 15. The system according to any one of Clauses 1 to 14, wherein the temperature regulating bracket comprises four to eight compartments, each of the four to eight compartments comprising a temperature regulating plate, an RFID reader, and a thermocouple.

[0347] Clause 16. The system according to any one of Clauses 1 to 15, wherein the temperature regulating bracket further comprises a regulating fluid manifold fluidly connected to the temperature regulating unit.

[0348] Clause 17. The system according to Clause 16, wherein the regulating fluid manifold is fluidly connected to two or more temperature regulating plates supported by the temperature regulating bracket.

[0349] 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.

[0350] Clause 19. The system described in Clause 18, wherein the temperature control unit includes a heat exchanger.

[0351] Clause 20. The system according to any one of Clauses 1 to 19, wherein the temperature control unit is fluidly connected to the temperature regulating bracket.

[0352] 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, wherein the actuator effectively adjusts the position of the support platform within the press.

[0353] Clause 22. The system according to any one of Clauses 1 to 21, wherein the press includes a universal flow channel plate that includes a plurality of outlets.

[0354] Clause 23. The system according to any one of Clauses 1 to 22, wherein the syringe is paired with the press via the universal flow channel plate.

[0355] Clause 24. The system according to any one of Clauses 1 to 23, wherein the universal runner plate is a hot runner plate and the plurality of outlets are hot runner outlets.

[0356] 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, the hot runner plate and the support plate being movably positioned in a first configuration having a first distance therebetween and in a second configuration having a second distance therebetween, wherein the first distance is greater than the second distance.

[0357] 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.

[0358] Clause 27. The system according to any one of Clauses 1 to 26, wherein the press includes a pressure lock movable between an unlocked configuration and a locked configuration, wherein the pressure lock effectively secures the mold in the press when in the locked configuration.

[0359] Clause 28. The system according to Clause 27, wherein the press lock includes a pair of sliding fingers that move in the lateral direction of the press when switching between the unlocked configuration and the locked configuration.

[0360] Clause 29. The system according to any one of Clauses 1 to 28, wherein the press comprises: a support platform; and a pressure plate having a top surface and a bottom surface, wherein the bottom surface of the pressure plate is supported by the support platform.

[0361] Clause 30. The system according to Clause 29, wherein the pressure plate includes a temperature-regulating fluid channel extending between a top surface of the pressure plate and a bottom surface of the pressure plate, wherein the temperature-regulating fluid channel of the pressure plate is fluidly connected to a temperature control unit.

[0362] Clause 31. The system according to Clause 29, wherein the top surface of the pressure plate includes a first protrusion extending outward from the top surface of the pressure plate.

[0363] Clause 32. The system according to Clause 31, wherein the top surface of the pressure plate includes a second protrusion extending outward from the top surface of the pressure plate and effectively received by the mold.

[0364] Clause 33. The system according to Clause 32, wherein the first protrusion of the pressure plate is asymmetrical relative to the second protrusion of the pressure plate in one or more features.

[0365] Clause 34. The system pursuant to Clause 33, wherein one or more of the features include protrusion length, protrusion cross-sectional shape, protrusion location, protrusion size, or any combination thereof.

[0366] Clause 35. The system according to Clause 29, wherein a first protrusion on the top surface of the pressure plate is asymmetrically located on the top surface of the pressure plate and is configured to be received by the base plate of the mold for alignment on the pressure plate.

[0367] Clause 36. The system according to Clause 35, wherein the syringe includes a plurality of heating elements along the longitudinal length of the syringe.

[0368] 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 heat to the syringe.

[0369] Clause 38. The system according to any one of Clauses 1 to 37, wherein the physical foaming agent port is fluidly connected to the physical foaming agent supply source.

[0370] Clause 39. The system according to any one of Clauses 1 to 38 further includes a metering feed source fluidly connected between the physical foaming agent port and the physical foaming agent supply source, wherein the metering feed source meteres supercritical fluid as a physical foaming agent into the injection barrel via the physical foaming agent port.

[0371] Clause 40. The system pursuant to any one of Clauses 1 to 39 further includes a gas back pressure source.

[0372] Clause 41. The system according to Clause 40, wherein the gas back pressure source is fluidly connected to the press to provide back pressure to the mold prior to injection from the syringe.

[0373] Clause 42. The system according to Clause 41, wherein the gas back pressure source supplies nitrogen or carbon dioxide to the compressor.

[0374] 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 on the die in the press during material injection through the syringe.

[0375] Clause 44. The system according to any one of Clauses 1 to 43, wherein the physical foaming agent supply source comprises a gas, a liquid, or a supercritical fluid.

[0376] Clause 45. The system according to any one of Clauses 1 to 44, wherein the physical foaming agent supply source comprises compressed carbon dioxide gas or compressed nitrogen gas.

[0377] Clause 46. The system according to any one of Clauses 1 to 45 further includes a supply hopper configured to receive polymer material, wherein the supply hopper is operatively coupled to the syringe to supply the polymer material to the syringe.

[0378] Clause 47. The system according to any one of Clauses 1 to 46, wherein the unloader includes an unloader lock that is switchable between an unlocked configuration and a locked configuration, wherein the unloader lock effectively secures the mold in the unloader when in the locked configuration.

[0379] Clause 48. The system according to Clause 47, wherein the unloader lock includes 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 is switched between the unlocked configuration and the locked configuration.

[0380] Clause 49. The system according to any one of Clauses 1 to 48, wherein the unloading plate includes a top surface and a bottom surface, wherein the bottom surface of the unloading plate is supported by an unloading frame.

[0381] Clause 50. The system described in Clause 49, wherein the unloading board includes an RFID reader.

[0382] Clause 51. The system according to Clause 49, wherein the top surface of the unloading plate includes a first protrusion extending outward from the top surface of the unloading plate.

[0383] Clause 52. The system according to Clause 51, wherein the top surface of the unloading plate includes a second protrusion extending outward from the top surface of the unloading plate and effectively received by the mold.

[0384] Clause 53. The system according to Clause 52, wherein the first protrusion of the unloading plate is asymmetrical relative to the second protrusion of the unloading plate in one or more features.

[0385] Clause 54. The system according to Clause 53, wherein said one or more features include protrusion length, protrusion cross-sectional shape, protrusion location, protrusion size, or any combination thereof.

[0386] Clause 55. The system according to Clause 52, wherein a first protrusion on the top surface of the unloading plate is asymmetrically located on the top surface of the unloading plate and is configured to be received by the base plate of the mold for alignment on the unloading plate.

[0387] Clause 56. The system according to any one of Clauses 1 to 55, wherein the unloading arm moves uniformly in the vertical direction and the unloading arm moves non-uniformly in the horizontal direction relative to the unloading frame.

[0388] Clause 57. The system according to any one of Clauses 1 to 56, wherein the unloading arm is slidably positioned between an open configuration and a closed configuration, the open configuration having a first distance between a first arm and a second arm of the unloading arm, and 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.

[0389] Clause 58. The system according to Clause 57, wherein the first unloading arm includes a first protrusion that effectively receives in the unloading interface of the mold.

[0390] Clause 59. The system described in Clause 58, wherein the first projection of the first unloading arm is asymmetrical.

[0391] Clause 60. The system according to Clause 58, wherein the first unloading arm includes a second protrusion that effectively receives in the unloading interface of the mold.

[0392] Clause 61. The system according to Clause 60, wherein the first unloading arm first protrusion is asymmetrical relative to the first unloading arm second protrusion in one or more features.

[0393] Clause 62. The system according to Clause 61, wherein said one or more features include protrusion length, protrusion cross-sectional shape, protrusion location, protrusion size, or any combination thereof.

[0394] Clause 63. The system according to Clause 57, wherein the second unloading arm includes a third protrusion that effectively receives in the unloading interface of the mold.

[0395] Clause 64. The system according to Clause 63, wherein the second unloading arm includes a fourth protrusion that effectively receives in the unloading interface of the mold.

[0396] Clause 65. The system according to Clause 64, wherein the first unloading arm first protrusion is symmetrical with respect to the second unloading arm third protrusion in one or more features.

[0397] Clause 66. The system according to Clause 64, wherein the second protrusion of the first unloading arm is symmetrical with respect to the fourth protrusion of the second unloading arm in one or more features.

[0398] Clause 67. The system according to Clause 66, wherein said one or more features include protrusion length, protrusion cross-sectional shape, protrusion location, protrusion size, or any combination thereof.

[0399] Clause 68. The system according to Clause 58, wherein the unloading arm includes a key extending in a direction parallel to the first projection of the first unloading arm, the key effectively engaging with the tool latch assembly to disengage from the mold fastening assembly.

[0400] Clause 69. The system according to any one of Clauses 1 to 68, wherein the first direction comprises at least three positions: a first position in which the mold is closed, a second position in which the mold is partially open, and a third position in which the mold is opened to a greater extent, wherein the second position and the third position are different.

[0401] Clause 70. The system according to Clause 60, wherein the first unloading arm has a first protrusion having a linear segment in cross-section and the second protrusion has a curved segment in cross-section.

[0402] Clause 71. The system according to Clause 60, wherein the first unloading arm first protrusion is asymmetrical relative to the first unloading arm second protrusion in one or more features.

[0403] Clause 72. The system according to Clause 71, wherein said one or more features include protrusion length, protrusion cross-sectional shape, protrusion location, protrusion size, or any combination thereof.

[0404] Clause 73. The system according to Clause 72, wherein the second unloading arm includes a third protrusion that effectively receives in the unloading interface of the mold.

[0405] Clause 74. The system according to Clause 1, wherein the robot rotates on at least one axis and moves on at least two other axes.

[0406] Clause 75. The system according to Clause 74, wherein the robot rotates about at least the Z-axis and moves on at least the X and Y axes.

[0407] Clause 76. The system according to any one of Clauses 1 to 75, wherein the robot moves on at least the X, Y and Z axes.

[0408] 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 adjustablely offset from the first side.

[0409] 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, and the closed configuration having a second distance between the first side and the second side, wherein the second distance is less than the first distance.

[0410] Clause 79. The system according to any one of Clauses 1 to 78, wherein the end effector is a lifting device, the lifting device comprising a first protrusion effectively received in the lifting device interface of the mold.

[0411] Clause 80. The system described in Clause 79, wherein the first protrusion of the end effector is asymmetrical.

[0412] 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.

[0413] Clause 82. The system according to Clause 81, wherein the first protrusion of the end effector is asymmetrical relative to the second protrusion of the end effector in one or more features.

[0414] Clause 83. The system according to Clause 82, wherein said one or more features include protrusion length, protrusion cross-sectional shape, protrusion location, protrusion size, or any combination thereof.

[0415] Clause 84. The system according to Clause 83, wherein the end effector further includes an RFID reader.

[0416] Clause 85. The system pursuant to any one of Clauses 1 to 84 further includes a controller having a processor and memory.

[0417] 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.

[0418] Clause 87. The system described in Clause 86, wherein the logical coupling is wired or wireless.

[0419] Clause 88. The system according to Clause 85, wherein the controller effectively stores data retrieved from the RFID reader and, in response to the data retrieved from the RFID reader, provides the robot with an instruction to retrieve the mold.

[0420] Clause 89. The system according to any one of Clauses 1 to 88, wherein the temperature regulating bracket, the press, and the unloader are positioned within three meters of an arc centered at the robot.

[0421] 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.

[0422] Clause 91. The system according to Clause 90, wherein the robot is movable along the line.

[0423] Clause 92. The system according to any one of Clauses 1 to 91, wherein the temperature regulating bracket is on the first side of the press and the unloading machine is on the second side of the press.

[0424] Clause 93. The system according to any one of Clauses 1 to 91, wherein the unloader is on the first side of the temperature regulating bracket and the press is on the second side of the temperature regulating bracket.

[0425] Clause 94. The system according to any one of Clauses 1 to 91, wherein the temperature regulating bracket is on the first side of the unloader and the press is on the second side of the unloader.

[0426] Clause 95. The system according to any one of Clauses 1 to 94 further includes a second temperature regulating bracket, a third temperature regulating bracket and a fourth temperature regulating bracket.

[0427] 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.

[0428] Clause 97. The system according to any one of Clauses 1 to 96, wherein the syringe is positioned in a fixed position relative to the temperature regulating bracket through a plurality of consecutive injection operations.

[0429] Clause 98. A physical foaming injection molding system for footwear components, the system comprising: a temperature regulating bracket adapted to regulate the temperature of a mold maintained at the temperature regulating bracket; a press; an unloading machine including a frame, an unloading plate, and a pair of unloading arms, wherein the unloading arms move co-currently in a first direction and unco-currently in a second direction; and a robot including 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 unloading machine to manipulate the end effector at the temperature regulating bracket, the press, and the unloading machine to reversibly engage with the mold.

[0430] Clause 99. A physical foaming injection molding system for footwear components, the system comprising: a temperature regulating bracket adapted to regulate the temperature of a mold maintained at the temperature regulating bracket; an unloading machine including a frame, an unloading platen, and a pair of unloading arms, wherein the unloading arms move co-currently in a first direction and unco-currently in a second direction; and a robot including 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 unloading machine to manipulate the end effector at the temperature regulating bracket and the unloading machine to reversibly engage with the mold.

[0431] Clause 100. A physical foaming injection molding system for footwear components, the system comprising: a temperature control unit; an injector; and a press, the press comprising: (1) a support platform; and (2) a pressure plate having a top surface and a bottom surface, wherein the bottom surface of the pressure plate is supported by the support platform, wherein the pressure plate includes a temperature-regulating fluid channel between the top surface of the pressure plate and the bottom surface of the pressure plate, wherein the temperature-regulating fluid channel of the pressure plate is fluidly connected to the temperature control unit.

[0432] Clause 101. An unloading machine in a physical foaming injection molding system for footwear components, the unloading machine comprising: an unloading machine plate, wherein the unloading machine plate includes a top surface, the top surface including a first protrusion extending outwardly from the top surface of the unloading machine plate; an unloading machine lock including 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 unloading machine plate when the unloading machine lock is switched between an unlocked configuration and a locked configuration; and a pair of unloading machine arms, wherein the unloading machine arms move uniformly toward and away from the unloading machine plate in a first direction and non-uniformly in a second direction parallel to the top surface of the unloading machine plate.

[0433] Clause 102. A press in a physical foaming injection molding system for footwear components, the press comprising: a universal runner plate; an actuator; and a pressure plate including a pressure lock, wherein the actuator adjustably positions the pressure plate from a first configuration to a second configuration, the first configuration having a first distance between the universal runner plate and the pressure plate, the second configuration having a second distance between the universal runner plate and the pressure plate, and wherein the pressure lock includes a pair of sliding fingers that move in a lateral direction relative to a direction of movement of the pressure plate between an unlocked configuration and a locked configuration, the pressure plate being adjustably positioned from the first configuration to the second configuration.

[0434] Clause 103. A method for physically foaming a footwear component formed from a polymer composition, the method comprising: adjusting a mold temperature to a temperature of 15 degrees Celsius to 90 degrees Celsius; engaging the mold with an end effector adapted for reversible engagement with the mold via a robot; conveying the mold to a press using the end effector; applying a gas back pressure 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 back pressure from the cavity of the mold; and removing the footwear component from the cavity of the mold.

[0435] Clause 104. The method described in Clause 103, wherein the footwear component is a footwear sole portion.

[0436] Clause 105. The method according to any one of Clauses 103 to 104, wherein the mold is temperature regulated at a temperature regulating bracket.

[0437] Clause 106. The method according to Clause 105, wherein the mold is selected from a plurality of molds included at the temperature regulating bracket.

[0438] Clause 107. The method according to Clause 105, wherein the temperature regulating bracket includes a temperature regulating plate having a top surface and a bottom surface.

[0439] Clause 108. The method according to Clause 107, wherein the temperature regulating plate includes a thermocouple.

[0440] Clause 109. The method according to Clause 108, wherein the thermocouple is a recess in the top surface of the temperature regulating plate.

[0441] Clause 110. The method according to Clause 108 further includes detecting the temperature using the thermocouple of the temperature regulating plate.

[0442] Clause 111. The method according to Clause 107, wherein the temperature regulating plate includes an RFID reader.

[0443] Clause 112. The method according to Clause 111 further includes detecting the RFID tag of the mold using the RFID reader.

[0444] Clause 113. The method according to any one of Clauses 103 to 112, wherein the temperature is 45 degrees Celsius to 80 degrees Celsius.

[0445] Clause 114. The method according to any one of Clauses 103 to 112, wherein the temperature is 50 degrees Celsius to 70 degrees Celsius.

[0446] Clause 115. The method according to any one of Clauses 103 to 112, wherein the temperature is 55 degrees Celsius to 65 degrees Celsius.

[0447] Clause 116. The method according to any one of Clauses 103 to 115 further includes circulating the temperature regulating fluid between the temperature control unit and the temperature regulating bracket.

[0448] 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 a first side of the mold such that a first protrusion of the first side of the end effector is inserted into a first plate-operator keyway of the first side.

[0449] Clause 118. The method according to Clause 117, wherein engaging the mold further comprises positioning the second side of the end effector to a second side of the mold such that a first protrusion on the second side of the end effector is inserted into a first plate-operator keyway on the second side.

[0450] Clause 119. The method according to any one of Clauses 103 to 118, wherein engaging the mold further comprises reading the RFID tag of the mold with an RFID reader of the end effector.

[0451] Clause 120. The method according to any one of Clauses 103 to 119 further includes selecting the mold having the end effector based at least in part on the mold reaching a defined temperature within a temperature regulation range.

[0452] Clause 121. The method according to any one of Clauses 103 to 120, wherein conveying the mold comprises moving the mold in a non-linear path between the mold and the press.

[0453] Clause 122. The method according to any one of Clauses 103 to 120, wherein conveying the mold comprises moving the mold in a linear path between the mold and the press.

[0454] Clause 123. The method according to any one of Clauses 103 to 122 further includes positioning the mold on the press platen of the press using the end effector.

[0455] Clause 124. The method according to Clause 123, wherein positioning the mold on the pressure plate further includes inserting a first protrusion extending outward from the pressure plate into a first plate alignment keyway.

[0456] Clause 125. The method according to Clause 123 further includes circulating temperature-regulating fluid through a temperature-regulating channel extending through the pressure plate.

[0457] Clause 126. The method according to Clause 123 further comprises: raising the pressure plate supporting the mold within the press; engaging the mold with a universal runner plate; aligning the runner outlet of the universal runner plate with the runner of the mold; and aligning the gas port of the universal runner plate with the gas port of the mold.

[0458] Clause 127. The method according to Clause 126, wherein the universal runner plate is a hot runner plate, and the method further includes circulating temperature-regulating fluid through channels of the universal runner plate.

[0459] Clause 128. The method according to Clause 127, wherein the temperature-regulating fluid circulating through the channels of the universal flow plate is in the range of 20 degrees Celsius to 250 degrees Celsius.

[0460] 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.

[0461] Clause 130. The method according to any one of Clauses 103 to 129, wherein the gas back pressure is supplied by a gas source comprising carbon dioxide, nitrogen and / or ambient air.

[0462] Clause 131. The method according to any one of Clauses 103 to 130, wherein the gas back pressure is established prior to the injection of the single-phase solution.

[0463] Clause 132. The method according to any one of Clauses 103 to 131 further comprises: dispensing a polymer material formed from the polymer composition from a hopper into a syringe; and mixing the polymer material with the screw of the syringe while heating the polymer material.

[0464] Clause 133. The method according to Clause 132, wherein the polymer material is in the form of beads, granules, fragments and / or particles in the hopper.

[0465] Clause 134. The method according to Clause 132, wherein the polymer composition comprises a thermoplastic polyester composition.

[0466] Clause 135. The method according to Clause 132 further comprises heating the polymer composition in the syringe to a temperature about 50 degrees Celsius above the tail temperature of the thermoplastic elastomer composition, from the melting temperature of the polymer composition to the tail temperature of the thermoplastic elastomer composition.

[0467] Clause 136. The method according to any one of Clauses 103 to 135 further includes rotating the screw in the syringe at a rate of 20 revolutions per minute (RPM) to 120 RPM.

[0468] Clause 137. The method according to Clause 103, wherein the polymer composition is a thermoplastic copolyester composition.

[0469] Clause 138. The method according to any one of Clauses 103 to 137 further includes metering the supercritical fluid before introducing it into the polymer composition.

[0470] Clause 139. The method according to any one of Clauses 103 to 138 further comprises impregnating the polymer composition with the supercritical fluid and injecting it as the single-phase solution into the cavity of the mold in a syringe.

[0471] Clause 140. The method according to any one of Clauses 103 to 138, wherein the polymer composition is impregnated with the supercritical fluid prior to dispensing the polymer composition into a syringe for injection into the cavity of the mold.

[0472] 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.

[0473] 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.

[0474] 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.

[0475] 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.

[0476] Clause 145. The method according to any one of Clauses 103 to 144, wherein after the injection of the single-phase solution, the gas back pressure is maintained in the mold cavity at a pressure that effectively maintains the single-phase solution as a single-phase solution in the cavity of the mold for 0.5 seconds to 10.0 seconds.

[0477] Clause 146. The method according to any one of Clauses 103 to 144, wherein after the injection of the single-phase solution, the gas back pressure is maintained in the mold cavity at a pressure that effectively maintains the single-phase solution as a single-phase solution in the cavity of the mold for 1 to 5.0 seconds.

[0478] Clause 147. The method according to any one of Clauses 103 to 146 further comprises: engaging the mold with the end effector at the press; and transferring the mold to the temperature regulating bracket using the end effector.

[0479] Clause 148. The method according to any one of Clauses 103 to 148 further comprises: reading the RFID tag of the mold using the RFID reader of the end effector; and reading the RFID tag of the mold using the RFID reader of the temperature regulating bracket.

[0480] Clause 149. The method according to any one of Clauses 103 to 148 further includes, after the injection of the single-phase solution and before the removal of the footwear component from the cavity of the mold, temperature-regulating the mold at the temperature-regulating bracket.

[0481] Clause 150. The method according to any one of Clauses 103 to 149 further comprises 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.

[0482] Clause 151. The method according to any one of Clauses 103 to 150 further includes engaging the mold with the end effector at the press, and transferring the mold to the unloading machine using the end effector.

[0483] Clause 152. The method according to Clause 151 further includes: reading the RFID tag of the mold using an RFID reader of the end effector; and reading the RFID tag of the mold using an RFID reader of the unloader.

[0484] Clause 153. The method according to any one of Clauses 103 to 152 further includes opening the mold at the unloading machine.

[0485] Clause 154. The method according to Clause 153, wherein opening the mold at the unloader comprises causing the first pair of fingers to shift between an unlocked configuration and a locked configuration in a plane parallel to the top surface of the unloader plate to secure the mold to the unloader.

[0486] Clause 155. The method according to Clause 153, wherein opening the mold at the unloading machine comprises inserting a pin into a tool latch assembly of the mold, wherein the pin disengages from the tool latch assembly to allow the mold to open.

[0487] Clause 156. The method according to Clause 153, wherein opening the mold at the unloader includes lifting a first portion of the mold from a second portion of the mold, wherein the first portion of the mold is secured by an unloader arm of the unloader, and the second portion of the mold is secured by at least a first pair of fingers of the unloader.

[0488] Clause 157. The method according to Clause 156, wherein opening the mold at the unloading machine includes raising the first portion a first distance, stopping raising the first portion for 1 second to 120 seconds, and raising the first portion a second distance after stopping raising the first portion.

[0489] Clause 158. The method according to Clause 153 further includes reading the RFID tag of the mold by means of an RFID reader of the unloading machine.

[0490] Clause 159. The method according to any one of Clauses 103 to 158, 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.

[0491] Clause 160. The method according to any one of Clauses 103 to 159 further comprises, after the injection of the single-phase solution and before reducing the gas back pressure to below the pressure that effectively maintains the supercritical fluid in a supercritical fluid state, lowering the temperature of the single-phase solution in the mold cavity.

[0492] Clause 161. The method described in accordance with Clause 160, wherein the temperature decrease is within the range of 0.5 degrees Celsius to 50 degrees Celsius.

[0493] Clause 162. The method according to any one of Clauses 103 to 161 further includes transferring the mold having the end effector to the temperature regulating bracket after removing the footwear component from the cavity of the mold.

[0494] Clause 163. The method according to Clause 160, wherein after the footwear component is removed from the cavity of the mold, the mold is held at the temperature regulating bracket until the mold is temperature-regulated to a temperature in the range of 45 degrees Celsius to 80 degrees Celsius.

[0495] Clause 164. A method for physically foaming a footwear component, the method comprising: adjusting a mold temperature to a temperature of 15 degrees Celsius to 90 degrees Celsius; applying a gas back pressure 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 back pressure from the cavity of the mold; and removing the footwear component from the cavity of the mold.

[0496] Clause 165. A method for physically foaming a footwear component, the method comprising: adjusting a mold temperature to a temperature of 15 degrees Celsius to 90 degrees Celsius at a temperature regulating 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.

[0497] Clause 166. A method for physically foaming a footwear component, the method comprising: adjusting a mold temperature to a temperature of 15 degrees Celsius to 90 degrees Celsius at a temperature regulating bracket; injecting a single-phase solution of a polymer composition and a supercritical fluid into a 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.

[0498] Clause 167. A method for physically foaming a footwear component, the method comprising: adjusting the temperature of a mold to a temperature of 15 degrees Celsius to 90 degrees Celsius at a temperature regulating 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 regulating bracket; transferring the mold from the second temperature regulating bracket to an unloading machine; and removing the footwear component from the cavity of the mold.

[0499] Clause 168. A method for physically foaming a footwear component, the method comprising: engaging a mold with a hot runner plate and a pressure plate at a press, wherein the hot runner plate is temperature-controlled and the pressure plate is temperature-controlled; injecting a single-phase solution of a polymer composition and a supercritical fluid into a cavity of the mold at the press; and removing the footwear component from the cavity of the mold.

[0500] Clause 169. A method for physically foaming a footwear component, the method comprising: reading an RFID tag of a mold using an RFID reader of a temperature regulating plate; associating a 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 a cavity of the mold at a press; and removing the footwear component from the cavity of the mold.

[0501] Clause 170. A temperature regulating bracket for a physical foaming injection molding system for footwear components, 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 connected to the temperature control 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.

[0502] In addition to the specific terms listed above, this document also contemplates combinations of additional terms, and these combinations are part of the scope of this disclosure. For convenience, each of the following combinations is provided in a list format, but is intended to be the same as that intended to be written in sentence and / or paragraph form.

[0503] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to those of Clause 98: Clauses 1 to 97.

[0504] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to those of Clause 99: Clauses 1 to 97.

[0505] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to, terms 100: 1 to 97.

[0506] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to, terms 101: terms 1 to 97.

[0507] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to, terms 102: 1 to 97.

[0508] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to, terms 170: 1 to 97.

[0509] The specific terms listed below may be individually or in any combination thereof, in lieu of or additional to Clause 164: Clauses 104 to 163.

[0510] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to those of Clause 165: Clauses 104 to 163.

[0511] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to those of Clause 166: Clauses 104 to 163.

[0512] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to those of Clause 167: Clauses 104 to 163.

[0513] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to those of Clause 168: Clauses 104 to 163.

[0514] The specific terms listed below may be individually or in any combination thereof, in lieu of or in addition to those of Clause 169: Clauses 104 to 163.

Claims

1. A physical foaming injection molding system for footwear components, the system comprising: A syringe; A press paired with the syringe, the press including a universal runner plate including at least one runner outlet and configured to interface with an array of two or more different molds configured to engage with the syringe and the press and configured to be switched immediately after injection during operation of the physical foaming injection molding system; And a robot including an end effector adapted to reversibly engage with a mold configured to engage with the syringe and the press, wherein the robot is positioned relative to the press to reversibly engage the end effector with the mold.

2. The system of claim 1, wherein the syringe is paired with the press via the universal runner plate.

3. The system of claim 1, wherein the press includes a platen, the universal runner plate is a hot runner plate, and one of the hot runner plate or the platen is movably positioned in a first configuration and a second configuration, the first configuration having a first distance between the hot runner plate and the platen, the second configuration having a second distance between the hot runner plate and the platen, wherein the first distance is greater than the second distance.

4. The system of claim 3, wherein the hot runner plate is statically positioned in the press and the platen is movably positioned in the press.

5. The system of claim 1, wherein the press comprises: A support platform; And a platen having a top surface and a bottom surface, wherein the bottom surface of the platen is supported by the support platform.

6. The system of claim 5, wherein the platen includes a temperature regulating fluid channel extending between the top surface of the platen and the bottom surface of the platen, wherein the temperature regulating fluid channel of the platen is fluidly coupled with a temperature control unit.

7. The system of claim 1, wherein the syringe includes at least two heating elements along a longitudinal length of the syringe, wherein the at least two heating elements are individually adjustable to supply varying thermal energy to the syringe.

8. The system of claim 1, further comprising a gas back pressure regulator to maintain a back pressure of the mold in the press during injection of a single phase solution of a polymeric composition and a supercritical fluid by the syringe.

9. The system of claim 1, further comprising: A temperature control unit; A temperature regulating cradle operatively coupled with the temperature control unit, wherein the temperature regulating cradle is adapted to regulate a temperature of the mold maintained at the temperature regulating cradle; a physical blowing agent supply source fluidly coupled with a syringe physical blowing agent port; and an unloader including a frame, an unloader plate, and a pair of unloader arms, wherein the unloader arms move in unison in a first direction and move out of unison in a second direction.

10. The system of claim 1, further comprising: A temperature control unit; And a temperature regulating cradle operatively coupled with the temperature control unit, wherein the temperature regulating cradle is adapted to regulate a temperature of the mold maintained at the temperature regulating cradle.

11. The system of claim 1, further comprising a physical blowing agent supply fluidly coupled to the injector physical blowing agent port, wherein the physical blowing agent supply is configured to contain carbon dioxide gas or nitrogen gas.

12. The system of claim 1, further comprising an unloader, the unloader comprising: a frame, an offloader plate, and a pair of offloader arms, wherein the offloader arms move in unison in a first direction and move out of unison in a second direction.

13. The system of claim 1, wherein the robot rotates on at least one axis and moves on at least two other axes.

14. The system of claim 1, wherein the end effector comprises a first side and a second side adjustably offset from the first side.

15. The system of claim 14, wherein the first side and the second side are slidably positioned between an open configuration having a first distance between the first side and the second side and a closed configuration having a second distance between the first side and the second side, wherein the second distance is less than the first distance.

16. The system of claim 1, further comprising a controller having a processor and a memory.

17. The system of claim 16, wherein the controller is logically coupled with the system, the robot, and an RFID reader of the press.

18. The system of claim 17, wherein the controller is effective to store data retrieved from the RFID reader and provide instructions to the robot to retrieve the mold in response to the data retrieved from the RFID reader.

19. A physical foam injection molding system for injection of a single phase solution of a polymeric composition and a supercritical fluid, the system comprising: a temperature control unit; a temperature conditioning cradle, the temperature conditioning cradle being effectively coupled with the temperature control unit, wherein the temperature conditioning cradle is adapted to condition a temperature of a mold maintained at the temperature conditioning cradle; a press, the press comprising a universal runner plate, the universal runner plate comprising at least one runner outlet and being configured to interface with an array of two or more different molds, the array of two or more different molds being configured to engage with an injector and the press and being configured to be switched immediately after injection during operation of the physical foaming injection molding system; a robot, the robot comprising an end effector adapted to reversibly engage with the mold, wherein the robot is positioned relative to the temperature conditioning cradle to manipulate the end effector at the temperature conditioning cradle to reversibly engage with the mold and to manipulate the press to reversibly engage with the mold; an RFID reader; and a controller having a processor and a memory, the controller being logically coupled with the RFID reader and the robot.

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