Manufacturing system for cushioning footwear

Abstract

The present application relates to a manufacturing system for cushioning footwear. The conformable cushioning pod contains a plurality of individual and discrete foam beads. The filling of the cushioning pod includes a system that includes a bead source, a weighing station, a metering station, and a filling station. To further increase efficiency, the system can include one or more valves that control the direction of bead transfer, thereby allowing multiple filling stations to utilize a common set of stations. The system uses fluid introduced by a fluid insertion nozzle to transfer the beads through a coupler. The fluid effectively increases the throughput of bead transfer.

Description

[0001] This application is a divisional application of the application filed on May 29, 2019, with application number 201980036036.6 and invention title "Manufacturing System for Cushioned Footwear". Technical Field

[0002] This invention relates to systems and methods for forming cushioning articles. Background Technology

[0003] Conventional methods and systems for forming cushioning articles, such as shoe soles, involve injection molding or otherwise shaping the article from a homogeneous foam polymer composition. The fit and impact attenuation of the cushioning article depend on the characteristics of the foam composition, such as its elasticity. However, in some cases, preload stress is applied to the cushioning article to achieve a fit, which affects the article's ability to attenuate impact forces under preload. Summary of the Invention

[0004] Various aspects of the present invention contemplate filling a cushioning pod with a plurality of discrete and independent foam beads conforming to the shape of the cushioning pod. The independent and discrete nature of the foam beads allows the plurality of beads to be reconfigured to conform to a static position, such as a part of a wearer's body. A system for filling a cushioning pod with a plurality of beads includes a bead source, a weighing station, a metering station, and a filling station to efficiently fill the pod with a target amount of the plurality of beads. These beads are at least partially conveyed through the system using a fluid injection nozzle capable of efficiently generating at least one of positive and / or negative pressure within a connector through which the beads are conveyed. The system may also include a bead nozzle with two magnetically coupled portions to further improve the efficiency and timing of the filling operation.

[0005] The content of this invention is provided for illustrative purposes and not for limiting the scope of the methods and systems described in full detail below. Attached Figure Description

[0006] The present invention will be described in detail herein with reference to the accompanying drawings, wherein:

[0007] Figure 1 An exemplary system for filling a buffer pod with a plurality of beads is described according to various aspects of the present invention;

[0008] Figure 2 A reinforcement system for filling a buffer pod with a plurality of beads is described according to various aspects of the present invention;

[0009] Figure 3 An exemplary weighing station according to various aspects of the present invention is depicted;

[0010] Figure 4A cross-sectional view of an exemplary metering station according to various aspects of the present invention is depicted;

[0011] Figure 5 The invention describes various aspects thereof. Figure 4 An isometric view of an exemplary fluid-driven funnel of the metering station shown in the diagram;

[0012] Figure 6 The invention describes various aspects thereof. Figure 5 A top view of the fluid-driven funnel;

[0013] Figure 7 The invention describes various aspects thereof. Figure 5 First cross-sectional view of the fluid-driven funnel;

[0014] Figure 8 The invention describes various aspects thereof. Figure 5 A second cross-sectional view of the fluid-driven funnel;

[0015] Figure 9 An exemplary bead nozzle in a separated configuration according to various aspects of the present invention is depicted;

[0016] Figure 10 The image depicts a connected configuration according to various aspects of the invention. Figure 9 Bead nozzle;

[0017] Figure 11 The invention describes aspects from Figure 10 The cross-section of the bead nozzle;

[0018] Figure 12 Exemplary filling fasteners according to various aspects of the present invention are depicted;

[0019] Figure 13 An exemplary buffer pod assembly filled with a plurality of beads is depicted according to various aspects of the present invention;

[0020] Figure 14 The invention describes various aspects thereof. Figure 13 A cross-sectional view of the buffer pod assembly;

[0021] Figure 15 A cross-sectional view of a cup-shaped sole with a top fabric as a cushioning pod, according to various aspects of the invention, is depicted.

[0022] Figure 16 A flowchart illustrating a method of filling a buffer pod according to various aspects of the present invention is provided.

[0023] Figure 17A fastener for positioning one or more bead nozzles in a cushioning pod, integral with a footwear sole component for filling, is described according to various aspects of the invention.

[0024] Figure 18 A fixed bead nozzle according to various aspects of the present invention is depicted. Figure 17 The fastener, the bead nozzle, is used to fill the cushioning pods that are integrated with the footwear sole components;

[0025] Figure 19 The invention describes various aspects thereof. Figure 18 The ground-facing surface of the sole components of footwear;

[0026] Figure 20 The invention describes various aspects thereof. Figure 19 The bottom perspective view; and

[0027] Figure 21 The description illustrates the process of filling various portions with a plurality of beads according to various aspects of the invention. Figure 18 A cross-sectional view of the sole component of a footwear product. Detailed Implementation

[0028] Cushions provide support or shock absorption for force impacts. Padding can be formed from various materials and techniques. The cushioning pods provided herein are pads formed from multiple independent and discrete elements (e.g., multiple beads) contained within a housing. Discrete elements, generally referred to herein as "beads," are individual and discrete particulate material elements of any size, material, or shape. In one exemplary aspect, a bead is a circular surface, such as a sphere. Each of the multiple beads may have a different size and / or shape. Having multiple independent and discrete beads allows the beads to move relative to each other to adhere and form on a static surface where they are close together. In one exemplary aspect, when the padding forms the sole portion of a footwear article, the static surface is the sole surface of the human foot. Achieving adhesion by relatively repositioning the discrete and independent beads allows the article to be formed onto the surface in a manner other than deforming each of the beads. This allows for a greater degree of adhesion with retained deformability to absorb and / or mitigate impact forces by the multiple beads.

[0029] The cushioning pod is envisioned as a padding element implemented in various applications. Non-limiting examples of cushioning pod implementations include its use as part of footwear articles, such as shoes. For example, the cushioning pod can be used as at least a portion of the sole of a footwear article. In one exemplary aspect, the cushioning pod forms a midsole having a separate and distinct outsole attached to form a ground contact surface. In yet another example, the cushioning pod is envisioned as integral with the sole, such that a portion of the pod forms an outsole portion. It is also envisioned that the cushioning pod can be implemented in various alternative articles, such as sports equipment, protective gear, clothing, etc.

[0030] Because the buffer pod is formed from the shell of multiple discrete elements, it can be tuned by manipulating the discrete elements and / or the material forming the cavities with beads. For example, different sizes, combinations of sizes, different materials, elements of different sizes, different numbers of elements, elements of different volumes, elements of different densities, etc., can all be adjusted to achieve the target cushioning characteristics of the buffer pod. Furthermore, two or more buffer pods can be used in combination to allow for greater variability. As presented herein, it is conceivable that multiple buffer pods with different characteristics can be formed simultaneously to provide alternative cushioning profiles for different parts of the overall buffer pod structure.

[0031] Since buffer pods are formed from multiple discrete elements, such as multiple beads, it is desirable to control the multiple elements inserted into the buffer pod to obtain a consistent buffer pod result. Therefore, the aspects provided in this paper support systems and methods for manufacturing controlled, consistent, and customizable buffer pods. The systems and methods in this paper allow for the production of varied but intentional buffer pods.

[0032] In a first exemplary aspect, a system is provided for filling a buffer pod with a plurality of beads. The system includes a bead source configured to hold the plurality of beads. The system also includes a filling station fluidly coupled to the bead source. As used herein, a fluid coupling is a connection that allows the transfer of bead-like elements. The coupling can be a closed coupling, such as a tubular coupling, or it can be an open coupling, such as a chute or conveyor. The filling station includes a fluid insertion nozzle for introducing fluid from the fluid source into the fluid coupling of the system. The fluid can be a gas, such as ambient air pressurized to form a fluid flow. At least a portion of the fluid coupling is configured to convey the plurality of beads from the bead source to the buffer pod. In this example, the fluid flow may facilitate the propulsion of the plurality of beads along the fluid coupling. Gravity may also be used to transfer the plurality of beads through one or more portions of the system. The system also includes a bead nozzle. The bead nozzle is coupled to the fluid coupling of the system and configured to engage with the buffer pod to deposit the plurality of beads into the buffer pod. The bead nozzle, which will be discussed in more detail below, may be formed of at least two portions. The first part is in contact with the buffer pod, and the second part is fluidly connected to the system's fluid connector. The second part of the bead nozzle can be connected to a tubular structure, allowing beads passing through the system to be guided into the second part. The first and second parts of the bead nozzle are then removably connected to allow multiple beads to be inserted from the system into the buffer pod.

[0033] Another aspect envisioned in this document includes a system for filling a buffer pod with a plurality of beads. The system includes a bead source configured to hold the plurality of beads; a first weighing station including a first load sensor; and a second weighing station including a second load sensor. The system also includes a first metering station fluidly connected to the first weighing station; a second metering station fluidly connected to the second weighing station; and a first valve. The system further includes a first filling station fluidly connected to the first and second metering stations via the first valve. The system also includes a second filling station fluidly connected to the first and second metering stations via the first valve.

[0034] A method for filling a cushioning pod with multiple beads has also been conceived. This method includes measuring a first weight of the multiple beads at a first measuring station and a second weight of the multiple beads at a second measuring station. The method continues by conveying the first multiple beads to a first filling station via a first valve, and then conveying a second multiple bead to the first filling station via the same first valve. The first and second multiple beads remain separate and distinct at the first valve. The method continues by injecting the first multiple beads into a first pod of the cushioning pod, and injecting the second multiple beads into a second pod of the cushioning pod. The first and second pods are discrete pods of a typical cushioning pod article.

[0035] Go to Figure 1It describes a system 100 for filling a buffer pod with a plurality of beads according to various aspects of the invention. The system includes a storage station 102, a weighing station 104, a metering station 106, a filling station 108, an input device 140, a computing device 142, and a fluid source 144. As will be provided in more detail below, it is envisioned that it can be implemented... Figure 1 Any quantity, combination and / or configuration of the various components provided herein, as will be described below. Figure 2 The example is described in the text.

[0036] Storage station 102 is the source of elements to be inserted into the buffer pod. Storage station 102 is a source of beads configured to hold a plurality of beads. For example, storage station 102 may include a hopper or other container sufficient to hold a plurality of beads for selection by the system and insertion into the buffer pod. Storage station 102 may include a conveying mechanism, such as a screw conveyor, conveyor, or other material conveying mechanism. In some aspects, storage station 102 is positioned vertically above a subsequent station to utilize the gravitational pull of the plurality of beads to assist in the conveying of the beads through the system. The conveying mechanism allows a large number of beads to be loaded at a level below storage station 102 (e.g., ground level) and conveyed to a higher relative position for final distribution into system 100.

[0037] Multiple beads can be formed from any material and have any size. In one exemplary aspect, the beads in the multiple beads are formed from a polymer composition. In one exemplary aspect, the beads are a foamed polymer composition. For example, the beads can be thermoplastic elastomers (“TPEs”). Examples contemplated as classes of TPEs include styrene-based block copolymers, thermoplastic polyolefin elastomers, thermoplastic vulcanizates, thermoplastic polyurethanes (“TPUs”), thermoplastic copolyesters, and thermoplastic polyamides. Foamed TPEs are TPEs having open-cell or closed-cell pores that produce a material with a lower density relative to its non-foamed form. The concept of foam helps reduce the mass of multiple beads to keep the cushioning pods lightweight and can enhance the cushioning characteristics of the beads. Non-polymeric compositions, such as organic materials, are also contemplated for forming beads. Furthermore, it is contemplated that multiple beads can be formed as a heterogeneous collection of various material components and / or beads as a hybrid composition.

[0038] The multiple beads can have any shape, such as spheres. The shape can be regular or irregular. The shape can be uniform or inconsistent. The shape, size, and / or type of the beads can vary between a portion and a second portion of the buffer pod. In one exemplary aspect, the average diameter of the multiple beads ranges from about 1 mm to about 10 mm. In one exemplary aspect, the average diameter ranges from about 2 mm to about 6 mm. In one exemplary aspect, the average diameter ranges from about 3 mm to about 4 mm. While beads of any size can be used, the provided range provides the range within which the fluid connector, weighing station 104, metering station 106, and filling station 108 are configured for optimal delivery.

[0039] A connector 110 is provided to transfer multiple beads between components. The connector may be an operable connector. An operable connector effectively transfers elements such as beads or multiple beads between components (e.g., stations, buffer pods). An operable connector may be a fluid connector. A fluid connector may be a closed connector (e.g., airtight). Examples of contemplated connectors include, but are not limited to: a gravity-driven channel extending between storage station 102 and weighing station 104, a gravity-driven channel extending between weighing station 104 and metering station 106, and, in one exemplary aspect, a tubular structure extending between metering station 106 and filling station 108 driven by gravity and pneumatic pressure (e.g., vacuum and / or positive pressure). A fluid connector is a connector that facilitates the transfer of multiple beads from a first component to a second component or toward a second component. In some aspects, a fluid connector is a closed connector that transfers multiple beads with the assistance of a fluid, such as a pressure difference (e.g., positive or negative pressure) generated by the fluid. When a guided pressurized fluid flow is inserted into a fluid connector, a pressure differential can be created. The guided fluid flow follows the direction of bead flow through the system (i.e., the direction in which the beads are expected to flow toward the buffer pod). In the case of guided fluid flow, the portion of the fluid connector upstream of the fluid insertion nozzle can withstand a reduced pressure relative to ambient conditions. The portion of the fluid connector downstream of the fluid insertion nozzle can withstand an increased pressure relative to ambient conditions. Therefore, a closed fluid connector can provide both pull (e.g., vacuum) delivery to the beads upstream of the fluid insertion and push (e.g., blowing) delivery to the beads downstream. A connector that can operate can also be a fluid connector if it can support a pressure differential. As will be discussed in more detail below, in some aspects, the terminals (e.g., bead nozzles and / or buffer pods) must allow pressure equalization to ambient conditions to ensure a pressure differential is achieved within the fluid connector. When a pressure differential is achieved in the fluid connector, the fluid flow is able to deliver multiple beads therein. A cushioning pod, at least partially formed of a breathable material, allows the pressure within the pod to equalize with environmental conditions. In other words, a breathable material is a material that allows for pressure equalization within the cushioning pod, for example, by allowing multiple beads (e.g., air) used as a carrier to escape from the pod containing the beads.

[0040] Weighing station 104 is a station configured to weigh multiple beads to achieve a target weight. For example, the weighing station effectively measures a specific mass of multiple beads within a defined tolerance. The tolerance may be within 2 grams, 1 gram, 0.5 grams, 0.1 grams, etc. Weighing station 104 is configured to weigh multiple beads to, for example, 50 grams, 40 grams, 30 grams, 25 grams, 20 grams, 15 grams, 10 grams, 5 grams, 1 gram, and / or any value between them. An exemplary buffer pod, such as buffer pod 120 having multiple discrete pods 122, 124, 130, and 132, each pod containing a different amount of multiple beads. For example, when the beads are TPU foam with a diameter in the range of 3 mm to 4 mm, pod 122 may have 20 grams of first plurality of beads 126, pod 124 may have 15 grams of second plurality of beads 128, pod 130 may have 10 grams of beads, and pod 132 may have 5 grams of beads. This will be discussed in conjunction with... Figure 3 Let's discuss the weighing station in more detail.

[0041] In one exemplary aspect, it is envisioned that weighing station 104 effectively applies variable-rate weighing. Variable-rate weighing allows for initial macroscopic weighing from a single device, followed by microscopic weighing, and then precise weighing. In use, it is envisioned that for a first percentage of the target weight, such as the first 80% to 90% of the target weight, beads are weighed at a relatively high flow rate. A medium flow rate, which has a lower bead flow rate than the high flow rate, can then be applied. This medium flow rate can be used to achieve up to about 90% to 98% of the target weight. Finally, in this example, a precise flow rate, even lower than the medium flow rate, can be used until weighing station 104 reaches the target weight. By adjusting the flow rate through weighing station 104, more control and granularity are achieved when weighing beads. For example, the lower the flow rate, the higher the accuracy typically obtained for weighing a particular target. Variable flow rate, i.e., the rate at which beads are weighed, precisely balances the cycle time target by achieving high throughput for the first portion of the target weight and then achieving higher accuracy of the target weight at lower flow rates. Alternative variable rate weighing is envisioned, for example, instead of the three or more rates mentioned above, only high flow rate and low flow rate.

[0042] Metering station 106 is a station configured to provide or otherwise release multiple beads in a controlled and / or regulated manner. Metering of the multiple beads prevents blockages and obstructions during the transport of the multiple beads. Metering can be accomplished using various techniques. For example, metering of multiple beads can be accomplished by using a vibrating surface that propels the beads along a surface having a vibration frequency that causes controlled movement of the beads along the surface. Alternatives, as will be discussed below... Figures 4 to 8In more detail, a fluid-driven funnel can be used. This fluid-driven funnel uses a directional airflow through the funnel structure to restrict the flow of multiple beads, while simultaneously propelling a portion of the multiple beads that can pass through the funnel with the assistance of the airflow, thereby agitating and driving the multiple beads in the direction of bead flow. Metering of the multiple beads by the metering station 106 effectively conveys the beads through the system 100, while minimizing interference with downstream bead conveying caused by blockages or other obstructions formed by the multiple beads.

[0043] Filling station 108 includes multiple fluid connectors, such as a first hose 112 and a second hose 116. The fluid connectors effectively guide multiple beads to specific buffer pods or portions thereof. Figure 2 The discussed approach aims to guide multiple beads to a desired buffer pod while maximizing the use of stations throughout the system. The first hose 112 and the second hose 116 can be flexible tubular structures through which multiple beads can be transported.

[0044] The filling station 108 also includes bead nozzles, such as a first bead nozzle 114 and a second bead nozzle 118. The bead nozzles are structures that efficiently transfer multiple beads from the system 100 to the buffer pod. (As will be combined...) Figures 9 to 10 Provided in more detail, the bead nozzle includes a first portion and a second portion. The first portion is engaged with a buffer pod, for example, inserted into the buffer pod. The second portion is connected to a fluid connector, such as a first hose 112. The first and second portions are removably connected such that the first portion can engage with the buffer pod before the buffer pod is introduced into the system 100. Once the buffer pod with the first portion of the bead nozzle is introduced into the system 100, the first and second portions of the bead nozzle can be connected, for example, by magnetic attraction, to complete the fluid connection between the system 100 and the buffer pod cavity.

[0045] Input device 140 is optionally provided. Input device 140 can be any input device that effectively provides information to computing device 142 or system 100, typically via logical connection 141, which is a wired or wireless connection that facilitates the transfer of data between input device 140 and one or more components. Examples of exemplary input devices include, but are not limited to, barcode scanners, vision systems, keyboards, cursor manipulators (e.g., computer mice), RFID readers, etc. For example, it is envisioned that a specific filling protocol can be invoked or developed for a particular buffer pod. The protocol can be retrieved from computer memory via input from the input device. For example, an identifier such as a barcode or other mark may be present on the buffer pod to be filled. Input device 140 is used to input the identifier, which causes system 100 to load and execute a unique filling protocol on the buffer pod. The use of a unique filling protocol allows for the customization of filling various buffer pods with a common system.

[0046] Computing device 142 generally includes various computer-readable media and a processor. Computer-readable media can be any available medium accessible by computing device 142, and includes volatile and non-volatile media, removable and non-removable media. By way of example and not limitation, computer-readable media can include computer storage media and communication media. Computer storage media includes volatile and non-volatile, removable and non-removable media implemented in any method or technique for storing information such as computer-readable instructions, data structures, program modules, or other data.

[0047] Computer storage media include RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disc (DVD) or other optical disc storage, magnetic tape cassettes, magnetic tape, disk storage or other magnetic storage devices. Computer storage media do not include transmitted data signals.

[0048] Communication media generally present computer-readable instructions, data structures, program modules, or other data as modulated data signals, such as carrier waves or other transmission mechanisms, and include any information transmission medium. The term "modulated data signal" refers to a signal whose one or more characteristics are set or altered in a manner that encodes information in the signal. By way of example, and not limitation, communication media include wired media such as wired networks or direct wired connections, and wireless media such as acoustic, RF, infrared, and other wireless media. Any combination of the above should also be included within the scope of computer-readable media.

[0049] The memory includes computer storage media in the form of volatile and / or non-volatile memory. The memory of computing device 142 may be removable, non-removable, or a combination thereof. Exemplary memory includes non-transitory solid-state memory, hard disk drives, optical disk drives, etc. Computing device 142 includes one or more processors that read data from various entities such as buses, memory, or I / O components. It may include presentation components(s) that present data instructions to a person or other device. Exemplary presentation components include display devices, speakers, printing components, vibrating components, etc. I / O ports of computing device 142 allow computing device 142 to be logically connected to other devices that include I / O components, some of which may be built-in. Illustrative I / O components include input device 140. A logical connection that allows the connection is a wired or wireless communication between two devices. Examples of logical connections include, but are not limited to, near-field electronic communication, WiFi, Bluetooth, infrared light, etc. Examples of wired logical connections include, but are not limited to, Ethernet, direct bus cabling, etc. If the first and second devices in the logical connection are not located between two devices, they are capable of data communication in at least one direction.

[0050] The computing device 142 is logically connected to one or more features of the system 100 via logical connection 143. For example, the computing device 142 may be logically connected to the storage station 102, the weighing station 104, the metering station 106, and / or the filling station 108 in a wired and / or wireless manner. Additionally, although in Figure 1 Not depicted, but the logical connection extends to other envisioned components, such as valves, fluid sources, nozzles, etc. Logical connection 143 is a wired and / or wireless connection that facilitates data transmission, as is known in the art.

[0051] Fluid source 144 is an exemplary fluid source. As provided above, in some aspects, the fluid is envisioned as compressed air, and the fluid source is used to supply air. In one exemplary aspect, the fluid may originate from a storage tank and / or a compressor. The fluid from fluid source 144 is fluidly connected to system 100 via fluid connector 145. Fluid connector 145, used to deliver fluid to various components of system 100, is a sealed conduit. In one exemplary aspect, a regulator controls the pressure of the fluid, for example, controlling the pressure at 8 bar, 7 bar, 6 bar, 5 bar, 4 bar, 3 bar, and / or 2 bar. A bar of pressure is defined as 100,000 Pascals (“Pa”). In yet another specific example, a fluid insertion nozzle is envisioned to insert pressurized air into the fluid connector at a pressure ranging from approximately 5 bar to 7 bar. In yet another more specific example, the fluid is inserted into the fluid connector at a pressure of approximately 6 bar. As will be discussed in detail below, the pressure of the air inserted into the fluid connector affects the velocity and volume delivered through the beads of the fluid connector. The provided pressure range is effective for the envisioned system and beads.

[0052] In one exemplary aspect, fluid inserted into system 100 is used to facilitate the transfer of multiple beads through a fluid connector and to aid in the metering of the multiple beads. Furthermore, as will be discussed in more detail below, the fluid is used to create a vacuum and / or positive pressure environment to facilitate the movement of the multiple beads. In various aspects, it is envisioned that gravity and fluid can be used in combination to transfer multiple beads through one or more sections of system 100.

[0053] supply Figure 1 This is to illustrate exemplary components; however, it is contemplated that any combination of these components can be utilized according to various aspects of the invention. Furthermore, it is contemplated that any number of any components can be implemented according to various aspects of the invention. Figure 1 Any component may be omitted or optionally included.

[0054] Figure 2 An extended system 200 for filling a buffer pod with a plurality of beads is described according to various aspects of the present invention; Figure 2 The components relate to the previous information. Figure 1 The components discussed. Although not Figure 1 All components (e.g., computing device 142) are in Figure 2 It is depicted, but it is envisioned that those components can be combined. Figure 2 The system 200 is included and combined. For example, such as Figure 2 As shown on the right, a storage station 102 is generally provided, a weighing station 104 is generally provided, a metering station 106 is generally provided, and a filling station 108 is generally provided.

[0055] and Figure 1 different, Figure 2 System 200 is configured to provide discrete bead streams for simultaneously filling multiple buffer pods (e.g., buffer pods having multiple discrete pods). Each of the discrete bead streams may include different beads (e.g., different material compositions), different weights of beads, and / or different metering. Thus, various components (e.g., stations) forming the different streams are identified along the top as a first group 230, a second group 232, a third group 234, and a fourth group 236. Similarly, filling station 108 includes discrete stations to which the bead stream is directed. For example, a first station 258 and a second station 262 are depicted. Beads are directed between the two stations via a valve (e.g., a first valve 240), which will be discussed in more detail below. Each of the different stations is depicted as having different sub-stations, such as a left station 254 and a right station 256 of the first station 258. Beads are directed between the left station 254 and the right station 256 via a valve (e.g., a second valve 260), which will be discussed in more detail below.

[0056] The first group 230 includes a first storage station 202, a first weighing station 204, and a first metering station 206. The first storage station 202 is operatively connected to the first weighing station 204 via a connector 208. This operative connection allows for the transfer of beads between the stations. The first weighing station 204 is operatively connected to the first metering station 206 via a connector 210. The first metering station 210 is operatively connected (e.g., fluidly connected) to a first valve 240 via a connector 211. The first valve 240 effectively directs a plurality of beads from the first group 230 to the first station 258 via a connector 223, or directs the plurality of beads to the second station 262 via a connector 227.

[0057] The second group 232 includes a second storage station 212, which is operatively connected to a second weighing station 214 via a connector 218. The second weighing station 214 is operatively connected to a second metering station 216 via a connector 220. The second metering station 216 is connected to a first valve 240 via a connector 221. The first valve 240 effectively directs a plurality of beads from the second group 232 toward a first station 258 via a connector 225, and then directs the plurality of beads toward a second station 262 via a connector 229.

[0058] The first valve 240 is described as a three-way valve with two alternative outputs (first station 258 and second station 262). However, it is contemplated that the first valve 240, or any valve herein, could alternatively be an X-way valve, which could have any number of alternative outputs. The first valve 240 and any other valve provided herein can be electronically controlled (e.g., altered) and / or monitored. For example, system 200 can logically connect the first valve 240 to a computing device to control the direction of the bead flow. Furthermore, as will be discussed in more detail below, the position of the first valve 240 when it guides multiple beads can be electronically determined. For example, at the first fluid insertion nozzle 246, the computing device can use the determination of the position of the first valve 240 to control fluid flow to limit fluid flow to those parts of the system to which the valve does not guide bead flow, which will be discussed in more detail below.

[0059] Separate from and distinct from the multiple beads from the second group 232, the first valve 240 effectively retains the multiple beads from the first group 230. Thus, if a specific weight or number of beads is measured in the first group 230, that weight or number is maintained toward the filling station 108 through the first valve 240.

[0060] To further facilitate the transfer of multiple beads through system 200, a first fluid insertion nozzle 246 is provided. The fluid insertion nozzle is a structure that effectively inserts a pressure differential, such as positive and / or negative pressure, into the fluid connector of the system. The fluid insertion nozzle can guide the airflow in the direction of bead flow, such that in the fluid connector, a positive pressure is experienced downstream of the fluid insertion nozzle, which pushes the beads in the direction of bead flow, and a negative pressure is experienced upstream of the fluid insertion nozzle, causing the beads to be pulled through the fluid connector.

[0061] In one exemplary aspect, the fluid insertion nozzle is a fluid connector aligned with a fluid connector that conveys multiple beads. Thus, when a fluid source, such as compressor 242, applies positive pressure through the fluid insertion nozzle, the fluid injected into the system through the nozzle causes the multiple beads conveyed in the fluid connector to advance toward the filling station. Since different connections can be maintained for different groups (e.g., the first group 230), each different connection can have a separate fluid insertion nozzle. For example, connector 223 for the first group 230 has a first fluid insertion nozzle 246, and connector 225 for the second group 232 has a second fluid insertion nozzle 248. Each fluid insertion nozzle can provide a different fluid pressure or volume. For example, if the first group conveys a larger quantity of beads than the second group, the first group can operate at a higher fluid velocity, pressure, and / or volume than the second group to convey a different amount of beads in, for example, a closer approximate time. In other words, it is envisioned that the fluid insertion nozzle can vary the amount, pressure, and / or velocity of the fluid in the insertion connector to regulate the bead conveying speed.

[0062] Compressor 242 may be an air compressor. Compressor 242 may include one or more valves and / or regulators to control fluid distribution of system 200. For example, when first valve 240 directs the bead flow to first station 258, compressor 242 may stop supplying fluid to second station 262 because the second station does not deliver multiple beads to conserve energy. Selective fluid distribution may be controlled at least in part by a computing device and one or more valves, such as manifolds.

[0063] Each of the first station 258 and the second station 262 is described as having two sides. In an exemplary aspect of manufacturing a cushioning pod that forms a footwear sole component (e.g., a midsole that reduces impact on the wearer), the right and left shoe components may be filled at a common station to complete the shoe pair. Thus, in the example of system 200, the left cushioning pod for the left shoe may be filled with beads at the right station 256, and the right cushioning pod for the right shoe may be filled with beads at the left station 254. In this example, the orientation of the beads between the left station 254 and the right station 256 is controlled by a second valve 260. The second valve 260 may be electronically controlled by a computing device to coordinate the distribution of the multiple beads. Switching the second valve 260 guides the multiple beads from the first group 230 between the connector 231 of the left 254 and the first bead nozzle 250 and the connector 235 of the right 256. Similarly, the second valve 260 directs multiple beads from the second group 232 between the connector 233 on the left side 254 and the connector 237 on the right side 256. Depending on the number of separate and distinct groups, the second valve 260 (or any valve in the system 200) effectively directs the flow and distribution of beads to the appropriate connectors to maintain separate and distinct bead flows.

[0064] The second station 262, although not discussed in detail here, operates similarly to the operation discussed in conjunction with the first station 258. For example, the use of the valve in the first valve 240 allows for more efficient use of the system 200 to allow for almost continuous filling of the cushioning pods, while preparing to fill other cushioning pods on an alternative side or station. For example, while the first pair of footwear cushioning components is filled by the system 200 at the first station 258, the second pair of footwear cushioning components is prepared at the second station 262 (e.g., by inserting bead nozzles, the bead nozzle portions being connected).

[0065] supply Figure 2 This is to illustrate exemplary components; however, it is contemplated that any combination of these components can be utilized according to various aspects of the invention. Furthermore, it is contemplated that any number of any components can be implemented according to various aspects of the invention. Figure 2 Any component may be omitted or optionally included.

[0066] Figure 3An exemplary weighing station 300 according to various aspects of the invention is depicted. The weighing of contemplated beads, such as TPE foam beads with diameters in the range of 3 mm to 4 mm at contemplated volumes (e.g., 50 g, 40 g, 30 g, 20 g, 15 g, 10 g, 5 g), benefits from the level of accuracy provided in the example. In one aspect, the weighing station 300 relies in part on the gravitational movement and vibrational energy of the plurality of beads. The vibrational energy is generated by a vibration generator, such as a first vibration generator 310 and a second vibration generator 308. In one example, the vibration is generated by the vibration generator through the unbalanced rotation of a component. For example, an electric motor may have an unbalanced element attached to a rotating output shaft. When the rotating shaft rotates the unbalanced element, oscillations are generated in coordination with the rotational rate of the shaft. As the rotational speed of the rotating shaft increases, the frequency of the generated vibration also increases. Similarly, when the rotational speed decreases, the frequency of the generated vibration also decreases. Therefore, the vibration frequency can be adjusted to control the bead movement rate according to the target rate of bead movement across the surface affected by the vibration generator.

[0067] The weighing station 300 also includes a load sensor 314. The load sensor is capable of measuring the weight of beads contained within a defined space, such as the weighing surface 312. In one exemplary aspect, the load sensor 314 detects the weight of the beads when they fall from the moving portion 302 at the first surface edge 318, and / or when they fall from the second surface 304 at the second surface edge 316. When the beads accumulate on the weighing surface 312, the load sensor determines the cumulative weight of the beads accumulated thereon.

[0068] In an exemplary use of the weighing station 300, multiple beads are supplied from a bead source to a moving part 302, for example, via a hopper, channel, or other connection that guides multiple beads from a source to the weighing station 300. The aggregated beads move along the moving part 302 by vibrational energy generated by a vibration generator. The vibrational energy can be adjusted, for example, by a computing device, to increase the flow of the multiple beads from the moving part 302 to the weighing surface 312. The vibrational energy effectively moves the beads along the surface, which is a result of the surface vibration causing a reduction in static friction in the variable contact between the beads and the surface.

[0069] The second surface 304 is optional. In aspects where there is greater control (e.g., microscopic control) over the movement of beads to the weighing surface, the second surface 304 and a second vibration generator 308, controlled independently of other vibration generators, serve as a fine-tuning motion mechanism that provides a higher level of control over the amount of beads applied to the weighing surface 312, compared to the first surface 306. The second surface 304 has a smaller surface area capable of conveying multiple beads to the weighing surface 312 compared to the first surface 306, thus achieving a higher level of control. In some aspects, the second surface 304 is omitted. In other examples, the second surface 304 is not used or is exposed to indirect vibration energy generation.

[0070] In some respects, when the load sensor detects proximity to the target weight, the weighing station 300 can adjust the movement rate of multiple beads. For example, the first vibration generator 310 can adjust the frequency from a first frequency that causes the beads to travel faster on the first surface 306 to a second frequency that causes the beads to travel slower on the first surface 306. Similarly, in the example using the second surface 304, it is envisioned that while the second surface 304 and the second vibration generator 308 are used to generate the final bead aggregation, the first vibration generator 310 can reduce or stop the vibration generation at the first surface 306. Although not depicted, it is envisioned that the weighing station includes openings, slots, channels, or other structures to aggregate the weighed beads, thereby guiding the weighed beads to a connector for transport to a subsequent station, such as a metering station.

[0071] Figure 4 An exemplary metering station 400 according to various aspects of the present invention is depicted. The metering station 400 includes a storage chamber 402 having a capacity for, for example, from... Figure 3 The weighing station 400 includes a pre-weighing bead housing 404. The weighing station 400 also includes a fluid-driven funnel 406. The fluid-driven funnel 406 includes a fluid passage 408, which is fluidly connected to a fluid source, such as an air compressor, via a connector 412. The fluid can be air. The fluid can be air at a pressure greater than atmospheric pressure. The fluid exits from the fluid passage 408 at a fluid outlet 410.

[0072] In use, metering station 400 receives a plurality of beads 416 contained within storage chamber 402, which are metered out from output port 414 at a controlled rate. A fluid-driven funnel 406 has a funnel-shaped opening to output port 414, which intentionally restricts the free flow movement of the plurality of beads 416 therethrough. The size of the funnel is determined in part by the average diameter 418 of the plurality of beads 416. The size of the funnel is selected to allow the plurality of beads 416 to move when agitated or otherwise stimulated by the fluid output from fluid port 410. Because interference between the plurality of beads 416 occurs at the funnel after fluid port 410 in the bead flow direction, this interference modulates the flow of the plurality of beads 416 through the funnel portion of fluid-driven funnel 406. In one exemplary aspect, for the contemplated exemplary beads, output port 414 has a diameter in the range of 10 mm to 14 mm. This diameter is larger than the restrictive portion located between fluid port 410 and output port 414. As depicted, the diameter of the limiting port can be 5%, 10%, 15%, 20%, 25%, 30%, 40%, 50% of the diameter of the output port 414, or any size between therewith. In other words, the minimum contraction in the bead flow path of the metering station 400 can be 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, or any size between therewith, for the bead size contemplated in the exemplary aspects herein.

[0073] The fluid discharged from fluid port 410 can be air with varying pressure and / or velocity to regulate the metering rate of the beads. For example, if smaller diameter beads are supplied to storage chamber 402, a lower pressure or velocity fluid can be discharged from fluid port 410 to maintain a metered outflow of beads that does not obstruct or otherwise interfere with the movement of beads through the system. Similarly, for larger diameter beads, the velocity and / or pressure of the fluid discharged from fluid port 410 can be increased to force the beads through the funnel portion of fluid-driven funnel 406.

[0074] Figures 5 to 8 An exemplary view of a fluid-driven funnel 500 removed from a metering station according to various aspects of the present invention is provided. Figure 5 An isometric projection of a fluid-driven funnel 500 according to various aspects of the present invention is depicted. The fluid-driven funnel 500 includes the following components: a fluid channel 408, a main body portion 502 terminating at a funnel portion, and an outlet 414 in the direction of bead flow. Figure 6 A top perspective view of a fluid-driven funnel 500 according to various aspects of the present invention is depicted. Figure 7 The description of various aspects according to the invention is as follows Figure 6 The cross-sectional view of the cutting line 7-7. Figure 8The description of various aspects according to the invention is as follows Figure 6 The cross-sectional view of the cutting line 8-8.

[0075] Figures 9 to 11 A bead nozzle 900 according to various aspects of the present invention is depicted. Figure 9 A bead nozzle 900 in a separate configuration according to various aspects of the invention is depicted. As previously discussed, the bead nozzle effectively introduces a plurality of beads into a buffer pod. For efficient filling, the bead nozzle can be formed in two parts. The first part 904 includes an injection portion 910. The injection portion 910 can be a rigid element that is effectively inserted into the receiving channel of the pod to enter the internal volume of the pod. The injection portion can have different lengths, extending to the distal end where the beads are discharged. The different lengths can depend on the shape of the pod and / or the pod for filling the beads. The first part 904 can be inserted into the pod before the pod is introduced into the filling system to improve efficiency by reducing the system's cycle time. The first part 904 can include a connecting element, such as a first magnetic element 916 at a connecting surface 912. The magnetic element can be a magnetic material and / or a material attracted by magnetic force (e.g., an ferrous material). Contemplated alternative connecting elements include, but are not limited to, mechanical hooks, loop elements, compression fittings, etc.

[0076] The bead nozzle also includes a second portion 906. The second portion 906 is coupled to a connector 908. The connector 908 may extend from the filling station, valve, or other part of the filling system. The second portion 906 includes a coupling element, such as a second magnetic element 918 at a coupling surface 914. The second magnetic element 918 is a magnetic element complementary to the first magnetic element 916 to facilitate magnetic attraction and removable coupling. A removable coupling is the connection of discrete elements in a manner that allows them to be maintained but can be disconnected, for example, by overcoming the magnetic attraction that maintains contact between the portions.

[0077] Figure 10 A bead nozzle 900 in a connecting arrangement 902 according to various aspects of the present invention is depicted. Figure 11 The invention describes various aspects thereof. Figure 10 The cross-section. Figure 11It is explained that the connecting surface 912 contacts the second magnetic element 918 and the connecting surface 914 contacts the first magnetic element 916, thereby forming a removable connection between the first portion 904 and the second portion 906. Additionally, the diameter 1102 of the connector 908 is described as an exemplary diameter. The diameter of the connector used in the system can be adjusted based on various factors, such as the average diameter of the beads to be conveyed through it. The diameter 1102 is larger than the expected maximum bead diameter. Furthermore, the diameter can be a multiple of the expected maximum bead diameter. In one exemplary aspect, this multiple can be two, three, or four times the bead diameter. Moreover, in a contemplated aspect, different portions of the bead nozzle 900 can have different diameters to aid bead delivery. For example, the connector 908 can have a first diameter, for example, from 12 mm to 18 mm. In one exemplary aspect, the diameters of the first portion 904 and the second portion 906 are from 8 mm to 12 mm. In one exemplary aspect, the diameter of the injection portion 910 is from 6 mm to 10 mm. Furthermore, in an exemplary aspect of the invention, it is envisioned that the diameter in the bead flow direction is consistent with or reduced from that of the previous portion. Additionally, it is envisioned that one or more portions may have variable diameters. For example, the injection portion 910 may have a tapered profile such that the diameter varies from a larger diameter to a smaller diameter along the bead flow direction. Furthermore, the inner diameter through which multiple beads pass may remain constant, while the outer dimensions (e.g., diameter) may decrease along the bead flow direction to facilitate insertion of the nozzle 900 into the bead pod.

[0078] Figure 12 An assembly 1200 according to various aspects of the invention is depicted, the assembly 1200 including a filling retainer 1202 and a second buffer pod assembly 123, the filling retainer 1202 holding having Figure 1The buffer pod assembly 121 of the buffer pod 120. A filling retainer 1202 provides a bracket for supporting the buffer pod assembly 121 during the filling operation. The filling retainer 1202 includes a first wing 1204 and a second wing 1206. The first wing 1204 is inclined at an angle 1210, and the second wing 1206 is inclined at an angle 1208. The angles of the wings relative to the horizontal position facilitate filling the buffer pod assembly 121. This angle allows bead nozzle portions, such as bead nozzle portions 1214 and 1216, to be vertically positioned above the low point of the pod to be filled. By varying the height from the position of the bead nozzle to the low point of the pod, the pod can be filled from the low point to the bead nozzle to achieve complete filling as beads are inserted into the pod through the bead nozzle. In other words, by positioning the bead nozzle above the opposing portions of the pod, the beads first gather at the opposing portions of the pod, thereby allowing the beads to flow out of the bead nozzle. The filler retainer 1202 also provides support to one or more bead nozzles as they are inserted into the buffer pod assembly 121. This support prevents the bead nozzles from folding, curling, or otherwise obstructing the entrance to the pod due to their own mass. Furthermore, the filler retainer 1202 allows for the pre-assembly of the buffer pod assembly 121 with multiple bead nozzles (e.g., attaching the first portion of the bead nozzle to the pod) before the assembly 1200 is introduced into the filling system, which can increase the system's throughput. In one exemplary aspect, the filler retainer 1202 also allows for a smaller footprint in the system's filling stations due to the angle of the wings.

[0079] Figure 13 A filled buffer pod assembly 121 according to various aspects of the invention is depicted. Each of the discrete pods 122, 124, 130, and 132 is filled with discrete volumes of beads, as previously discussed. The beads are introduced into the discrete pods through bead nozzles, as previously described. Figure 12 As described. The bead nozzle enters the pod through an insertion port, such as a first insertion port 1302 and a second insertion port 1304. Figure 12 As described, the bead nozzle portion 1214 extends through Figure 13 The first insertion port 1302 is used to deposit a plurality of beads 126 therein. Similarly, as Figure 12As described, the bead nozzle portion 1216 extends through the second insertion port 1304 to deposit a plurality of beads 128 therein. In some aspects, the insertion port is envisioned to be inherently resilient and self-sealing after the bead nozzle is withdrawn. Alternatively, the insertion port may be sealed after the bead nozzle is withdrawn, for example by ultrasonic welding, thermal welding, stitching, bonding, etc. Furthermore, it is envisioned that the withdrawal process seals the insertion port when a set of pods is withdrawn from the buffer pod assembly 121. For example, if the buffer pods 120 are removed from the buffer pod assembly 121 by laser or other heat-based removal techniques, the removal operation (e.g., cutting) seals the insertion port.

[0080] Figure 14 The buffer pod assembly 121 according to various aspects of the present invention is depicted along... Figure 13 The cross-section of the cut line 14-14. First material 1402 and second material 1404 form the buffer pod assembly 121. In one exemplary aspect, the first material is a membrane material, such as a polymer composition formed as a sheet membrane. First material 1402 can be formed from any material, such as TPE. In one exemplary aspect, first material 1402 is an impermeable material. First material 1402 is a conformable and flexible material. In one exemplary aspect, second material 1404 is a breathable material. In other words, second material 1404 has greater permeability than first material 1402, as will be discussed below. Second material 1404 can be formed from any material composition, such as a polymer composition. In one exemplary aspect, second material 1404 is a fabric. A fabric is a woven, knitted, braided, or non-woven material formed by the mechanical bonding of one or more strands of material (e.g., filaments, threads, yarns). In one exemplary aspect, the mechanical bonding provides porosity that promotes permeability.

[0081] The relative air permeability of the first material 1402 and the second material 1404 is relevant to filling the pod with beads. Specifically, it is envisioned that a fluid be used to assist in conveying the beads through one or more parts of the system, such as a filling station. As a result, the fluid assisting in conveying the beads through the system also deposits into the pod. In the absence of sufficient air permeability at the pod, the discharged fluid may fill the pod and may deform the pod during the filling operation. Furthermore, in the absence of sufficient air permeability at the pod, the fluid insertion nozzle may not generate a pressure difference relative to ambient conditions, thereby failing to effectively assist in conveying multiple beads along the bead flow direction.

[0082] In one exemplary aspect, when used in footwear components, the second material 1404 forms a surface facing the foot. The second material 1404 may be a highly conforming material such that when a load is placed on the second material 1404, it conforms to the wearer's foot and transfers the load to a plurality of beads contained within a pod. Thus, the individual and discrete beads forming the plurality of beads also conform to the wearer's foot, thereby providing support and an effective cushioning system for the footwear. In one exemplary aspect, the second material 1404 is a polyurethane fabric with relatively high elasticity and breathability, which adapts to the wearer's body when a load is applied to the plurality of beads.

[0083] Although the examples provided in this paper describe four discrete pods, it should be understood that the pods can be of any number and configuration. For example, a single pod can form a buffer pod structure. Multiple pods can form a buffer pod structure. Furthermore, although a planar structure is described relative to the second material 1404, it is contemplated that, as follows... Figure 21 As described, non-planar structures can be formed, for example, by “overfilling” one or more pods. In one exemplary aspect, under compressive forces provided by the wearer or the ground, the non-planar cross-section increases the foot contact surface compared to filling the pods to a flat horizontal plane, allowing the bead-filled pods to conform largely to the wearer's foot.

[0084] Figure 15 An alternative cushioning pod 1500 concept according to various aspects of the invention is depicted. The cushioning pod 1500 represents a cross-section of a cup-shaped sole 1504 filled with a plurality of beads 1506 and comprising a top fabric 1502. In one exemplary aspect, the top fabric 1502 has a... Figure 14 The second material 1404 has similar characteristics. For example, the top fabric 1502 has greater air permeability than the cup-shaped sole 1504 to allow for pressure equalization within the pod cavity when the beads are inserted under fluid pressure. Although in Figure 15 A single pod is depicted, but it is envisioned that multiple pods can be formed to provide discrete and controlled pods with different or similar characteristics, as discussed in conjunction with other aspects herein. In one exemplary aspect, the insertion port may extend through the top fabric 1502 to allow for the insertion of a plurality of beads 1506.

[0085] Figure 16 A flowchart illustrating a method 1600 for filling a buffer pod according to various aspects of the invention is described. In block 1602, a first measuring station measures a first weight of a plurality of beads. See, for example, [link to relevant documentation]. Figure 2The first weighing station 204 can weigh a first weight of multiple beads according to a given buffer pod formulation. Simultaneously, in frame 1604, a second weighing station weighs a second weight of multiple beads. See, for example... Figure 2 The second weighing station 214 can weigh the second weight of multiple beads according to the formulation of the buffer pod.

[0086] In frame 1606, the first plurality of beads are conveyed to the first filling station via the first valve. See also Figure 2 The first plurality of beads are transferred from the first weighing station 204 to the first station 258 via the first valve 240. The first valve 240, or any valve herein, can be pneumatically operated to change between valve positions. Additionally or alternatively, electrical actuation of the valve may cause changes between valve positions. In block 1608, the second plurality of beads are transferred to the first filling station via the first valve. See also Figure 1 The second plurality of beads are transferred from the second weighing station 214 to the first station 258 via the first valve 240. It should be understood that the transfer of beads may include transfer via an additional station, such as a metering station. Transfer can be achieved by vacuum pressure, positive pressure, gravity feed, mechanical motion, and / or similar methods.

[0087] In box 1610, the first plurality of beads are injected into the first pod. See, for example, [link to example]. Figure 2 A first plurality of beads are conveyed through connector 231 to a first bead nozzle 250, which abuts against a first pod to inject the first plurality of beads therein. In block 1612, a second plurality of beads are injected into a second pod. The first and second pods are discrete pods of a common article. See also Figure 2 The second plurality of beads are conveyed through connector 233 to a second bead nozzle 252, which docks with the second pod to inject the second plurality of beads therein.

[0088] Figure 17 An exemplary fastener 1700 according to various aspects of the present invention is described. The fastener 1700 positions one or more bead nozzles for filling one or more pods with a plurality of beads, as described below. Figure 18The fastener 1700, as depicted, includes a transverse member 1702 that transitions to a first inner vertical member 1704, then to a first top member 1706, then to a first outer member 1708, then to a first foot portion 1710, then to a first nozzle vertical member 1712, and finally terminates at a first nozzle hook member 1714. Returning to the transverse member 1702 and extending in the opposite direction of the fastener 1700, the transverse member 1702 transitions to a second inner vertical member 1716, then to a second top member 1718, then to a second outer member 1720, then to a second foot portion 1722, then to a second nozzle vertical member 1724, and finally terminates at a second nozzle hook member 1726. While an exemplary configuration is depicted, alternative configurations for the fastener are contemplated.

[0089] The fastener 1700 can be formed of any material. In one exemplary aspect, the fastener 1700 is formed of a metallic material such as steel or aluminum. However, other materials, such as polymer-based compositions, are contemplated. The fastener 1700 may include additional materials, such as materials having a relatively high coefficient of friction to stabilize and / or secure the fastener 1700 to the footwear article (or a portion thereof). For example, when various components are primarily formed of metallic materials, a polymeric material may cover or otherwise form the outer surface of a portion of the fastener 1700 to increase the secureness of the fastener 1700 to the footwear part. This will be explained below. Figure 18 As shown in Figure 17 In the depicted example, material covers the first nozzle hook member 1714 and the second nozzle hook member 1726 to secure the respective bead nozzles. In one exemplary aspect, the cover at the hook member prevents the bead nozzle from ejecting from the pod it is filling under its own insertion pressure.

[0090] In another example of fasteners, imagine that a portion of the fastener could be adjustable to accommodate different parts (or sections) of footwear, thus making the fastener universal. For example, similar to... Figure 17The vertical members that function in the manner of the first nozzle vertical member 1712 and / or the second vertical member 1724 can alternatively be length-adjustable. For example, it is conceivable that the length of a common vertical member or separate vertical members for each hook member can be adjusted to accommodate different sizes, shapes, and configurations of the footwear components. The adjustable nature allows for selective engagement and disengagement of a certain length. For example, a ratchet-like assembly can allow for shortening to generate compressive force on the nozzle held by the fastener. When the vertical length of the fastener is reduced, a greater force is applied to the first end of the nozzle, causing the nozzle to pivot on the fastener or a portion of the footwear component, so that the opposite second end of the nozzle rises onto the material of the pod or the top cover forming the pod. Thus, regardless of the configuration of the footwear component, the adjustable-length vertical members of the fastener allow for proper fixation and positioning of the nozzle relative to the pod or the footwear component with the pod.

[0091] In a specific example of a general-purpose fastener used to secure and retain nozzles in footwear for filling pods with particulate material, a single vertical member is envisioned extending from the foot portion. The vertical member is rotatably coupled to the foot portion to allow for positioning and compensation of the angle relative to the sidewalls of the footwear component. At the opposite end of the foot portion, the single vertical member includes one or more nozzle hooks. For example, a lateral member may extend from the vertical member at the end opposite the foot portion. At each end of the lateral member is a nozzle hook. The length of the lateral member can also be adjusted to accommodate different pods and / or nozzle spacing requirements. The lateral member can be pivotally coupled to the vertical member to adjust the different vertical distances for each nozzle and nozzle hook when adjusting the length of the vertical member. The pivoting or rotational movement of the lateral member allows for the general application of additional flexibility in the fastener to different products. The adjustable nature of the fastener is adjusted using ratchet mechanisms, friction locking mechanisms, mechanical locking mechanisms, etc., and then maintained at the set length during use.

[0092] Figure 18 Depicting fixed bead nozzles 1818, 1824 according to various aspects of the invention for filling cushioning pods 1810, 1814 integral with footwear sole components 1802 Figure 17 The fastener 1700. The footwear sole component 1802 is a sole having multiple cushioning pods 1806, 1810, 1814 integrally formed therein and enclosed by material 1804.

[0093] Material 1804 is a breathable material attached to sole component 1802. Material 1804 can be adhered, welded, or otherwise attached to the sole component. In the depicted aspect, a periphery is recessed into sole component 1802 to provide a position for securing material 1804 to sole component 1802. This attachment portion allows various pods 1806, 1810, 1814 to be covered by a monolithically selected portion of material 1804 while maintaining discrete pods. However, the separate and distinct portions of the material can enclose the various pods. The attachment portion includes an outer periphery 1803, a first dividing portion 1808, and a second dividing portion 1812. At the periphery 1803, the first dividing portion 1808, and the second dividing portion 1812, material 1804 is secured to sole component 1802 to maintain the pods 1806, 1810, and 1814 separate and discrete.

[0094] Material 1804 can be any material. In one exemplary aspect, Material 1804 is a knitted or woven material formed from a synthetic material such as a polyether-polyurethane copolymer. Material 1804 provides a degree of air permeability such that when air carrying the beads is inserted into a pod at least partially enclosed by Material 1804, the pressure within the pod can be balanced through the transmission of air through Material 1804. Furthermore, Material 1804 is inherently elastic to facilitate a conformity to the wearer's foot. For example, because the beads filling the pod are separate and distinct beads capable of being reoriented under the pressure exerted by the wearer's foot, Material 1804 allows the beads to reposition and additionally conform to the wearer's foot.

[0095] Each of the pods includes an insertion port. The first pod 1806 has a first insertion port 1826. The second pod 1810 has a second insertion port 1822. The third pod 1814 has a third insertion port 1816. The insertion port serves as an opening through which a bead nozzle extends for injecting beads into the pod. In some aspects, the insertion port is an unfixed edge of material 1804. In other aspects, the insertion port is an opening or void through material 1804. In other examples, the insertion port includes valve material, as described below. Figure 21 Valve material 2102 is optimally positioned within the pod. This valve material prevents or restricts the movement of beads from the inside of the pod to the outside. This will be explained below. Figure 21As discussed and described, the valve material enables the insertion port to function as a one-way valve that allows bead insertion but restricts bead withdrawal from the pod. This is accomplished, in part, through the physical separation of the valve material from material 1804 when the bead nozzle is inserted through the insertion port. Once the bead nozzle is removed from the insertion port, the valve material contacts material 1804 to close the insertion port and prevent or restrict bead exit from the pod. The elastic properties of material 1804 and / or the valve material further facilitate the insertion of the bead nozzle, the sealing around the inserted bead nozzle, and then the sealing of the pod. For example, the material can be stretched to insert and secure the bead nozzle, and then elastically return to an unstretched state to seal the pod and hold the inserted bead within it.

[0096] like Figure 18 As described, the retainer 1700 is configured to provide fixation of the first bead nozzle 1818 and the second bead nozzle 1824 in their respective inserts. Specifically, a nozzle hook member interacts with the bead nozzles to position and hold them in a filling configuration. A filling configuration is a position in which the distal end of the bead nozzle extends above or into the filling level of the pod. In some examples, if the distal end of the bead nozzle, such as the ejection end, is not positioned above the filling level, then the beads are prevented from leaving the filling nozzle when they impact or collide with beads within the pod. Thus, when the bead nozzle is at or above the filling level, a portion of the bead nozzle ejects the desired amount of beads undisturbed. To achieve this filling configuration, the retainer 1700 resists forces exerted by the elastic material 1804 at the insert. Figure 18 As described, against the resistance of material 1804, the retainer 1700 uses a portion of the sole component 1802 as a fulcrum, about which the bead nozzle pivots to raise the distal end of the bead nozzle. The nozzle hook member of the retainer 1700 thus pulls the bead nozzle to raise the opposite end of the bead nozzle within the pod. Therefore, the raised distal end is not obstructed by the inserted beads at the end of the filling process.

[0097] Further enhancements to the filling process and the structures supporting it are envisioned. For example, spacer 1820 may be used in conjunction with the bead nozzle, rather than solely or entirely relying on sole component 1802 as a fulcrum or support structure for the bead nozzle. Spacer 1820 is located on the first bead nozzle 1818 and serves as physical support for the first bead nozzle 1818 during the filling operation. In some examples, a portion of sole component 1802 may not provide sufficient physical support or be able to effectively position the bead nozzle properly during the filling operation. To achieve the filling structure for the first bead nozzle 1818, the sidewalls of sole component 1802 at the heel end may be flexible or otherwise not serve as a fulcrum. As a result, in one exemplary aspect, the fulcrum is formed by spacer 1820 resting on the insole portion of sole component 1802. Alternative spacers are envisioned for achieving suitable filling configurations. Furthermore, it is envisioned that spacers may be omitted entirely. Additionally, in some aspects, it is envisioned that the filling configuration may not have a distal end of the bead nozzle raised above the filling level.

[0098] On a first side, such as on the outer side of the sole component 1802, the fastener 1700 is described as a lateral member (e.g., Figure 17 The transverse member 1702 is joined to the sole member 1802. (See below) Figure 19 As described, the retainer 1700 extends below the sole component 1802 to the opposite side of the sole component 1802. On the opposite side, for example, the inward side, the retainer 1700 extends upward to a nozzle hook portion, the size and configuration of which are adapted to engage a bead nozzle inserted into a pod of the sole component 1802.

[0099] Figure 19 The invention describes various aspects thereof. Figure 18 The ground-facing surface of the sole component 1802. Figure 20 The invention describes various aspects thereof. Figure 19 Bottom perspective view.

[0100] Figure 21 The invention describes a method where, after filling each part with a plurality of beads, the fastener 1700 is omitted. Figure 18 A cross-sectional view of the sole component 1802. This cross-section is along... Figure 18Lines 21-21 are cut off. A first pod 1806, a second pod 1810, and a third pod 1814 are described. Furthermore, the first pod 1806 describes a first valve material 2102 at a first insertion port 1826. The first valve material 2102 is separable from material 1804 to allow insertion of the bead nozzle. After the pod is filled with beads, the valve material and material 1804 converge to seal the insertion port, thus securing the beads within the pod. It is also envisioned that the pod could fill above a portion of the sole component to create a protruding or overfilled effect, as described in the second pod 1810 and the third pod 1814. The second pod 1810 is filled with a plurality of beads 2104 extending above the sole component 1802 forming the second pod 1810. Similarly, multiple beads 2106 fill the third pod 1814 to an overfilled state, such that the multiple beads 2106 extend above the sole component 1802 forming the third pod 1814.

[0101] Although Figure 21 Pods of various sizes, shapes, and positions are described; however, it is contemplated that pods can have any size, shape, or position. Furthermore, the sole portions are exemplary in nature and not limiting. Other sole portions are also contemplated as other pod configurations. Additionally, although the described insertion port is in a different position relative to the pod, it is contemplated that the insertion port can be in alternative positions and / or configurations.

[0102] As used herein and in conjunction with the terms listed below, the term "any one of the terms" or similar variations thereof are intended to be interpreted as such that the features of the terms can be combined in any combination. For example, exemplary clause 4 may indicate a method / apparatus of any one of clauses 1 through 3, which is intended to be interpreted as such that the features of clauses 1 and 4 can be combined, the elements of clauses 2 and 4 can be combined, the elements of clauses 3 and 4 can be combined, the elements of clauses 1, 2, and 4 can be combined, the elements of clauses 2, 3, and 4 can be combined, and / or other variations thereof. Furthermore, the term "any one of the terms" or similar variations thereof are intended to include "any one of the terms" or other variations of such terms, as indicated by some of the examples provided above.

[0103] 1. A system for filling a buffer pod with a plurality of beads, the system comprising: a bead source configured to store the plurality of beads; a filling station operatively coupled to the bead source, the filling station comprising: a fluid insertion nozzle for introducing fluid from the fluid source into a fluid connector of the system, wherein the fluid connector is configured to deliver at least a portion of the plurality of beads for operative coupling from the bead source to the buffer pod; and a bead nozzle coupled to the fluid connector of the system and configured to engage with the buffer pod to deposit the plurality of beads in the buffer pod.

[0104] 2. The system according to Clause 1, wherein the fluid insertion nozzle introduces the fluid in the direction of bead flow from the bead source toward the filling station.

[0105] 3. The system according to any one of clauses 1 to 2, wherein the fluid insertion nozzle selectively introduces the fluid.

[0106] 4. The system according to any one of clauses 1 to 3, wherein the fluid is a gas.

[0107] 5. The system according to any one of Clauses 1-4, wherein the fluid comprises air.

[0108] 6. The system according to any one of Clauses 1 to 5, wherein the fluid source is an air compressor.

[0109] 7. The system according to any one of clauses 1 to 6, wherein the fluid connector is a tubular structure.

[0110] 8. The system according to any one of clauses 1 to 7, wherein the fluid connector is a hose.

[0111] 9. The system according to any one of clauses 1 to 8, wherein the bead nozzle comprises a first portion and a second portion, the first portion and the second portion being removably coupled.

[0112] 10. The system according to Clause 9, wherein at least one of the first portion or the second portion includes a magnetic element that effectively removably connects the first portion and the second portion.

[0113] 11. The system according to any one of clauses 1 to 10, further comprising a weighing station operatively connected between the bead source and the filling station.

[0114] 12. The system according to Clause 11, wherein the weighing station includes a load sensor.

[0115] 13. The system according to Clause 11, wherein the weighing station includes a vibration generator.

[0116] 14. The system according to Clause 13, wherein the vibration generator is configured to selectively generate at least a first vibration level and a second vibration level.

[0117] 15. The system according to Clause 11 further includes a metering station operatively connected between the weighing station and the filling station.

[0118] 16. The system according to Clause 15, wherein the metering station includes a fluid-driven funnel.

[0119] 17. The system according to Clause 16, wherein the fluid-driven funnel includes a fluid port that effectively discharges fluid toward the filling station in the direction of bead flow.

[0120] 18. The system according to Clause 17, wherein the fluid-driven funnel is fluidly connected to the fluid source.

[0121] 19. The system according to any one of Clauses 1 to 18, wherein at least a portion of the cushioning pod comprises a breathable material.

[0122] 20. The system according to Clause 19, wherein the breathable material is a fabric.

[0123] 21. The system according to any one of clauses 1 to 20, wherein the plurality of beads have a diameter between 1 mm and 10 mm.

[0124] 22. The system according to any one of clauses 1 to 21, wherein the plurality of beads have a diameter between 2 mm and 5 mm.

[0125] 23. A system for filling a buffer pod with a plurality of beads, the system comprising: a bead source configured to store the plurality of beads; a first weighing station including a first load sensor; a second weighing station including a second load sensor; a first metering station operatively coupled to the first weighing station; a second metering station operatively coupled to the second weighing station; a first valve; a first filling station fluidly coupled to the first metering station and the second metering station via the first valve through a fluid connector; and a second filling station fluidly coupled to the first metering station and the second metering station via the first valve.

[0126] 24. The system according to Clause 23 further includes a fluid insertion nozzle for introducing fluid from a fluid source into a fluid connector of the system, wherein at least a portion of the fluid connector is configured to deliver the plurality of beads from the first metering station toward the first filling station.

[0127] 25. The system according to any one of clauses 23 to 24, further comprising a bead nozzle connected to a fluid connector of the system and configured to engage with the buffer pod to deposit the plurality of beads in the buffer pod.

[0128] 26. The system according to any one of clauses 23 to 25, wherein the bead nozzle comprises a first portion and a second portion, the first portion and the second portion being magnetically coupled.

[0129] 27. The system according to any one of clauses 23 to 26, wherein the fluid connector is a tubular structure with an inner diameter of at least 8 mm.

[0130] 28. The system according to any one of Clauses 23 to 27, wherein the first valve is pneumatically controlled to selectively direct beads to the first filling station or the second filling station.

[0131] 29. The system according to any one of Clauses 23 to 28, wherein the first metering station includes a fluid-driven funnel having a fluid port that effectively discharges fluid toward the first filling station in the direction of bead flow.

[0132] 30. The system according to any one of clauses 23 to 29, wherein the first filling station further comprises a second valve that selectively directs beads from the first valve to a first plurality of bead nozzles or a second plurality of bead nozzles.

[0133] 31. The system according to Clause 30, wherein the second valve is logically connected to a computing device to selectively direct beads to the first plurality of bead nozzles or the second plurality of bead nozzles.

[0134] 32. The system according to Clause 30, wherein the second filling station further includes a third valve that selectively directs beads from the first valve to a third or a fourth plurality of bead nozzles.

[0135] 33. The system according to claim 32, further comprising: a first fluid insertion nozzle for introducing fluid from a fluid source into a fluid connector of the system, wherein at least a portion of the fluid connector is configured to convey the plurality of beads from the first metering station toward the first filling station; and a second fluid insertion nozzle for introducing fluid from the fluid source into the fluid connector of the system, wherein at least a portion of the fluid connector is configured to convey the plurality of beads from the first metering station toward the second filling station.

[0136] 34. The system according to Clause 33, wherein the first fluid insertion nozzle and the second fluid insertion nozzle are logically connected to a computing device to selectively introduce the fluid.

[0137] 35. The system according to Clause 34, wherein the computing device selectively introduces fluid into the first fluid insertion nozzle and the second fluid insertion nozzle based on the configuration of the first valve.

[0138] 36. A method of filling a buffer pod with a plurality of beads, the method comprising: measuring a first weight of the plurality of beads at a first measuring station; measuring a second weight of the plurality of beads at a second measuring station; conveying the first plurality of beads to a first filling station through a first valve; conveying a second plurality of beads to the first filling station through the first valve; injecting the first plurality of beads into a first pod; and injecting the second plurality of beads into a second pod, wherein the first pod and the second pod are discrete pods of a common article.

[0139] 37. The method according to Clause 36, wherein taking the measurement at the first measuring station further comprises: adjusting the vibration frequency of the vibration generator when the first plurality of beads approach the first weight.

[0140] 38. The method according to any one of clauses 36 to 37, further comprising injecting fluid into a fluid connector for conveying the first plurality of beads between the first weighing station and the first filling station, the fluid being injected through a fluid insertion nozzle.

[0141] 39. The method according to clause 38, wherein the fluid connector is subjected to negative pressure upstream of the fluid insertion nozzle along the direction of bead flow, and the fluid connector is subjected to positive pressure downstream of the fluid insertion nozzle along the direction of bead flow.

[0142] 40. The method according to any one of clauses 36 to 39, wherein conveying the first plurality of beads includes a movement of metering the first plurality of beads to the first filling station.

[0143] 41. The method according to any one of clauses 36 to 40, wherein metering the movement of the first plurality of beads comprises injecting fluid through a fluid-driven funnel along the flow direction of the beads.

[0144] 42. The method according to any one of clauses 36 to 41, wherein the first valve keeps the first plurality of beads and the second plurality of beads separated while guiding the first plurality of beads and the second plurality of beads to the first filling station.

[0145] 43. The method according to any one of clauses 36 to 42, further comprising, before injecting the first plurality of beads into the first pod, the first plurality of beads passing through a second valve that guides the first plurality of beads into the first pod.

[0146] 44. The method according to Clause 43, wherein the first pod comprises a breathable material.

[0147] 45. The method according to clause 44, wherein the breathable material is a fabric.

[0148] 46. ​​The method according to any one of clauses 36 to 45, wherein the common article is a component of a footwear article.

[0149] 47. The method according to any one of clauses 36 to 46, further comprising: inserting a first portion of a bead nozzle into the first pod; magnetically connecting the first portion of the bead nozzle to a second portion of the bead nozzle, wherein the second portion of the bead nozzle is fluidly connected to the first filling station.

[0150] Many different arrangements of the various components depicted, as well as those not shown, are possible without departing from the spirit and scope of this disclosure. Embodiments of this disclosure have been described in an illustrative rather than limiting manner. Alternative embodiments without departing from their scope will be apparent to those skilled in the art. Alternative ways of implementing the above-described improvements can be developed by those skilled in the art without departing from the scope of this disclosure.

[0151] It should be understood that certain features and sub-combinations are useful and can be employed without reference to other features and sub-combinations, and are contemplated within the scope of the claims. Not all steps listed in the figures need to be performed in the specific order described.

Claims

1. A method for filling a buffer pod with a plurality of beads, the method comprising: The first weight of the plurality of beads is measured at the first measuring station; The second weight of the plurality of beads is measured at the second measuring station; The first plurality of beads are conveyed to the first filling station through the first valve; The second plurality of beads are conveyed to the first filling station through the first valve; the first plurality of beads are injected into the first pod; The second plurality of beads are injected into a second pod, wherein the first pod and the second pod are discrete pods of a common article, wherein the first pod and the second pod are not connected, wherein the first measuring station effectively applies variable rate weighing, and the first measuring station includes a vibration generator capable of controlling the movement rate of the beads within the first measuring station.

2. The method according to claim 1, wherein taking the measurement at the first measuring station further comprises: When the first plurality of beads approach the first weight, the vibration frequency of the vibration generator is adjusted.

3. The method according to any one of claims 1-2, further comprising injecting fluid into a fluid connector for conveying the first plurality of beads between the first measuring station and the first filling station, the fluid being injected through a fluid insertion nozzle.

4. The method of claim 3, wherein the fluid connector is subjected to negative pressure upstream of the fluid insertion nozzle along the bead flow direction, and the fluid connector is subjected to positive pressure downstream of the fluid insertion nozzle along the bead flow direction.

5. The method according to any one of claims 1-4, wherein conveying the first plurality of beads includes the movement of metering the first plurality of beads to the first filling station.

6. The method of claim 5, wherein metering the movement of the first plurality of beads comprises injecting fluid through a fluid-driven funnel along the flow direction of the beads.

7. The method according to any one of claims 1-6, wherein the first valve keeps the first plurality of beads and the second plurality of beads separated while guiding the first plurality of beads and the second plurality of beads to the first filling station.

8. The method according to any one of claims 1-7, further comprising, before injecting the first plurality of beads into the first pod, the first plurality of beads passing through a second valve that guides the first plurality of beads into the first pod.

9. The method of claim 8, wherein the first pod comprises a breathable material.

10. The method of claim 9, wherein the breathable material is a fabric.

11. The method according to any one of claims 1-10, wherein the common article is a component of a footwear article.

12. The method according to any one of claims 1-11, further comprising: Insert the first part of the bead nozzle into the first pod; The first portion of the bead nozzle is magnetically connected to the second portion of the bead nozzle, wherein the second portion of the bead nozzle is fluidly connected to the first filling station.

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