Foamed articles and methods of making foamed articles

Abstract

Foamed articles including a foamed thermoplastic elastomer material, methods of manufacturing foamed articles, and methods for manufacturing articles of footwear, articles of apparel, and articles of sports equipment incorporating such foamed articles are provided. In one aspect, a method for manufacturing a foamed article includes placing an article including a foamable material and carbon dioxide in a container; maintaining the container at a first pressure and a first temperature at which the carbon dioxide is a liquid and the carbon dioxide is soluble in the foamable material; optionally exposing the infused article to a second temperature and a second pressure; and subjecting the article to a third pressure and a third temperature at which the infused carbon dioxide phase changes to a gas, thereby expanding the foamable material into a foamed material and forming a foamed article.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 153,259, filed February 24, 2021, which is incorporated by reference in its entirety. TECHNICAL FIELD

[0003] The present disclosure relates to foamed articles. More particularly, the present disclosure relates to foamed articles comprising a foamed thermoplastic elastomer material, methods of making such foamed articles, and methods for making articles of footwear comprising such foamed articles.

[0004] BACKGROUND

[0005] The design of athletic equipment and apparel, as well as footwear, involves a variety of factors ranging from aesthetics to comfort and feel, to performance and durability. While design and fashion can change rapidly, the demand for enhanced performance in the market is constant. To balance these demands, designers employ a variety of materials and designs for the various components that make up athletic equipment and apparel, as well as footwear. SUMMARY

[0006] The present disclosure provides the following items:

[0007] 1. A method for making a foamed article, the method comprising:

[0008] placing an article and carbon dioxide in a container, wherein the article comprises a solid foamable material that is a thermoplastic elastomer material comprising one or more first thermoplastic elastomers;

[0009] maintaining the container at a first pressure and a first temperature after the placing step, wherein the first pressure and first temperature are a pressure and temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining comprises holding the article and the liquid carbon dioxide in the container for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the article;

[0010] optionally exposing the infused article to a second pressure and a second temperature after the maintaining and holding steps at which the carbon dioxide remains infused within at least a portion of the solid foamable material;

[0011] after the step of maintaining and holding, and optionally the step of exposing, subjecting the article to a third pressure and a third temperature at which the carbon dioxide injected into the solid foamable material phase changes into a gas, thereby causing the solid foamable material to expand into a foamed material and form the foamed article;

[0012] wherein the article comprises a first sheet and a second sheet, wherein a first side of the first sheet faces a second side of the second sheet, and wherein the first sheet and the second sheet are joined together to form an internal cavity in a space between the first side of the first sheet and the second side of the second sheet, wherein a junction extends around at least a portion of a perimeter of the internal cavity, optionally wherein (a) the junction abuts only one or more portions of the perimeter of the internal cavity and includes one or more apertures that can allow fluid to enter the internal cavity, forming an open cavity; or wherein (b) the junction abuts the entire perimeter of the internal cavity, forming a sealed pocket that can hold fluid in the internal cavity at a pressure higher or lower than atmospheric pressure.

[0013] 2. The method of item 1, wherein the article comprises more than one internal cavity.

[0014] 3. The method of item 1 or 2, wherein the article comprises the sealed pocket, and during the step of subjecting and expanding, the first side of the first sheet and the second side of the second sheet remain unfoamed within the sealed pocket.

[0015] 4. The method of item 1 or 2, wherein the article comprises the sealed pocket, and during the step of subjecting and expanding, one or more layers of the first sheet or the second sheet or both are foamed within the sealed pocket.

[0016] 5. The method of item 2, wherein at least one of the more than one internal cavities is an open cavity that includes one or more apertures in a perimeter of the internal cavity; during the step of maintaining and holding, the carbon dioxide enters the open cavity and is injected into a solid foamable material contained in the open cavity; and during the step of subjecting and expanding, the solid foamable material contained in the open cavity expands and foams into the foamed material.

[0017] 6. The method of item 5, wherein during the step of maintaining and retaining, the carbon dioxide entering the open cavity is liquid carbon dioxide and / or carbon dioxide vapor, and the liquid carbon dioxide and / or carbon dioxide vapor enters the open cavity through the one or more holes in the perimeter of the inner cavity.

[0018] 7. The method of item 5 or 6, wherein during the step of maintaining and retaining, the carbon dioxide enters the open cavity and infuses into the solid foamable material of the first side of the first sheet or the second side of the second sheet or both; and during the step of undergoing and expanding, the infused solid foamable material of the first side or the second side or both expands and foams into the foamed material.

[0019] 8. The method of item 7, wherein the foamed material defines at least a portion of the first side of the first sheet, or at least a portion of the second side of the second sheet, or both.

[0020] 9. The method of item 7 or 8, wherein the foamed material is present in an inner layer of the first sheet or the second sheet or both.

[0021] 10. The method of any one of items 5-9, wherein during the step of maintaining and retaining, the carbon dioxide enters the open cavity and infuses into the solid foamable material in contact with or bonded to the first side of the first sheet or the second side of the second sheet or both; and during the step of undergoing and expanding, the solid foamable material in contact with or bonded to the first side or the second side or both expands and foams into the foamed material.

[0022] 11. The method of any one of items 5-10, wherein the open cavity comprises more than one fiber, more than one yarn, more than one particle, or any combination thereof, and the more than one fiber, the more than one yarn, the more than one particle, or any combination thereof comprises or consists essentially of the solid foamable material in contact with or bonded to the first side or the second side or both.

[0023] 12. The method of any one of items 5-11, further comprising, after the step of undergoing and expanding, closing and sealing the one or more holes in the perimeter of the inner cavity, thereby forming the sealed pocket, wherein the sealed pocket comprises the foamed material.

[0024] 13. The method of item 12, further comprising, prior to or during the step of closing and sealing the one or more holes, charging the interior cavity with a fluid.

[0025] 14. The method of any of items 1-13, wherein the first sheet, or the second sheet, or both the first sheet and the second sheet has a layered structure.

[0026] 15. The method of item 14, wherein the first sheet has a second side opposite the first side of the first sheet, the second side of the first sheet being bounded by a first sheet outer layer, and in the foamed article, the first sheet outer layer remains unfoamed; or

[0027] wherein the second sheet has a first side opposite the second side of the second sheet, the first side of the second sheet being bounded by a second sheet outer layer, and in the foamed article, the second sheet outer layer remains unfoamed; or

[0028] wherein in the foamed article, both the first sheet outer layer and the second sheet outer layer remain unfoamed.

[0029] 16. A foamed article made by the method of any of items 1-15.

[0030] 17. The foamed article of item 16, wherein the foamed article is or comprises an open cavity or a sealed bladder.

[0031] 18. The foamed article of item 17, wherein the foamed article is or comprises the sealed bladder, and the sealed bladder is a cushioning element.

[0032] 19. The foamed article of item 18, wherein the cushioning element is a cushioning element for an article of apparel, an article of footwear, or an article of sports equipment.

[0033] 20. An article comprising a first sheet comprising at least one layer and a second sheet comprising at least one layer, wherein a first side of the first sheet faces a second side of the second sheet, and wherein the first sheet and the second sheet are joined together to form an interior cavity in a space between the first side of the first sheet and the second side of the second sheet, wherein a joint extends around at least a portion of a perimeter of the interior cavity, wherein

[0034] the interior cavity comprises a foamed material;

[0035] wherein the foamed material is a physically expanded foam formed from a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers; and

[0036] wherein the foamed material is the product of placing an unfoamed article comprising a solid foamable material in liquid carbon dioxide, infusing the solid foamable material with the liquid carbon dioxide, and expanding the infused solid foamable material by phase changing the infused carbon dioxide into a gas under conditions that do not soften the solid foamable material, thereby forming the foamed material. BRIEF DESCRIPTION OF DRAWINGS

[0038] Further aspects of the present disclosure will be appreciated after a careful review of the detailed description that follows, taken in conjunction with the accompanying drawings.

[0039] Figures 1A-1M FIGS. illustrate various articles of footwear, articles of apparel, and articles of sports equipment, including containers, electronic equipment, and vision wear, that are foamed articles or include foamed articles, in accordance with the present disclosure, and Figures 1N(a)-1Q(e) FIGS. illustrate additional details regarding different types of footwear.

[0040] Figure 2 FIG. illustrates a thermoplastic elastomeric material for forming a foamed thermoplastic elastomeric material during an early manufacturing stage, in accordance with an example embodiment, in a side view.

[0041] Figure 3 FIG. illustrates a thermoplastic elastomeric material in a container for forming a foamed thermoplastic elastomeric material during an intermediate manufacturing stage, in accordance with an example embodiment, in a cross-sectional view. Figure 2 FIG. illustrates a thermoplastic elastomeric material in a container for forming a foamed thermoplastic elastomeric material during an intermediate manufacturing stage, in accordance with an example embodiment, in a cross-sectional view.

[0042] Figure 4 FIG. illustrates a thermoplastic elastomeric material for forming a foamed thermoplastic elastomeric material during an intermediate manufacturing stage, in accordance with an example embodiment, in a partial cross-sectional side view.

[0043] Figure 5 FIG. illustrates an infused carbon dioxide foamable article during a second temperature and second pressure exposure, in accordance with an example embodiment, in a partial cross-sectional side view.

[0044] Figure 6 FIG. illustrates an infused carbon dioxide foamable article being introduced to a water bath for forming a foamed article during an experiencing step, in accordance with an example embodiment, in a partial cross-sectional side view.

[0045] Figure 7 FIG. illustrates a flowchart of a method for manufacturing a foamed article, in accordance with an example embodiment.

[0046] Figures 8A-8D FIGS. illustrate various configurations of single-sided foamable articles according to example embodiments.

[0047] Figures 9A-9C FIGS. illustrate various configurations of double-sided foamable articles according to another example embodiment.

[0048] Figures 10A-10F are schematic illustrations of a multi-layer article according to example embodiments before foaming ( Figure 10A , Figure 10C and Figure 10E ) and after foaming ( Figure 10B , Figure 10D and Figure 10F ).

[0049] Figures 11A-11K is a schematic illustration of a foamable article according to example embodiments, wherein a selected portion of the foamable article can be foamed by controlled injection and diffusion of carbon dioxide into and / or controlled output and diffusion of carbon dioxide out of all or a portion of the article prior to performing the expansion steps disclosed herein, while leaving other portions of the article unfoamed.

[0050] Described

[0051] A new foamed article comprising a foamed thermoplastic elastomeric material has been identified, as well as a method for making such a foamed article. The method described herein includes a step of injecting carbon dioxide into a solid foamable material of an article (i.e., a solid article). After injection, the injected solid foamable material is foamed by expanding the injected carbon dioxide, for example by phase changing the injected carbon dioxide into carbon dioxide gas, without thermally softening the solid foamable material, which in turn causes the solid foamable material to expand into a foamed material, forming a foam, for example a foam having a cellular foam structure. In this way, the solid foamable material is physically foamed in the process without being melted. The foamed article described herein includes one or more foamed materials that are physically foamed materials. These physically foamed materials, comprising a thermoplastic elastomeric material as described herein, have been found to have low density, uniform cellular foam structure, and / or other beneficial properties, making the foamed materials suitable for use in many mass-produced consumer products, including apparel articles, footwear articles, and sports equipment articles. Figures 1A-1M FIGS. illustrate various footwear articles, apparel articles, and sports equipment articles, including containment, electronic equipment, and vision protection, that are or include foamed articles according to the present disclosure. Figures 1N(a)-1Q(e) FIGS. illustrate additional details regarding different types of footwear.

[0052] It has also been found that the multi-step foaming processes described herein can be readily adapted for use with conventional materials and production lines, as they use simpler, cheaper, and more energy-efficient equipment and processes than other physical foaming processes. For example, maintaining carbon dioxide as a liquid and maintaining a solid foamable material in liquid carbon dioxide requires maintaining lower extreme temperatures and pressures than using supercritical carbon dioxide to infuse a solid foamable material (and thus requires cheaper, more energy-efficient equipment). In many aspects, the step of expanding a solid foamable material into a foamed material can be performed at or near atmospheric pressure and at a relatively low temperature well below the melting temperature of the foamable material, and thus can be performed using simple, inexpensive heating methods and equipment, making the overall foaming process efficient and cost-effective. Additionally, the present disclosure can be applied to a wide range of solid foamable materials, as well as to articles having many different geometries, including but not limited to sheets of solid foamable material. Furthermore, by using articles comprising two or more types of solid foamable material, articles comprising two or more portions or regions of solid foamable material, and articles comprising a combination of one or more solid foamable materials and one or more solid non-foamable materials, and / or by varying processing conditions, the processes described herein for foaming a solid article can be adapted to selectively foam portions or regions of an article without requiring additional tools or equipment.

[0053] The use of foamed thermoplastic elastomer material in the foamed articles disclosed herein can reduce the weight or density of the article compared to an article without foamed material, i.e., an article comprising only solid material. Additionally or alternatively, by using foamed material in place of unfoamed material, the total amount of material required to provide the same volume is reduced, lowering material costs and making the foamed article more sustainable compared to a comparable article without foamed material. Furthermore, by using foamed thermoplastic elastomer material, alone or in combination with one or more additional thermoplastic materials, to form a foamed article, a component of the foamed article or the entire foamed article can comprise recycled thermoplastic material, and in turn, the component or the entire foamed article itself can be recycled. In some aspects, by controlling the foaming conditions and optionally controlling an optional stabilization process, the overall volume of the foamed article can be increased within a predicted range or a predetermined range. The increase in volume can be relatively small, e.g., less than a 10% or less than a 5% increase in volume, compared to the overall volume of the article prior to undergoing the foaming process. Alternatively, the increase in volume can be relatively large, e.g., greater than a 20% or greater than a 40% increase in volume, compared to the overall volume of the article prior to undergoing the foaming process.

[0054] In some aspects, the foamed material of the foamed article is a stabilized foam material that has undergone a stabilization process. In some aspects, the foamed article includes a layer or region of foamed material adjacent to a layer or region of solid (i.e., unfoamed) material. In some aspects, the foamed article can be a cushioning element, such as a fluid-filled bladder. In some aspects, the thermoplastic elastomer material can include one or more thermoplastic polyurethanes. In some aspects, the foamed article can include a second material, such as a second thermoplastic material, in addition to the thermoplastic elastomer material, including a second thermoplastic material that does not foam during the foaming process.

[0055] In one aspect, the present disclosure relates to a method for manufacturing a foamed article. The foaming process as disclosed herein is a multi-step process that includes first injecting a solid foamable material with carbon dioxide, and then exposing the injected article to conditions that cause the carbon dioxide injected into the solid foamable material to undergo a phase change, which causes the solid foamable material to expand and foam into a foamed material. Optionally, prior to the foaming step, the injected article can be exposed to and held (e.g., stored) at a pressure and temperature at which the injected carbon dioxide remains injected into the article, allowing the injected article to be foamed at a later time. Alternatively, the injected article can be exposed to and held for a duration of time conditions that allow a portion of the injected carbon dioxide to diffuse out of the injected article. In this way, the injected carbon dioxide can be removed from selected regions or portions of the article prior to foaming, which results in only the selected regions or portions of the article foaming when exposed to foaming conditions. Optionally, after undergoing foaming, the foamed article can be stabilized to release residual carbon dioxide and / or to release residual stresses in the article.

[0056] In another aspect, the present disclosure relates to a foamed article. The foamed article includes or consists essentially of a foamed material, wherein the foamed material is a physically expanded foam formed from a thermoplastic elastomer material including one or more first thermoplastic elastomers. The foamed material is the product of injecting carbon dioxide into a solid foamable material including the thermoplastic elastomer material, and creating a phase change that causes the injected carbon dioxide to expand, thereby causing the solid foamable material to foam into the foamed material without thermally softening the solid foamable material. Optionally, the foamed article can include additional foamed material or additional unfoamed material. Optionally, the foamed article can be a stabilized foam article from which residual carbon dioxide has been removed, or from which residual stresses created during the foaming process have been reduced or removed.

[0057] In one aspect, disclosed herein is a method for manufacturing a foamed article, the method comprising: placing an article and carbon dioxide in a container, wherein the article comprises a solid foamable material that is a thermoplastic elastomer material comprising one or more first thermoplastic elastomers; after the placing, maintaining the container at a first pressure and a first temperature, wherein the first pressure and the first temperature are a pressure and a temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining comprises holding the article and the liquid carbon dioxide in the container for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the article; after the maintaining and the holding, optionally exposing the infused article to a second pressure and a second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material; after the maintaining and the holding and the optional exposing, subjecting the article to a third pressure and a third temperature at which the carbon dioxide infused into the solid foamable material phase changes into a gas, thereby expanding the solid foamable material into a foamed material and forming a foamed article; wherein the article comprises a first sheet and a second sheet, wherein a first side of the first sheet faces a second side of the second sheet, and wherein the first sheet and the second sheet are bonded together to form an internal cavity in a space between the first side of the first sheet and the second side of the second sheet, wherein the bond extends around at least a portion of a perimeter of the internal cavity, optionally wherein the bond abuts only one or more portions of the perimeter of the internal cavity and comprises one or more apertures that are capable of allowing fluid to enter the internal cavity, forming an open cavity; or wherein the bond abuts the entire perimeter of the internal cavity, forming a sealed pocket capable of retaining fluid in the internal cavity at a pressure higher or lower than atmospheric pressure. Also disclosed is a foamed article manufactured according to the disclosed method.

[0058] The following list of example aspects supports and is supported by the disclosure provided herein.

[0059] According to Aspect 1, the present disclosure relates to a method for manufacturing a foamed article, the method comprising:

[0060] placing an article and carbon dioxide (CO2) in a container, wherein the article comprises a solid foamable material that is a thermoplastic elastomer material comprising one or more first thermoplastic elastomers;

[0061] After the placing, the container is maintained at a first pressure and a first temperature, wherein the first pressure and the first temperature are a pressure and a temperature at which carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining comprises holding the article and the liquid carbon dioxide in the container for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the article;

[0062] After the maintaining and holding, the infused article is optionally exposed to a second pressure and a second temperature at which carbon dioxide remains infused within at least a portion of the solid foamable material;

[0063] After the maintaining and holding and the optional exposing, the article is subjected to a third pressure and a third temperature at which the carbon dioxide infused into the solid foamable material phase changes into a gas, thereby causing the solid foamable material to expand into a foamed material and forming a foamed article.

[0064] According to aspect 2, the present disclosure relates to the method of aspect 1, further comprising, after the subjecting and expanding, bringing the foamed article to a fourth temperature and a fourth pressure, and holding the foamed article at or below the fourth temperature, the fourth pressure, or both, for a period of time.

[0065] According to aspect 3, the present disclosure relates to the method of aspect 1 or 2, further comprising, after the subjecting and expanding or after the optional bringing, stabilizing the foamed article at a fifth pressure and a fifth temperature at which carbon dioxide diffuses out of the foamed material of the foamed article while causing the foamed material to remain in a foam structure, forming a stabilized foamed article.

[0066] According to aspect 4, the present disclosure relates to the method of aspect 3, wherein the stabilizing comprises holding the foamed article at the fifth pressure and the fifth temperature for a duration of time sufficient to remove substantially all of the carbon dioxide from the foamed material.

[0067] According to aspect 5, the present disclosure relates to the method of any of the preceding aspects, wherein at the first pressure and the first temperature, the liquid carbon dioxide is soluble in the solid foamable material at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent.

[0068] According to aspect 6, the present disclosure relates to the method of any of the preceding aspects, wherein the foamed material of the foamed article is substantially opaque.

[0069] According to Aspect 7, the present disclosure relates to the method of any of the preceding aspects, wherein the foamed material has a split-tear value of from about 2.5 kilograms per centimeter to about 3.0 kilograms per centimeter.

[0070] According to Aspect 8, the present disclosure relates to the method of any of the preceding aspects, wherein the foamed material has an Asker C hardness of from about 10 to about 50.

[0071] According to Aspect 9, the present disclosure relates to the method of any of the preceding aspects, wherein the foamable material includes a polymer component comprising all polymers present in the foamable material, and the polymer component consists of one or more first thermoplastic elastomers.

[0072] According to Aspect 10, the present disclosure relates to the method of Aspect 9, wherein the one or more first thermoplastic elastomers include or consist essentially of one or more thermoplastic elastomer polyolefin homopolymers or copolymers, one or more thermoplastic elastomer polyamide homopolymers or copolymers, one or more thermoplastic elastomer polyester homopolymers or copolymers, one or more thermoplastic elastomer polyurethane homopolymers or copolymers, one or more thermoplastic elastomer styrene homopolymers or copolymers, or any combination thereof.

[0073] According to Aspect 11, the present disclosure relates to the method of Aspect 9 or 10, wherein the one or more first thermoplastic elastomers include or consist essentially of one or more thermoplastic elastomer polyamide homopolymers or copolymers.

[0074] According to Aspect 12, the present disclosure relates to the method of any of Aspects 9-11, wherein the one or more first thermoplastic elastomers include or consist essentially of a polyether block polyamide (PEBA) copolymer elastomer.

[0075] According to Aspect 13, the present disclosure relates to the method of any of Aspects 9-12, wherein the one or more first thermoplastic elastomers include or consist essentially of one or more thermoplastic elastomer styrene homopolymers or copolymers.

[0076] According to Aspect 14, the present disclosure relates to the method of any of Aspects 9-13, wherein the one or more first thermoplastic elastomers include or consist essentially of a styrene butadiene styrene (SBS) block copolymer elastomer, a styrene ethylene butylene styrene (SEBS) copolymer elastomer, a styrene acrylonitrile (SAN) copolymer elastomer, or any combination thereof.

[0077] According to Aspect 15, the present disclosure is directed to the method of any one of Aspects 9-14, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more thermoplastic polyurethane elastomer homopolymers or copolymers.

[0078] According to Aspect 16, the present disclosure is directed to the method of any one of Aspects 9-15, wherein the one or more first thermoplastic elastomers comprise or consist essentially of a thermoplastic polyester-polyurethane elastomer, a polyether-polyurethane elastomer, a polycarbonate-polyurethane elastomer, or a combination thereof.

[0079] According to Aspect 17, the present disclosure is directed to the method of any one of Aspects 9-16, wherein the one or more first thermoplastic elastomers of the foamable material comprise or consist essentially of one or more thermoplastic polyester-polyurethane elastomers, optionally wherein the polymeric component of the foamable material consists of one or more thermoplastic polyester-polyurethane elastomers.

[0080] According to Aspect 18, the present disclosure is directed to the method of any one of Aspects 9-16, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more thermoplastic polyolefin elastomer homopolymers or copolymers.

[0081] According to Aspect 19, the present disclosure is directed to the method of any one of Aspects 9-18, wherein the one or more first thermoplastic elastomers comprise or consist essentially of a thermoplastic elastomer polypropylene homopolymer or copolymer, a thermoplastic elastomer polyethylene homopolymer or copolymer, a thermoplastic elastomer polybutylene homopolymer or copolymer, or any combination thereof.

[0082] According to Aspect 20, the present disclosure is directed to the method of any one of Aspects 9-18, wherein the one or more first thermoplastic elastomers comprise or consist essentially of a thermoplastic elastomer ethylene-vinyl acetate copolymer.

[0083] According to Aspect 21, the present disclosure is directed to the method of Aspect 20, wherein the thermoplastic elastomer ethylene-vinyl acetate copolymer comprises a vinyl acetate content of from about 25 weight percent to about 50 weight percent.

[0084] According to Aspect 22, the present disclosure relates to the method of any one of Aspects 9-21, wherein the foamable material comprises a mixture of a polymeric component and a non-polymeric component consisting of one or more non-polymeric additives, optionally wherein the foamable material comprises from about 0.005% to about 20% by weight of the non-polymeric component based on the total weight of the foamable material, or from about 0.5% to about 10% by weight of the non-polymeric additive based on the total weight of the foamable material.

[0085] According to Aspect 23, the present disclosure relates to the method of any one of Aspects 9-22, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more recycled first thermoplastic elastomers.

[0086] According to Aspect 24, the present disclosure relates to the method of any one of Aspects 9-20, wherein the foamable material comprises or consists essentially of a blend of the one or more first thermoplastic elastomers and a second material, optionally wherein the second material comprises or consists essentially of one or more second polymers, optionally wherein the one or more second polymers comprise or consist essentially of one or more second thermoplastics.

[0087] According to Aspect 25, the present disclosure relates to the method of any one of Aspects 9-24, wherein the polymeric component of the foamable material consists of a blend of the one or more first thermoplastic elastomers and one or more second thermoplastics, optionally wherein the blend foams during the steps of exposing and expanding.

[0088] According to Aspect 26, the present disclosure relates to the method of Aspect 25, wherein the one or more second thermoplastics comprise or consist essentially of one or more thermoplastic polyolefin homopolymers or copolymers, one or more thermoplastic polyamide homopolymers or copolymers, one or more thermoplastic polyester homopolymers or copolymers, one or more thermoplastic polyurethane homopolymers or copolymers, one or more thermoplastic styrene homopolymers or copolymers, or any combination thereof.

[0089] According to Aspect 27, the present disclosure relates to the method of Aspect 25 or 26, wherein the one or more second thermoplastics comprise or consist essentially of a thermoplastic polypropylene homopolymer or copolymer, a thermoplastic polyethylene homopolymer or copolymer, a thermoplastic polybutylene homopolymer or copolymer, or any combination thereof.

[0090] According to Aspect 28, the present disclosure relates to the method of any one of Aspects 24-27, wherein the one or more second thermoplastics comprises or consists essentially of one or more thermoplastic polyethylene copolymers.

[0091] According to Aspect 29, the present disclosure relates to the method of any one of Aspects 24-28, wherein the one or more second thermoplastics comprises or consists essentially of one or more thermoplastic ethylene-vinyl alcohol copolymers.

[0092] According to Aspect 30, the present disclosure relates to the method of Aspect 24, wherein the polymeric component of the foamable material consists of one or more first thermoplastic elastomeric polyurethane homopolymers or copolymers and one or more second thermoplastic ethylene-vinyl alcohol copolymers.

[0093] According to Aspect 31, the present disclosure relates to the method of Aspect 30, wherein the polymeric component consists of one or more first thermoplastic elastomeric polyester- polyurethane copolymers and one or more second thermoplastic ethylene-vinyl alcohol copolymers.

[0094] According to Aspect 32, the present disclosure relates to the method of any one of Aspects 24-31, wherein the blend comprises one or more recycled first thermoplastic elastomers, or one or more recycled second thermoplastics, or both.

[0095] According to Aspect 33, the present disclosure relates to the method of Aspect 32, wherein the blend is a phase-separated blend of the one or more first thermoplastic elastomers and the one or more second thermoplastics.

[0096] According to Aspect 34, the present disclosure relates to the method of Aspect 33, wherein the phase-separated blend comprises one or more phase-separated regions comprising an interface between the one or more first thermoplastic elastomers and the one or more second thermoplastics.

[0097] According to Aspect 35, the present disclosure relates to the method of any one of Aspects 24-34, wherein the blend comprises about 95% by weight of the one or more first thermoplastic elastomers and about 5% by weight of the one or more second thermoplastics, based on the total weight of the blend.

[0098] According to Aspect 36, the present disclosure relates to the method of any one of Aspects 24-35, wherein the liquid carbon dioxide is soluble in the one or more first thermoplastic elastomers at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, based on the total weight of the one or more first thermoplastic elastomers present in the foamable material, and wherein the liquid carbon dioxide is soluble in the one or more second thermoplastic plastics at a concentration of less than 1 weight percent, optionally less than 0.1 weight percent, based on the total weight of the one or more second thermoplastic plastics present in the foamable material, or optionally wherein the liquid carbon dioxide is substantially insoluble in the one or more second thermoplastic plastics.

[0099] According to Aspect 37, the present disclosure relates to the method of any one of the preceding Aspects, wherein the article comprises a further material, wherein the further material is a material separate from the foamable material, wherein the further material comprises or consists essentially of one or more polymers, and comprises a further material polymer component consisting of all polymers present in the further material; optionally wherein the further material comprises or consists essentially of a second material, optionally wherein the second material is a thermoplastic material, optionally wherein the further material comprises a further material polymer component mixed with a further material non-polymer component consisting of all non-polymer components present in the further material.

[0100] According to Aspect 38, the present disclosure relates to the method of any one of the preceding Aspects, wherein the article comprises one or more first portions of the foamable material and one or more second portions of the further material, and wherein the one or more first portions are different from the one or more second portions.

[0101] According to Aspect 39, the present disclosure relates to the method of Aspect 37 or 38, wherein the further material comprises a barrier material comprising one or more barrier polymers, the barrier material comprising a barrier polymer component consisting of all polymers present in the barrier material.

[0102] According to Aspect 40, the present disclosure relates to the method of any one of Aspects 37-39, wherein the further material comprises a plasticizer.

[0103] According to Aspect 41, the present disclosure relates to the method of Aspect 39 or 40, wherein during the expanding step, the further material remains substantially unfoamed.

[0104] According to aspect 42, the present disclosure relates to the method of aspect 41, wherein the barrier material has a hardness that is at least 10 Shore A units greater than the foamable material, or optionally at least 20 Shore A units greater than the foamable material, at least 30 Shore A units greater than the foamable material, or at least 40 Shore A units greater than the foamable material.

[0105] According to aspect 43, the present disclosure relates to the method of any one of aspects 37-42, wherein the barrier material has a nitrogen transmission rate that is at least 50% lower than the nitrogen transmission rate of the foamable material, optionally a nitrogen transmission rate that is less than or equal to 10 cubic centimeters per square meter per 24 hours, or less than or equal to 1 cubic centimeter per square meter per 24 hours.

[0106] According to aspect 44, the present disclosure relates to the method of any one of aspects 37-43, wherein the barrier polymer component of the barrier material consists of one or more barrier polymers, each individually having a nitrogen transmission rate that is less than or equal to 30 cubic centimeters per square meter per 24 hours, or less than or equal to 10 cubic centimeters per square meter per 24 hours, or less than or equal to 1 cubic centimeter per square meter per 24 hours.

[0107] According to aspect 45, the present disclosure relates to the method of aspect 44, wherein the one or more barrier polymers comprise or consist essentially of one or more vinylidene chloride polymers, one or more acrylonitrile polymers or copolymers, one or more polyamides, one or more epoxy resins, one or more amine polymers or copolymers, or one or more thermoplastic polyolefin homopolymers or copolymers, optionally wherein the one or more thermoplastic polyolefin homopolymers or copolymers comprise or consist essentially of one or more thermoplastic polyethylene copolymers, one or more thermoplastic ethylene-vinyl alcohol copolymers, or one or more thermoplastic elastomeric ethylene-vinyl alcohol copolymers.

[0108] According to aspect 46, the present disclosure relates to the method of any one of aspects 37-43, wherein at the first temperature and first pressure, liquid carbon dioxide is soluble in the foamable material at a first concentration, liquid carbon dioxide is soluble in the barrier material at a second concentration, and the first concentration is at least 20% greater than the second concentration, optionally wherein the first concentration is at least 50% greater than the second concentration or at least 70% greater than the second concentration.

[0109] According to aspect 47, the present disclosure relates to the method of aspect 46, wherein the second concentration is less than 1 weight percent, optionally less than 0.1 weight percent, or optionally wherein liquid carbon dioxide is substantially insoluble in the barrier material.

[0110] According to aspect 48, the present disclosure relates to the method of any one of aspects 37-47, wherein the barrier material comprises one or more ethylene-vinyl alcohol copolymers, optionally wherein the one or more ethylene-vinyl alcohol copolymers are thermoplastic, optionally wherein the one or more ethylene-vinyl alcohol thermoplastic copolymers comprise one or more thermoplastic elastomeric copolymers; optionally wherein the barrier polymer component consists of one or more ethylene-vinyl alcohol copolymers, optionally wherein the one or more ethylene-vinyl alcohol copolymers are thermoplastic, optionally wherein the one or more ethylene-vinyl alcohol thermoplastic copolymers comprise one or more thermoplastic elastomeric copolymers.

[0111] According to aspect 49, the present disclosure relates to the method of aspect 37 or 38, wherein the additional material is a thermoplastic material, optionally wherein the additional material is an additional thermoplastic elastomeric material, optionally wherein the additional thermoplastic elastomeric material is an additional foamable material.

[0112] According to aspect 50, the present disclosure relates to the method of aspect 49, wherein the additional material is an additional foamable material, and during the expanding step, the additional foamable material expands into an additional foamed material.

[0113] According to aspect 51, the present disclosure relates to the method of aspect 50, wherein in the foamed article, the density of the first foamed material differs from the density of the additional foamed material by at least 5%, or at least 10%, or at least 20%.

[0114] According to aspect 52, the present disclosure relates to the method of aspect 49, wherein the article comprises a first foamable material comprising or consisting essentially of a solid foamable material, and further comprises an additional material, wherein the additional material is an additional foamable material, the maintaining and holding step comprises holding the article and the liquid carbon dioxide in the container for a duration sufficient to inject at least a portion of the liquid carbon dioxide into the first foamable material but not into the additional foamable material, and the experiencing and expanding step comprises expanding the first foamable material into a first foamed material while maintaining the additional foamable material as a substantially unfoamed additional foamable material.

[0115] According to aspect 53, the present disclosure relates to the method of aspect 49, wherein the article comprises a solid first foamable material and further comprises a further material, wherein the further material is a further foamable material, the step of maintaining and holding comprises holding the article and the liquid carbon dioxide in the container for a duration sufficient to infuse at least a portion of the liquid carbon dioxide into the solid first foamable material and into the solid further foamable material, the method comprises an optional exposing step, and the exposing comprises exposing the article to a second pressure and a second temperature at which carbon dioxide remains infused into the solid further foamable material but at which carbon dioxide diffuses out of the solid first foamable material, and the step of undergoing and expanding comprises expanding the further foamable material into a further foamed material while maintaining the solid first foamable material as a substantially unfoamed first foamable material.

[0116] According to aspect 54, the present disclosure relates to the method of aspect 49, wherein the further material is a recycled material comprising one or more recycled polymers, optionally wherein the one or more recycled polymers comprise one or more recycled thermoplastics, optionally wherein the one or more recycled thermoplastics comprise one or more recycled thermoplastic elastomers; optionally wherein the recycled material comprises a recycled material polymer component consisting of one or more recycled thermoplastics, optionally wherein the recycled material polymer component comprises or consists essentially of one or more recycled thermoplastic elastomers.

[0117] According to aspect 55, the present disclosure relates to the method of aspect 54, wherein the recycled material comprises one or more recycled first thermoplastic elastomers, optionally wherein the one or more recycled first thermoplastic elastomers comprise one or more regrind first thermoplastic elastomers, optionally wherein the one or more recycled first thermoplastic elastomers or regrind first thermoplastic elastomers comprise the thermoplastic elastomer of any of aspects 9-23 or 24-36.

[0118] According to aspect 56, the present disclosure relates to the method of aspect 54 or 55, wherein the recycled material further comprises one or more recycled second thermoplastics, optionally wherein the one or more recycled second thermoplastics comprise one or more regrind second thermoplastics, optionally wherein the one or more recycled second thermoplastics or regrind second thermoplastics comprise the thermoplastic of any of aspects 26-29.

[0119] According to Aspect 57, the present disclosure relates to the method of Aspect 56, wherein the recycled material comprises one or more recycled thermoplastic polyurethane elastomers or regrind thermoplastic polyurethane elastomers, or one or more recycled thermoplastic ethylene-vinyl alcohol copolymers or regrind thermoplastic ethylene-vinyl alcohol copolymers, or both.

[0120] According to Aspect 58, the present disclosure relates to the method of Aspect 56 or 57, wherein the recycled material comprises a blend of one or more recycled thermoplastic elastomers or regrind thermoplastic elastomers and one or more second thermoplastics, or wherein the recycled material comprises a blend of one or more thermoplastic elastomers and one or more recycled thermoplastics or one or more recycled second thermoplastics, optionally wherein the blend is a phase-separated blend, and optionally wherein the phase-separated blend comprises one or more interfaces between the one or more first thermoplastic elastomers and the one or more second thermoplastics.

[0121] According to Aspect 59, the present disclosure relates to the method of any one of Aspects 56-58, wherein the recycled material comprises from about 99% to about 90% by weight of the one or more first thermoplastic elastomers and from about 1% to about 10% by weight of the second thermoplastic, based on the total weight of the recycled material, optionally wherein the recycled material comprises from about 99% to about 93% by weight of the one or more first thermoplastic elastomers and from about 1% to about 7% by weight of the one or more second thermoplastics, or from about 99% to about 95% by weight of the one or more first thermoplastic elastomers and from about 1% to about 5% by weight of the one or more second thermoplastics.

[0122] According to Aspect 60, the present disclosure relates to the method of any one of Aspects 54-59, wherein the recycled material comprises from about 99% to about 50% by weight of the recycled or regrind polymer, optionally from about 99% to about 75% by weight of the recycled or regrind polymer, based on the total weight of the recycled material.

[0123] According to Aspect 61, the present disclosure relates to the method of any one of Aspects 54-60, wherein the liquid carbon dioxide is soluble in the recycled material at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, based on the total weight of the recycled material.

[0124] According to Aspect 62, the present disclosure relates to the method of any one of Aspects 54-59, wherein the liquid carbon dioxide is soluble in the one or more recycled thermoplastic elastomers or regrind thermoplastic elastomers at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, based on the total weight of the one or more recycled thermoplastic elastomers or regrind thermoplastic elastomers.

[0125] According to Aspect 63, the present disclosure relates to the method of any one of Aspects 54-62, wherein the liquid carbon dioxide is soluble in the one or more recycled second thermoplastic or regrind second thermoplastic at less than 1 weight percent, optionally less than 0.1 weight percent, based on the total weight of the one or more recycled second thermoplastic or regrind second thermoplastic, or optionally the liquid carbon dioxide is substantially insoluble in the one or more recycled second thermoplastic or regrind second thermoplastic.

[0126] According to Aspect 64, the present disclosure relates to the method of any one of Aspects 55-63, wherein the recycled material comprises a recycled foamed article produced by the method of any one of Aspects 1-54, optionally wherein the recycled foamed article is a regrind foamed article.

[0127] According to Aspect 65, the present disclosure relates to the method of any one of Aspects 55-63, wherein the recycled material comprises a foamable material, wherein the foamable material is an unfoamed material.

[0128] According to Aspect 66, the present disclosure relates to the method of any one of Aspects 55-65, wherein the recycled material further comprises one or more virgin first thermoplastic elastomers, optionally wherein the one or more virgin first thermoplastic elastomers comprise one or more virgin thermoplastic polyurethane elastomers.

[0129] According to Aspect 67, the present disclosure relates to the method of any one of Aspects 58-66, wherein the recycled material comprises one or more nucleating agents or nucleation sites for foaming the recycled material, optionally wherein the one or more nucleation sites comprise one or more interfaces between phase-separated polymers.

[0130] According to Aspect 68, the present disclosure relates to the method of any one of Aspects 55-67, wherein the solid foamable material is the recycled material.

[0131] According to aspect 69, the present disclosure relates to the method of any one of aspects 55-67, wherein the article comprises a first solid foamable material and a further solid foamable material, and the first solid foamable material is a recycled material, or the further solid foamable material is a recycled material, or both the first solid foamable material and the further solid foamable material are recycled materials.

[0132] According to aspect 70, the present disclosure relates to the method of any one of the preceding aspects, wherein the article comprises a barrier layer comprising or consisting essentially of a barrier material.

[0133] According to aspect 71, the present disclosure relates to the method of aspect 70, wherein the barrier material is the further material of any one of aspects 37-67.

[0134] According to aspect 72, the present disclosure relates to the method of any one of the preceding aspects, wherein the article comprises a structural layer comprising or consisting essentially of a structural material.

[0135] According to aspect 73, the present disclosure relates to the method of aspect 72, wherein the structural material is the further material of any one of aspects 37-67, optionally wherein the structural material comprises a blend of two or more further materials, optionally wherein at least one of the two or more further materials is a recycled material.

[0136] According to aspect 74, the present disclosure relates to the method of any one of the preceding aspects, wherein the article comprises one or more tie layers, each of the one or more tie layers individually comprising or consisting essentially of a tie material, wherein each of the one or more tie layers increases the bond strength between two adjacent layers, optionally wherein the tie material is the solid foamable material of any one of aspects 1-73, optionally wherein the solid foamable material is a recycled material.

[0137] According to aspect 75, the present disclosure relates to the method of any one of the preceding aspects, wherein the article comprises one or more protective layers, each of the one or more protective layers individually comprising or consisting essentially of a protective material, wherein each of the one or more protective layers is adjacent to a core layer and has a protective layer thickness, wherein the combination of the one or more protective layers and the adjacent core layer has a minimum radius of curvature that is greater than a minimum radius of curvature that causes cracking of the core layer or causes cracking of one or more individual layers within the core layer, optionally wherein the protective material is the solid foamable material of any one of aspects 1-73, optionally wherein the solid foamable material is a recycled material.

[0138] According to Aspect 76, the present disclosure is directed to the method of any one of Aspects 34-36, wherein the steps of maintaining and expanding comprise nucleating foaming at one or more interfaces in the foamable material.

[0139] According to Aspect 77, the present disclosure is directed to the method of any one of the preceding Aspects, wherein the steps of maintaining and holding comprise maintaining a first pressure from about 0.05 pounds per square inch (0.345 kiloPascals) to about 6000 pounds per square inch (41,300 kiloPascals), optionally about 15 pounds per square inch (103.4 kiloPascals) to about 5500 pounds per square inch (37,900 kiloPascals), from about 100 pounds per square inch (689.5 kiloPascals) to about 5000 pounds per square inch (34,500 kiloPascals), from about 500 pounds per square inch (3450 kiloPascals) to about 2000 pounds per square inch (13,790 kiloPascals), or from about 1000 pounds per square inch (6895 kiloPascals) to about 1500 pounds per square inch (10,300 kiloPascals).

[0140] According to Aspect 78, the present disclosure is directed to the method of any one of the preceding Aspects, wherein the steps of maintaining and holding comprise maintaining the first temperature from about -57 degrees Celsius to about 31 degrees Celsius.

[0141] According to Aspect 79, the present disclosure is directed to the method of any one of the preceding Aspects, wherein the steps of maintaining and holding comprise holding the article at the first pressure and the first temperature for a duration from about 20 seconds to about 72 hours.

[0142] According to Aspect 80, the present disclosure is directed to the method of any one of the preceding Aspects, wherein the optional exposing step comprises exposing the article to a second pressure from about 1 atmosphere (101 kiloPascals) to about 85 atmospheres (8613 kiloPascals).

[0143] According to Aspect 81, the present disclosure is directed to the method of any one of the preceding Aspects, wherein the optional exposing step comprises exposing the article to a second temperature less than the softening point of the solid foamable material by more than about 30 degrees, or less than the softening point of the solid foamable material by more than about 50 degrees, optionally less than the softening point of the solid foamable material by more than about 100 degrees.

[0144] According to Aspect 82, the present disclosure is directed to the method of any one of the preceding Aspects, wherein the optional exposing step comprises exposing the article to the second pressure and the second temperature for a duration from about 30 minutes to about 4 weeks.

[0145] According to aspect 83, the present disclosure relates to the method of any of the preceding aspects, wherein the step of subjecting and expanding comprises subjecting the article to a third pressure from about 13 pounds per square inch (89.6 kiloPascals) to about 16 pounds per square inch (110.3 kiloPascals).

[0146] According to aspect 84, the present disclosure relates to the method of any of the preceding aspects, wherein the step of subjecting and expanding comprises subjecting the article to a third temperature from about 20 degrees Celsius to about 150 degrees Celsius.

[0147] According to aspect 85, the present disclosure relates to the method of any of the preceding aspects, wherein the step of subjecting and expanding comprises subjecting the article to the third pressure and the third temperature for a duration from about 2 seconds to about 5 minutes.

[0148] According to aspect 86, the present disclosure relates to the method of any of the preceding aspects, wherein the optional step of subjecting comprises subjecting the foamed article to a fourth pressure from about 0.03 atmospheres (3.04 kiloPascals) to about 2 atmospheres (202.65 kiloPascals).

[0149] According to aspect 87, the present disclosure relates to the method of any of the preceding aspects, wherein the optional step of subjecting comprises subjecting the foamed article to a fourth temperature from about 30 degrees Celsius to about 70 degrees Celsius.

[0150] According to aspect 88, the present disclosure relates to the method of any of the preceding aspects, wherein the optional step of subjecting comprises subjecting the foamed article to the fourth pressure and the fourth temperature for a duration from about 15 minutes to about 1 hour.

[0151] According to aspect 89, the present disclosure relates to the method of any of aspects 2-88, wherein in the optional step of subjecting, the fourth temperature is at or below the glass transition temperature of the solid foamable material.

[0152] According to aspect 90, the present disclosure relates to the method of any of aspects 2-88, wherein in the optional step of subjecting, the fourth temperature is from about 10 degrees Celsius less than the glass transition temperature of the solid foamable material to about 10 degrees Celsius greater than the glass transition temperature of the solid foamable material.

[0153] According to aspect 91, the present disclosure relates to the method of any one of the preceding aspects, wherein in the foamed article, the foamed material has a density from about 0.01 grams per cubic centimeter to about 3.0 grams per cubic centimeter, optionally from about 0.01 grams per cubic centimeter to about 0.1 grams per cubic centimeter, from about 0.01 grams per cubic centimeter to about 0.05 grams per cubic centimeter, from about 0.01 grams per cubic centimeter to about 0.025 grams per cubic centimeter, from about 0.05 grams per cubic centimeter to about 0.1 grams per cubic centimeter, from about 0.1 grams per cubic centimeter to about 3.0 grams per cubic centimeter, from about 0.2 grams per cubic centimeter to about 2.0 grams per cubic centimeter, from about 0.3 grams per cubic centimeter to about 1.5 grams per cubic centimeter, from about 0.3 grams per cubic centimeter to about 1.2 grams per cubic centimeter, or from about 0.4 grams per cubic centimeter to about 1.0 grams per cubic centimeter.

[0154] According to aspect 92, the present disclosure relates to the method of any one of the preceding aspects, wherein in the foamed article, the foamed material has a volume that is less than 10% greater, optionally less than 5% greater, than the foamable material prior to foaming, optionally wherein the foamed article is a stabilized foamed article.

[0155] According to aspect 93, the present disclosure relates to the method of any one of aspects 1-91, wherein in the foamed article, the foamed material has a volume that is more than 20% greater, optionally more than 30% greater, or more than 40% greater, than the foamable material prior to foaming, optionally wherein the foamed article is a stabilized foamed article.

[0156] According to aspect 94, the present disclosure relates to the method of any one of the preceding aspects, wherein the step of subjecting and expanding comprises expanding the foamable material into a foamed material until the foamed material has a density from about 0.01 grams per cubic centimeter to about 3.0 grams per cubic centimeter.

[0157] According to aspect 95, the present disclosure relates to the method of any one of the preceding aspects, wherein after the step of subjecting and expanding, the foamed material has an expansion ratio from about 3: 1 to about 120: 1 relative to the solid foamable material prior to subjecting and expanding.

[0158] According to aspect 96, the present disclosure relates to the method of any one of the preceding aspects, wherein the solid foamable material has a Shore A hardness from about 35A to about 95A, optionally from about 55A to about 90A.

[0159] According to aspect 97, the present disclosure relates to the method of any one of the preceding aspects, wherein the foamed material of the foamed article has a Shore A hardness from about 35A to about 95A, optionally from about 55A to about 90A.

[0160] According to aspect 98, the present disclosure relates to the method of any of the preceding aspects, further comprising forming the solid foamable material using an extrusion process prior to the step of placing.

[0161] According to aspect 99, the present disclosure relates to the method of any of the preceding aspects, further comprising forming the solid foamable material using an injection molding process prior to the step of placing.

[0162] According to aspect 100, the present disclosure relates to the method of any of the preceding aspects, further comprising forming the solid foamable material using a thermoforming process and / or a vacuum forming process prior to the step of placing.

[0163] According to aspect 101, the present disclosure relates to the method of any of the preceding aspects, further comprising forming the solid foamable material using an additive manufacturing process prior to the step of placing.

[0164] According to aspect 102, the present disclosure relates to the method of any of the preceding aspects, wherein the optional exposing step occurs in the container.

[0165] According to aspect 103, the present disclosure relates to the method of any of the preceding aspects, wherein the undergoing and expanding steps occur in the container.

[0166] According to aspect 104, the present disclosure relates to the method of any of aspects 1-101, wherein the optional exposing step further comprises removing the article infused with liquid carbon dioxide from the container prior to exposing the article to the optional second pressure and second temperature.

[0167] According to aspect 105, the present disclosure relates to the method of any of aspects 1-101, wherein the undergoing step further comprises removing the article infused with liquid carbon dioxide from the container prior to subjecting the article to the third pressure and third temperature.

[0168] According to aspect 106, the present disclosure relates to the method of aspect 105, wherein the step of placing carbon dioxide in the container comprises introducing carbon dioxide vapor into the container prior to the step of maintaining and holding.

[0169] According to aspect 107, the present disclosure relates to the method of aspect 106, wherein introducing carbon dioxide vapor comprises charging the container with carbon dioxide vapor at a pressure and temperature condition that is a liquid / vapor equilibrium of carbon dioxide.

[0170] According to aspect 108, the present disclosure relates to the method of any of aspects 105-107, wherein the method further comprises venting liquid carbon dioxide from the container after the step of maintaining and holding, prior to the optional exposing step, or prior to the undergoing and expanding step.

[0171] According to aspect 109, the present disclosure relates to the method of aspect 108, wherein discharging the liquid carbon dioxide from the container comprises converting the liquid carbon dioxide to carbon dioxide vapor prior to or during discharging.

[0172] According to aspect 110, the present disclosure relates to the method of any of the preceding aspects, wherein the step of subjecting the article to a third temperature and a third pressure comprises introducing the article to a fluid bath, optionally wherein the fluid bath is a water bath.

[0173] According to aspect 111, the present disclosure relates to the method of aspect 110, wherein the fluid bath has a temperature from about 20 degrees Celsius to about 90 degrees Celsius.

[0174] According to aspect 112, the present disclosure relates to the method of aspect 110 or 111, wherein the article is held in the fluid bath for a duration from about 15 seconds to about 5 minutes during the subjecting.

[0175] According to aspect 113, the present disclosure relates to the method of any of aspects 1-109, wherein the step of subjecting comprises subjecting the article to an energy source or a heat source, optionally wherein the energy source or heat source comprises steam, microwave energy, infrared (IR) energy, radio frequency (RF) energy, or any combination thereof.

[0176] According to aspect 114, the present disclosure relates to the method of aspect 113, wherein the step of subjecting the article to an energy source or a heat source increases the temperature of at least a portion of the foamable material of the article to a temperature from about 60 degrees Celsius to about 150 degrees Celsius, optionally wherein the subjecting is for a duration from about 2 seconds to about 5 minutes.

[0177] According to aspect 115, the present disclosure relates to the method of any of aspects 3-114, wherein the optional step of fifth pressure and fifth temperature stabilization comprises placing the foamed article in an oven.

[0178] According to aspect 116, the present disclosure relates to the method of any of aspects 3-115, wherein the optional step of stabilization comprises stabilization at a fifth pressure of about atmospheric pressure.

[0179] According to aspect 117, the present disclosure relates to the method of any of aspects 3-116, wherein the optional step of stabilization comprises stabilization at a fifth temperature greater than a glass transition temperature of the solid foamable material.

[0180] According to aspect 118, the present disclosure relates to the method of any of aspects 3-117, wherein the optional step of stabilization comprises stabilization at a fifth temperature from about 30 degrees Celsius to about 70 degrees Celsius, optionally about 50 degrees Celsius.

[0181] According to aspect 119, the present disclosure relates to the method of any of aspects 3-118, wherein the optional stabilizing step comprises stabilizing the foamed article at the fifth temperature for from about 15 minutes to about 60 minutes, optionally for from about 30 minutes to about 45 minutes.

[0182] According to aspect 120, the present disclosure relates to the method of any of the preceding aspects, wherein the article is configured as a roll, and wherein the placing step comprises disposing the roll into the container, and wherein the subjecting and expanding steps comprise unwinding the article prior to or during the subjecting, or prior to or during the expanding.

[0183] According to aspect 121, the present disclosure relates to the method of aspect 120, wherein the placing step further comprises disposing a porous spacer between adjacent portions of the article prior to or during the placing, and wherein the maintaining and retaining steps comprise flowing the liquid carbon dioxide through the porous spacer to the adjacent portions of the article.

[0184] According to aspect 122, the present disclosure relates to the method of any of the preceding aspects, wherein at least a portion of the article comprising the solid foamable material expands in length, width, and height during the expanding due to the solid foamable material expanding into the foamable material.

[0185] According to aspect 123, the present disclosure relates to the method of aspect 122, wherein the size of the foamed article in at least one dimension is greater after the expanding compared to the size of the article prior to the placing, optionally wherein the foamed article is at least 5% larger, or at least 10% larger, or at least 15% larger, or at least 20% larger in one or more of length, width, and height.

[0186] According to aspect 124, the present disclosure relates to the method of aspect 122 or 123, wherein the article is a layered sheet, the subjecting and expanding steps foams at least one layer of the sheet, and after the subjecting and expanding, the foamed layered sheet is at least 5% thicker, or at least 10% thicker, or at least 15% thicker, or at least 20% thicker than the thickness of the layered sheet in its unfoamed state.

[0187] According to aspect 125, the present disclosure relates to the method of any of aspects 122-124, wherein the method comprises a stabilizing step, and after the stabilizing, the stabilized foamed article is larger in at least one dimension compared to the size of the article prior to the placing, optionally wherein the stabilized foamed article is at least 5% larger, or at least 10% larger, or at least 15% larger, or at least 20% larger in one or more of length, width, and height.

[0188] According to aspect 126, the present disclosure relates to the method of any one of the preceding aspects, further comprising thermoforming the foamed article, optionally wherein the foamed article is a stabilized foamed article.

[0189] According to aspect 127, the present disclosure relates to the method of aspect 126, wherein the foamed article is a sheet, optionally wherein the sheet is a layered sheet, optionally wherein the layered sheet comprises at least one unfoamed cap layer, optionally wherein the layered sheet comprises one or more foamed inner layers and two unfoamed cap layers.

[0190] According to aspect 128, the present disclosure relates to the method of any one of the preceding aspects, wherein the article is a thermoformed article, optionally wherein the method further comprises the step of thermoforming the article prior to the step of placing.

[0191] According to aspect 129, the present disclosure relates to the method of any one of the preceding aspects, wherein the foamed article is a component of an apparel article, a footwear article, or a sporting equipment article.

[0192] According to aspect 130, the present disclosure relates to the method of any one of the preceding aspects, wherein the article comprises or is a textile.

[0193] According to aspect 131, the present disclosure relates to the method of any one of aspects 1-130, wherein the article comprises or is a sheet.

[0194] According to aspect 132, the present disclosure relates to the method of aspect 131, wherein the sheet is from about 300 micrometers thick to about 1 centimeter thick, optionally from about 500 micrometers thick to about 1 centimeter thick, or from about 500 micrometers thick to about 750 micrometers thick.

[0195] According to aspect 133, the present disclosure relates to the method of any one of the preceding aspects, wherein the article comprises a layered structure comprising a series of three or more layers, the layered structure comprising:

[0196] a first cap layer comprising or consisting essentially of a first cap layer material, the first cap layer comprising a first cap layer outer surface defining a first outer surface of the layered structure, a first cap layer inner surface opposite the first cap layer outer surface, a first cap layer thickness extending from the first cap layer inner surface to the first cap layer outer surface, wherein the first cap layer outer surface defines a first outer surface of the article;

[0197] a second cap layer comprising or consisting essentially of a second cap layer material, the second cap layer comprising a second cap layer outer surface defining a second outer surface of the layered structure, a second cap layer inner surface opposite the second cap layer outer surface, a second cap layer thickness extending from the second cap layer inner surface to the second cap layer outer surface, optionally wherein the second cap layer outer surface defines a second outer surface of the article; and

[0198] one or more core layers, wherein each core layer of the one or more core layers comprises or consists essentially of a core layer material, each core layer of the one or more core layers comprising a core layer first surface, a core layer second surface, and a core layer thickness extending from the core layer first surface to the core layer second surface, wherein each core layer of the one or more core layers is positioned between the first cap layer inner surface and the second cap layer inner surface;

[0199] wherein at least one layer of the three or more layers of the article comprises or consists essentially of a solid foamable material, and the step of experiencing and expanding expands at least a portion of the solid foamable material of the at least one layer of the three or more layers into a foamed material, forming a foamed article.

[0200] According to Aspect 134, the disclosure relates to the method of Aspect 133, wherein at least one of the first cap layer material or the second cap layer material is a solid foamable material, or both the first cap layer material and the second cap layer material are solid foamable materials, and the core layer material of at least one core layer of the one or more core layers comprises a barrier material, optionally wherein the polymeric components of the first cap layer material and the second cap layer material are substantially the same.

[0201] According to Aspect 135, the disclosure relates to the method of Aspect 134, wherein the step of maintaining and retaining injects carbon dioxide into the first cap layer, or injects carbon dioxide into the first cap layer and at least one core layer of the one or more core layers, or injects carbon dioxide into the first cap layer and each core layer of the one or more core layers, or injects carbon dioxide into the first cap layer, each core layer of the one or more core layers, and the second cap layer.

[0202] According to Aspect 136, the present disclosure relates to the method of Aspect 133 or 134, wherein the method comprises a step of exposing, and the exposing releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in at least one of the one or more core layers, or releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in each of the one or more core layers, or releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in each of the one or more core layers and the second cap layer, or releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in the second cap layer, optionally retaining the injected carbon dioxide in at least one of the one or more core layers, or releases substantially all of the injected carbon dioxide from the first cap layer and each of the one or more core layers while retaining the injected carbon dioxide in the second cap layer.

[0203] According to Aspect 137, the present disclosure relates to the method of any one of Aspects 133-136, wherein at least one of the one or more core layers comprises a plurality of alternating layers, wherein each alternating layer in the series of alternating layers individually comprises a first alternating layer material or a second alternating layer material, optionally wherein the first alternating layer material and the second alternating layer material individually are a thermoplastic material or a thermoplastic elastomer material.

[0204] According to Aspect 138, the present disclosure relates to the method of any one of Aspects 133-137, wherein each alternating layer individually has an average thickness of from about 0.01 micrometers to about 1 millimeter, optionally from about 0.05 micrometers to about 0.5 millimeter or from about 1 micrometers to about 0.25 millimeter.

[0205] According to Aspect 139, the present disclosure relates to the method of any one of Aspects 133-138, wherein an inner surface of the first cap layer is in contact with the first surface of the core layer, or an inner surface of the second cap layer is in contact with the second surface of the core layer, or both.

[0206] According to Aspect 140, the present disclosure relates to the method of any one of Aspects 133-139, wherein the article is configured to comprise a series of four or more layers of one or more structural layers, each of the one or more structural layers comprising a structural layer material and comprising a structural layer first surface, a structural layer second surface opposite the structural layer first surface, and a structural layer thickness extending from the structural layer first surface to the structural layer second surface;

[0207] optionally wherein at least one of the one or more structural layers is positioned between the first cap layer and the core layer, or is positioned between the second cap layer and the core layer; or

[0208] Optionally, the one or more structural layers include two or more structural layers, and at least a first structural layer of the two or more structural layers is positioned between the inner surface of the first cap layer and the first surface of the core layer, and at least a second structural layer of the two or more structural layers is positioned between the second surface of the core layer and the inner surface of the second cap layer.

[0209] According to Aspect 141, the present disclosure relates to the method of Aspect 140, wherein a first surface of a first structural layer of the structural layers is in contact with the inner surface of the first cap layer, and a second surface of the first structural layer of the structural layers is in contact with a first surface of a core layer of the one or more core layers, or wherein a first surface of a second structural layer of the one or more structural layers is in contact with a second surface of a core layer of the one or more core layers, and a second surface of the second structural layer of the structural layers is in contact with the inner surface of the second cap layer, or both.

[0210] According to Aspect 142, the present disclosure relates to the method of Aspect 140 or 141, wherein in the article, a structural layer material of at least one structural layer of the one or more structural layers comprises or consists essentially of a solid foamable material, and the step of undergoing and expanding expands at least a portion of the solid foamable material of the one or more structural layers into a foamed material, forming a foamed article.

[0211] According to Aspect 143, the present disclosure relates to the method of any of Aspects 140-142, wherein the step of maintaining and retaining injects carbon dioxide into the first cap layer, or injects carbon dioxide into the first cap layer and at least one structural layer of the one or more structural layers; or injects carbon dioxide into the first cap layer, at least one structural layer of the one or more structural layers; or injects carbon dioxide into the first cap layer, at least one structural layer of the one or more structural layers, and at least one core layer of the one or more core layers; or injects carbon dioxide into the first cap layer, each structural layer of the one or more structural layers, each core layer of the one or more core layers, and the second cap layer.

[0212] According to Aspect 144, the present disclosure relates to the method of any of Aspects 140-143, wherein the method includes a step of exposing, and the exposing releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in at least one structural layer of the one or more structural layers; or

[0213] releasing substantially all of the injected carbon dioxide from the first cap layer and a first structural layer of the one or more structural layers, while retaining the injected carbon dioxide in a second structural layer of the one or more structural layers; or

[0214] releasing substantially all of the injected carbon dioxide from the first cap layer, one or more structural layers of the at least one structural layer, and a first core layer of the one or more core layers, while retaining the injected carbon dioxide in a second core layer of the one or more core layers, a second structural layer of the one or more structural layers, and the second cap layer; or

[0215] releasing substantially all of the injected carbon dioxide from the first cap layer, at least a first structural layer of the one or more structural layers, and at least one core layer of the one or more core layers, while retaining the injected carbon dioxide in at least one core layer of the one or more core layers, the second cap layer, and optionally a second structural layer of the one or more structural layers; or

[0216] releasing substantially all of the injected carbon dioxide from the first cap layer, each structural layer of the one or more structural layers, and each core layer of the one or more core layers, while retaining the injected carbon dioxide in the second cap layer.

[0217] According to aspect 145, the present disclosure relates to the method of any one of aspects 140-144, wherein the article comprises a first structural layer and a second structural layer, the structural layer material of at least one of the first structural layer and the second structural layer comprises or consists essentially of a solid foamable material, and the step of subjecting and expanding causes at least a portion of the solid foamable material of the first structural layer or the second structural layer or both to expand into a foamed material, forming a foamed article.

[0218] According to aspect 146, the present disclosure relates to the method of any one of aspects 133-145, wherein the article is configured to comprise a series of five or more layers including one or more connecting layers, each connecting layer of the one or more connecting layers comprises a connecting layer material and includes a connecting layer first surface, a connecting layer second surface opposite the connecting layer first surface, and a connecting layer thickness extending from the connecting layer first surface to the connecting layer second surface;

[0219] optionally wherein at least one connecting layer of the one or more connecting layers is positioned between one structural layer of the one or more structural layers and one core layer of the one or more core layers, or between the first cap layer and one structural layer of the one or more structural layers, or between the second cap layer and one structural layer of the one or more structural layers, or any combination thereof; or

[0220] Optionally, the one or more tie layers include two or more tie layers, and at least a first tie layer of the two or more tie layers is positioned between the second surface of the first structural layer and the first layer of the core layer, and at least a second tie layer of the two or more tie layers is positioned between the second surface of the core layer and the first surface of the structural layer.

[0221] According to Aspect 147, the disclosure relates to the method of Aspect 146, wherein a first surface of a first tie layer of the one or more tie layers is in contact with a second surface of a first structural layer of the one or more structural layers, and a second surface of the first tie layer of the one or more tie layers is in contact with a first surface of the core layer; or wherein a first surface of a second tie layer of the one or more tie layers is in contact with a second surface of a core layer of the one or more core layers, and a second surface of the second tie layer of the one or more tie layers is in contact with a first surface of a second structural layer of the one or more structural layers, or both.

[0222] According to Aspect 148, the disclosure relates to the method of Aspect 146 or 147, wherein in the article, the tie layer material of at least one tie layer of the one or more tie layers comprises or consists essentially of a solid foamable material, and the step of undergoing and expanding expands at least a portion of the solid foamable material of the one or more tie layers into a foamed material, forming a foamed article.

[0223] According to Aspect 149, the disclosure relates to the method of any of Aspects 146-148, wherein the step of maintaining and retaining injects carbon dioxide into the first cap layer, at least one structural layer of the one or more structural layers, and at least one tie layer of the one or more tie layers; or injects carbon dioxide into the first cap layer, at least one structural layer of the one or more structural layers, at least one tie layer of the one or more tie layers, and at least one core layer of the one or more core layers; or injects carbon dioxide into the first cap layer, at least one structural layer of the one or more structural layers, at least one tie layer of the one or more tie layers, and each core layer of the one or more core layers; or injects carbon dioxide into the first cap layer, each structural layer of the one or more structural layers, each tie layer of the one or more tie layers, each core layer of the one or more core layers, and the second cap layer.

[0224] According to aspect 150, the present disclosure relates to the method of any one of aspects 140-143, wherein the method comprises the step of exposing, and the exposing releases substantially all of the injected carbon dioxide from the first cap layer and a first structural layer of the one or more structural layers, while retaining the injected carbon dioxide in a first connecting layer of the one or more connecting layers; or

[0225] releases substantially all of the injected carbon dioxide from the first cap layer, a first structural layer of the one or more structural layers, a first connecting layer of the one or more connecting layers, and a first core layer of the one or more core layers, while retaining the injected carbon dioxide in a second core layer of the one or more core layers, a second connecting layer of the one or more connecting layers, a second structural layer of the one or more structural layers, the second cap layer.

[0226] According to aspect 151, the present disclosure relates to the method of any one of aspects 146-148, wherein the steps of subjecting and expanding do not expand and foam at least a portion of a connecting material of at least one connecting layer of the one or more connecting layers, leaving the at least one connecting layer substantially unfoamed in the foamed article; optionally wherein the connecting material of the at least one connecting layer comprises or consists essentially of a barrier material.

[0227] According to aspect 152, the present disclosure relates to the method of aspect 151, wherein the steps of subjecting and expanding do not expand and foam substantially any connecting material of each connecting layer of the one or more connecting layers, leaving each connecting layer of the one or more connecting layers substantially unfoamed in the foamed article; optionally wherein the connecting material of each connecting layer of the one or more connecting layers comprises or consists essentially of a barrier material.

[0228] According to aspect 153, the present disclosure relates to the method of any one of aspects 133-152, wherein the layered structure comprises a first cap layer, a first structural layer, a first connecting layer, a core layer, a second connecting layer, a second structural layer, and a second cap layer, wherein an inner surface of the first cap layer contacts a first surface of the first structural layer, a second surface of the first structural layer contacts a first surface of the first connecting layer, a second surface of the first connecting layer contacts a first surface of the core layer, a second surface of the core layer contacts a first surface of the second connecting layer, a second surface of the second connecting layer contacts a first surface of the second structural layer, and a second surface of the second structural layer contacts an inner layer of the second cap layer, optionally wherein the core layer comprises one or more core layers, or comprises more than one microlayer.

[0229] According to Aspect 154, the present disclosure relates to the method of any one of aspects 133-153, wherein the average thickness of each layer of the three or more layers in the series is individually from about 100 micrometers to about 0.5 centimeters or from about 100 micrometers to about 0.1 centimeters.

[0230] According to Aspect 155, the present disclosure relates to the method of any one of aspects 133-154, wherein the article is a layered sheet, optionally wherein the layered sheet is a co-extruded layered sheet or a laminated layered sheet.

[0231] According to Aspect 156, the present disclosure relates to the method of any one of aspects 133-154, wherein at least one layer of the three or more layers of the series comprises a plurality of alternating layers, wherein each alternating layer of the series of alternating layers individually comprises a first alternating layer material or a second alternating layer material, optionally wherein the plurality of alternating layers comprises from about 3 to about 50 individual layers, or from about 3 to about 25 individual layers or from about 3 to about 7 individual layers, and optionally wherein the plurality of alternating layers forms at least one core layer of the one or more core layers of the layered structure.

[0232] According to Aspect 157, the present disclosure relates to the method of aspect 156, wherein in the article the first alternating layer material is a thermoplastic material, optionally wherein the thermoplastic material is a thermoplastic elastomer material, optionally wherein the thermoplastic elastomer material is the thermoplastic elastomer material of any one of aspects 9-23 or 208-220.

[0233] According to Aspect 158, the present disclosure relates to the method of aspect 157, wherein in the article the first alternating layer material of the plurality of alternating layers is a solid thermoplastic elastomer material, optionally wherein the solid thermoplastic elastomer material is the solid thermoplastic elastomer material of any one of aspects 9-23 or 208-220.

[0234] According to Aspect 159, the present disclosure relates to the method of any one of aspects 156-158, wherein the second alternating layer material is a thermoplastic material, optionally wherein the thermoplastic material is a barrier material, optionally wherein the barrier material is the barrier material of any one of aspects 39-48, 70, 71, or 239-248.

[0235] According to Aspect 160, the present disclosure relates to the method of any one of aspects 156-159, wherein the plurality of alternating layers comprises or consists essentially of a plurality of microlayers, and the plurality of microlayers comprises from about 5 to about 1000 microlayers, optionally about 10 to about 1000 microlayers, about 30 to about 500 microlayers, about 50 to about 200 microlayers, or about 20 to about 100 microlayers.

[0236] According to Aspect 161, the present disclosure relates to the method of Aspect 160, wherein each individual microlayer of the plurality of microlayers has an average thickness of from about 0.01 micrometers to about 2.5 micrometers.

[0237] According to Aspect 162, the present disclosure relates to the method of Aspect 160 or 161, wherein each layer of the one or more layers comprising the plurality of alternating layers has an average thickness of from about 0.01 micrometers to about 2.5 micrometers or from about 0.1 micrometers to about 1 micrometer.

[0238] According to Aspect 163, the present disclosure relates to the method of any of the preceding aspects, wherein the article further comprises a textile.

[0239] According to Aspect 164, the present disclosure relates to the method of Aspect 163, wherein the article comprises a sheet, and the textile forms a layer of the sheet.

[0240] According to Aspect 165, the present disclosure relates to the method of Aspect 164, wherein the textile forms an outer layer of the sheet, or wherein the textile forms an inner layer of the sheet.

[0241] According to Aspect 166, the present disclosure relates to the method of Aspect 164 or 165, wherein the textile is a spacer textile having a first textile face, a second textile face, and a textile thickness extending from the first textile face to the second textile face, wherein the textile thickness is from about 0.3 centimeters to about 3 centimeters or from about 0.5 centimeters to about 1 centimeter, optionally wherein a fiber density of the first textile face and the second textile face is at least 25% greater, or at least 50% greater, or at least 75% greater than a fiber density between the first textile face and the second textile face.

[0242] According to Aspect 167, the present disclosure relates to the method of any of Aspects 163-166, wherein the fibers or yarns of the textile comprise or consist essentially of synthetic fibers or yarns formed from one or more thermoplastic materials, optionally wherein the thermoplastic material of the synthetic fibers or yarns comprises or consists essentially of a thermoplastic elastomeric material.

[0243] According to Aspect 168, the present disclosure relates to the method of Aspect 167, wherein the article comprises a layered sheet, and the polymeric component of the thermoplastic material of the synthetic fibers or yarns is substantially the same as the polymeric component of the thermoplastic material of one or more layers of the layered sheet, optionally wherein the polymeric component of the thermoplastic material of the synthetic fibers or yarns is substantially the same as the polymeric component of the thermoplastic material of a cap layer or a structural layer of the layered sheet.

[0244] According to aspect 169, the present disclosure relates to the method of aspect 167 or 168, wherein the thermoplastic material of the synthetic fiber or yarn is the solid foamable material of any of aspects 1, 5, 9-36, 68-69, or 92-101, optionally wherein the solid foamable material is the recycled material of any of aspects 54-67.

[0245] According to aspect 170, the present disclosure relates to a method of manufacturing an article, the method comprising:

[0246] attaching a first component to a second component, wherein the first component is a foamed article manufactured by the method of any of aspects 1-169.

[0247] According to aspect 171, the present disclosure relates to the method of aspect 170, wherein the first component is a first component of an apparel article, the second component is a second component of the apparel article, and the article is an apparel article.

[0248] According to aspect 172, the present disclosure relates to the method of aspect 170, wherein the first component is a first component of an article of footwear, the second component is a second component of the article of footwear, and the article is an article of footwear.

[0249] According to aspect 173, the present disclosure relates to the method of aspect 172, wherein the first component is a cushioning element, and the second component is a sole component or an upper component.

[0250] According to aspect 174, the present disclosure relates to the method of aspect 170, wherein the first component is a first component of an article of sports equipment, the second component is a second component of the article of sports equipment, and the article is an article of sports equipment.

[0251] According to aspect 175, the present disclosure relates to a foamed article manufactured by the method of any of aspects 1-174.

[0252] According to aspect 176, the present disclosure relates to the method of any of aspects 37-129, wherein the article comprises a first sheet and a second sheet, wherein a first side of the first sheet faces a second side of the second sheet, and wherein the first sheet and the second sheet are joined together to form an internal cavity in a space between the first side of the first sheet and the second side of the second sheet, wherein the joint extends around at least a portion of a perimeter of the internal cavity, optionally wherein the joint abuts only one or more portions of the perimeter of the internal cavity and comprises one or more apertures that can allow fluid to enter the internal cavity, forming an open cavity; or wherein the joint abuts the entire perimeter of the internal cavity, forming a sealed pouch that can hold fluid in the internal cavity at a pressure higher or lower than atmospheric pressure.

[0253] According to Aspect 177, the present disclosure relates to the method of Aspect 176, wherein during the step of maintaining and retaining, the carbon dioxide enters the open cavity and infuses into the solid foamable material in contact or bonded with the first side of the first sheet or the second side of the second sheet or both; and during the step of experiencing and expanding, the solid foamable material in contact or bonded with the first side or the second side or both expands and foams into a foamed material.

[0254] According to Aspect 178, the present disclosure relates to the method of Aspect 176 or 177, wherein the open cavity comprises more than one fiber, more than one yarn, more than one particle, or any combination thereof, and the more than one fiber, more than one yarn, more than one particle, or any combination thereof comprises or consists essentially of the solid foamable material in contact or bonded with the first side or the second side or both.

[0255] According to Aspect 179, the present disclosure relates to the method of Aspect 176, wherein the article comprises one or more internal cavities, optionally wherein the one or more internal cavities comprises at least two internal cavities, and optionally wherein each of the one or more internal cavities is an open cavity, or each of the one or more internal cavities is a sealed pocket, or the one or more internal cavities comprises at least one open cavity and at least one sealed pocket.

[0256] According to Aspect 180, the present disclosure relates to the method of Aspect 176, wherein the first sheet and the second sheet are adhesively bonded or are thermally bonded, optionally wherein the first sheet and the second sheet comprise a thermal bond formed by radio frequency (RF) welding.

[0257] According to Aspect 181, the present disclosure relates to the method of any one of Aspects 176-180, wherein the article comprises one or more sealed pockets, and during the step of maintaining and retaining, the bond around the entire perimeter of the internal cavity prevents the carbon dioxide from flowing into the internal cavity of the sealed pocket, optionally wherein the first sheet and the second sheet comprise one or more barrier layers comprising or consisting essentially of a barrier material, and the one or more layers of barrier material prevent the infusion of carbon dioxide into the first sheet and the second sheet at a depth greater than a depth of the one or more barrier layers, wherein the depth is determined from an outer surface of the sheet.

[0258] According to aspect 182, the present disclosure relates to the method of any one of aspects 181, wherein the first side of the first sheet and the second side of the second sheet remain unfoamed within the sealed pocket during the step of subjecting and expanding, optionally wherein one or more layers of the first sheet or the second sheet or both are foamed during the step of subjecting and expanding, optionally wherein the one or more foamed layers are positioned in the first sheet and the second sheet at a depth that is less than a depth of the one or more barrier layers.

[0259] According to aspect 183, the present disclosure relates to the method of any one of aspects 176-182, wherein the article comprises one or more open cavities, and during the maintaining and retaining, carbon dioxide enters the one or more open cavities, optionally wherein the carbon dioxide is infused into the material forming the first side of the first sheet or the material forming the second side of the second sheet or both.

[0260] According to aspect 184, the present disclosure relates to the method of aspect 183, wherein during the step of subjecting and expanding, the material within the one or more open cavities that is infused with carbon dioxide expands and foams, forming a foamed material, optionally wherein one or more additional layers of the first sheet or the second sheet or both are foamed during the step of subjecting and expanding.

[0261] According to aspect 185, the present disclosure relates to the method of any one of aspects 176-184, wherein the article comprises an initial geometry or topography prior to foaming, and wherein the foamed article substantially retains the initial geometry or topography, but at least a portion of the foamed article has expanded in one or more of width, length, and height as compared to the article prior to the step of placing.

[0262] According to aspect 186, the present disclosure relates to the method of any one of aspects 176-185, further comprising a step of closing one or more apertures in the perimeter of the internal cavity, thereby forming a sealed pocket, optionally wherein the step of closing comprises forming an adhesive or thermal bond between the first side of the first sheet and the second side of the second sheet.

[0263] According to aspect 187, the present disclosure relates to the method of any one of aspects 176-186, further comprising a step of infusing the sealed pocket with a fluid.

[0264] According to aspect 188, the present disclosure relates to the method of aspect 187, wherein the step of infusing occurs prior to the step of placing, or after the step of subjecting and expanding.

[0265] According to aspect 189, the present disclosure relates to the method of aspect 187, wherein the method comprises a step of reaching, and the step of infusing occurs after the step of reaching.

[0266] According to Aspect 190, the present disclosure relates to the method of any one of aspects 187-189, wherein the method comprises a step of stabilizing and the step of charging occurs after the step of stabilizing.

[0267] According to Aspect 191, the present disclosure relates to the method of any one of aspects 187-190, wherein the fluid comprises nitrogen or air.

[0268] According to Aspect 192, the present disclosure relates to the method of any one of aspects 187-191, wherein the sealed bladder comprises an initial internal pressure from about 20 pounds per square inch (137.9 kiloPascals) to about 22 pounds per square inch (151.7 kiloPascals) at the time of charging.

[0269] According to Aspect 193, the present disclosure relates to the method of aspect 192, wherein after 2 years of use, the sealed bladder comprises an internal pressure of at least about 70% to about 80% of the initial internal pressure.

[0270] According to Aspect 194, the present disclosure relates to a component made by the method of any one of aspects 187-193, wherein the component is an open cell or a sealed bladder.

[0271] According to Aspect 195, the present disclosure relates to the component of aspect 194, wherein the sealed bladder has a nitrogen transmission rate of less than about 10 cubic centimeters per square meter per atmosphere per day, optionally less than about 3 cubic centimeters per square meter per atmosphere per day, or optionally less than about 2 cubic centimeters per square meter per atmosphere per day.

[0272] According to Aspect 196, the present disclosure relates to the component of aspect 194 or 195, wherein the sealed bladder is a cushioning element for an apparel item, an article of footwear, or an article of sports equipment.

[0273] According to Aspect 197, the present disclosure relates to the sealed bladder of aspect 196, wherein the cushioning element is a cushioning element for an article of footwear, optionally wherein the cushioning element is a midsole or a component of a midsole for an article of footwear.

[0274] According to Aspect 198, the present disclosure relates to an apparel item comprising the bladder of any one of aspects 194-197.

[0275] According to Aspect 199, the present disclosure relates to an article of footwear comprising the bladder of any one of aspects 194-197.

[0276] According to Aspect 200, the present disclosure relates to an article of sports equipment comprising the bladder of any one of aspects 194-197.

[0277] According to aspect 201, the present disclosure relates to a foamed article comprising:

[0278] a foamed material that is a physically expanded foam formed from a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers.

[0279] According to aspect 202, the present disclosure relates to the foamed article of aspect 201, wherein the foamed material is the product of placing an unfoamed article comprising a solid foamable material in liquid carbon dioxide, infusing the solid foamable material with the liquid carbon dioxide, and expanding the infused solid foamable material by phase changing the infused carbon dioxide into a gas under conditions that do not soften the solid foamable material, thereby forming the foamed material of the foamed article.

[0280] According to aspect 203, the present disclosure relates to the foamed article of aspect 201 or 202, wherein the foamed article is a stabilized foamed article comprising a stabilized foamed material, wherein the stabilized foamed material is free of infused carbon dioxide or substantially free of infused carbon dioxide.

[0281] According to aspect 204, the present disclosure relates to the foamed article of any one of aspects 201-203, wherein the liquid carbon dioxide is soluble in the foamed material, or the solid foamable material, or both, at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, at a first pressure of from about 0.05 pounds per square inch (0.345 kiloPascals) to about 6000 pounds per square inch (41,300 kiloPascals) and a first temperature of from about -57 degrees Celsius to about 31 degrees Celsius.

[0282] According to aspect 205, the present disclosure relates to the foamed article of any one of aspects 201-204, wherein the foamed material of the foamed article is substantially opaque.

[0283] According to aspect 206, the present disclosure relates to the foamed article of any one of aspects 201-205, wherein the foamed material has a split-tear value of from about 2.5 kilograms per centimeter to about 3.0 kilograms per centimeter.

[0284] According to aspect 207, the present disclosure relates to the foamed article of any one of aspects 201-206, wherein the foamed material has an Asker C hardness of from about 10 to about 50.

[0285] According to Aspect 208, the present disclosure relates to the foamed article of any one of Aspects 201-207, wherein the thermoplastic elastomer material comprises a polymer component comprising all polymers present in the thermoplastic elastomer material, and the polymer component consists of one or more first thermoplastic elastomers.

[0286] According to Aspect 209, the present disclosure relates to the foamed article of any one of Aspects 201-208, wherein the one or more first thermoplastic elastomers comprise one or more thermoplastic elastomer polyolefin homopolymers or copolymers, one or more thermoplastic elastomer polyamide homopolymers or copolymers, one or more thermoplastic elastomer polyester homopolymers or copolymers, one or more thermoplastic elastomer polyurethane homopolymers or copolymers, one or more thermoplastic elastomer styrene homopolymers or copolymers, or any combination thereof.

[0287] According to Aspect 210, the present disclosure relates to the foamed article of any one of Aspects 201-209, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more thermoplastic elastomer polyamide homopolymers or copolymers.

[0288] According to Aspect 211, the present disclosure relates to the foamed article of any one of Aspects 201-210, wherein the one or more first thermoplastic elastomers comprise or consist essentially of a polyether block polyamide (PEBA) copolymer elastomer.

[0289] According to Aspect 212, the present disclosure relates to the foamed article of any one of Aspects 201-211, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more thermoplastic elastomer styrene homopolymers or copolymers.

[0290] According to Aspect 213, the present disclosure relates to the foamed article of any one of Aspects 201-212, wherein the one or more first thermoplastic elastomers comprise or consist essentially of a styrene butadiene styrene (SBS) block copolymer elastomer, a styrene ethylene butylene styrene (SEBS) copolymer elastomer, a styrene acrylonitrile (SAN) copolymer elastomer, or any combination thereof.

[0291] According to Aspect 214, the present disclosure relates to the foamed article of any one of Aspects 201-213, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more thermoplastic polyurethane elastomer homopolymers or copolymers.

[0292] According to aspect 215, the present disclosure relates to the foamed article of any one of aspects 201-214, wherein the one or more first thermoplastic elastomers comprise or consist essentially of a thermoplastic polyester-polyurethane elastomer, a polyether-polyurethane elastomer, a polycarbonate-polyurethane elastomer, or any combination thereof.

[0293] According to aspect 216, the present disclosure relates to the foamed article of any one of aspects 201-215, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more thermoplastic polyester-polyurethane elastomers.

[0294] According to aspect 217, the present disclosure relates to the foamed article of any one of aspects 201-216, wherein the polymeric component of the thermoplastic elastomer material consists of one or more thermoplastic polyester-polyurethane elastomers.

[0295] According to aspect 218, the present disclosure relates to the foamed article of any one of aspects 201-217, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more thermoplastic polyolefin elastomer homopolymers or copolymers.

[0296] According to aspect 219, the present disclosure relates to the foamed article of any one of aspects 201-218, wherein the one or more first thermoplastic elastomers comprise or consist essentially of a thermoplastic elastomer polypropylene homopolymer or copolymer, a thermoplastic elastomer polyethylene homopolymer or copolymer, a thermoplastic elastomer polybutylene homopolymer or copolymer, or any combination thereof.

[0297] According to aspect 220, the present disclosure relates to the foamed article of any one of aspects 201-219, wherein the one or more first thermoplastic elastomers comprise or consist essentially of a thermoplastic elastomer ethylene-vinyl acetate copolymer.

[0298] According to aspect 221, the present disclosure relates to the foamed article of aspect 220, wherein the thermoplastic elastomer ethylene-vinyl acetate copolymer comprises a vinyl acetate content of from about 25 weight percent to about 50 weight percent.

[0299] According to aspect 222, the present disclosure relates to the foamed article of any one of aspects 201-221, wherein the thermoplastic elastomer material comprises a blend of a polymeric component and a non-polymeric component consisting of one or more non-polymeric additives, optionally wherein the foamable material comprises from about 0.005% to about 20% by weight of the non-polymeric component based on the total weight of the foamable material, or from about 0.5% to about 10% by weight of the non-polymeric additive based on the total weight of the foamable material.

[0300] According to aspect 223, the present disclosure relates to the foamed article of any one of aspects 201-222, wherein the one or more first thermoplastic elastomers comprise or consist essentially of one or more recycled first thermoplastic elastomers.

[0301] According to aspect 224, the present disclosure relates to the foamed article of any one of aspects 201-223, wherein the thermoplastic elastomer material comprises or consists essentially of a blend of one or more first thermoplastic elastomers and a second material, optionally wherein the second material comprises or consists essentially of one or more second polymers, optionally wherein the one or more second polymers comprise or consist essentially of one or more second thermoplastics.

[0302] According to aspect 225, the present disclosure relates to the foamed article of aspect 224, wherein the polymeric component of the thermoplastic elastomer material consists of a blend of one or more first thermoplastic elastomers and one or more second thermoplastics.

[0303] According to aspect 226, the present disclosure relates to the foamed article of aspect 224 or 225, wherein the one or more second thermoplastics comprise or consist essentially of one or more thermoplastic polyolefin homopolymers or copolymers, one or more thermoplastic polyamide homopolymers or copolymers, one or more thermoplastic polyester homopolymers or copolymers, one or more thermoplastic polyurethane homopolymers or copolymers, one or more thermoplastic styrene homopolymers or copolymers, or any combination thereof.

[0304] According to aspect 227, the present disclosure relates to the foamed article of any one of aspects 224-226, wherein the one or more second thermoplastics comprise or consist essentially of a thermoplastic polypropylene homopolymer or copolymer, a thermoplastic polyethylene homopolymer or copolymer, a thermoplastic polybutylene homopolymer or copolymer, or any combination thereof.

[0305] According to Aspect 228, the present disclosure relates to the foamed article of any one of Aspects 224-227, wherein the one or more second thermoplastics comprises or consists essentially of one or more thermoplastic polyethylene copolymers.

[0306] According to Aspect 229, the present disclosure relates to the foamed article of any one of Aspects 224-228, wherein the one or more second thermoplastics comprises or consists essentially of one or more thermoplastic ethylene-vinyl alcohol copolymers.

[0307] According to Aspect 230, the present disclosure relates to the foamed article of any one of Aspects 224-229, wherein the polymeric component of the thermoplastic elastomer material consists of one or more first thermoplastic elastomer polyurethane homopolymers or copolymers and one or more second thermoplastic ethylene-vinyl alcohol copolymers.

[0308] According to Aspect 231, the present disclosure relates to the foamed article of any one of Aspects 224-230, wherein the polymeric component of the thermoplastic elastomer material consists of one or more first thermoplastic elastomer polyester-polyurethane copolymers and one or more second thermoplastic ethylene-vinyl alcohol copolymers.

[0309] According to Aspect 232, the present disclosure relates to the foamed article of any one of Aspects 224-231, wherein the blend comprises one or more recycled first thermoplastic elastomers, or one or more recycled second thermoplastics, or both.

[0310] According to Aspect 233, the present disclosure relates to the foamed article of any one of Aspects 224-232, wherein the blend is a phase-separated blend of the one or more first thermoplastic elastomers and the one or more second thermoplastics.

[0311] According to Aspect 234, the present disclosure relates to the foamed article of Aspect 233, wherein the phase-separated blend comprises one or more phase-separated regions comprising an interface between the one or more first thermoplastic elastomers and the one or more second thermoplastics.

[0312] According to Aspect 235, the present disclosure relates to the foamed article of any one of Aspects 224-234, wherein the blend comprises about 95% by weight of the one or more first thermoplastic elastomers and about 5% by weight of the one or more second thermoplastics, based on the total weight of the blend.

[0313] According to Aspect 236, the present disclosure relates to the foamed article of any one of Aspects 224-235, wherein liquid carbon dioxide is soluble in the one or more first thermoplastic elastomers at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, based on the total weight of the one or more first thermoplastic elastomers present in the thermoplastic elastomeric material, and wherein liquid carbon dioxide is soluble in the one or more second thermoplastic plastics at a concentration of less than 1 weight percent, optionally less than 0.1 weight percent, based on the total weight of the one or more second thermoplastic plastics present in the thermoplastic elastomeric material, or optionally wherein liquid carbon dioxide is substantially insoluble in the one or more second thermoplastic plastics at a first pressure of from about 0.05 pounds per square inch (0.345 kiloPascals) to about 6000 pounds per square inch (41,300 kiloPascals) and a first temperature of from about -57 degrees Celsius to about 31 degrees Celsius.

[0314] According to Aspect 237, the present disclosure relates to the foamed article of any one of Aspects 201-236, wherein the foamed article comprises an additional material, wherein the additional material is a material separate from the foamed material, wherein the additional material comprises or consists essentially of one or more polymers and comprises an additional material polymer component consisting of all polymers present in the additional material; optionally wherein the additional material comprises or consists essentially of a second material, optionally wherein the second material is a thermoplastic material, optionally wherein the additional material comprises an additional material polymer component mixed with an additional material non-polymer component consisting of all non-polymer components present in the additional material.

[0315] According to Aspect 238, the present disclosure relates to the foamed article of any one of Aspects 201-237, wherein the foamed article comprises one or more first portions of foamed material and one or more second portions of additional material, and wherein the one or more first portions are different from the one or more second portions.

[0316] According to Aspect 239, the present disclosure relates to the foamed article of Aspect 237 or 238, wherein the additional material comprises a barrier material comprising one or more barrier polymers, the barrier material comprising a barrier polymer component consisting of all polymers present in the barrier material.

[0317] According to Aspect 240, the present disclosure relates to the foamed article of any one of Aspects 237-239, wherein the additional material comprises a plasticizer.

[0318] According to Aspect 241, the present disclosure relates to the foamed article of Aspect 239 or 240, wherein in the foamed article the additional material is substantially unfoamed.

[0319] According to Aspect 242, the present disclosure relates to the foamed article of any of Aspects 239-241, wherein the barrier material has a hardness that is at least 10 Shore A units greater than the thermoplastic elastomer material in solid form, or optionally at least 20 Shore A units greater, or at least 30 Shore A units greater, or at least 40 Shore A units greater than the thermoplastic elastomer material in solid form.

[0320] According to Aspect 243, the present disclosure relates to the foamed article of any of Aspects 239-242, wherein the barrier material has a nitrogen gas transmission rate that is at least 50% lower than the nitrogen gas transmission rate of the thermoplastic elastomer material in solid form, optionally less than or equal to 10 cubic centimeters per square meter per 24 hours, or less than or equal to 1 cubic centimeter per square meter per 24 hours.

[0321] According to Aspect 244, the present disclosure relates to the foamed article of any of Aspects 239-243, wherein the barrier polymer component of the barrier material consists of one or more barrier polymers, each individually having a nitrogen gas transmission rate of less than or equal to 30 cubic centimeters per square meter per 24 hours, or less than or equal to 10 cubic centimeters per square meter per 24 hours, or less than or equal to 1 cubic centimeter per square meter per 24 hours.

[0322] According to Aspect 245, the present disclosure relates to the foamed article of any of Aspects 239-244, wherein the one or more barrier polymers comprise or consist essentially of one or more vinylidene chloride polymers, one or more acrylonitrile polymers or copolymers, one or more polyamides, one or more epoxy resins, one or more amine polymers or copolymers, or one or more thermoplastic polyolefin homopolymers or copolymers, optionally wherein the one or more thermoplastic polyolefin homopolymers or copolymers comprise or consist essentially of one or more thermoplastic polyethylene copolymers, one or more thermoplastic ethylene-vinyl alcohol copolymers, or one or more thermoplastic elastomeric ethylene-vinyl alcohol copolymers.

[0323] According to Aspect 246, the present disclosure relates to the foamed article of any one of Aspects 239-245, wherein liquid carbon dioxide is soluble in the thermoplastic elastomeric material at a first concentration, liquid carbon dioxide is soluble in the barrier material at a second concentration, and the first concentration is at least 20% greater than the second concentration, optionally wherein the first concentration is at least 50% greater than the second concentration, or at least 70% greater than the second concentration, at a first pressure from about 0.05 pounds per square inch (0.345 kiloPascals) to about 6000 pounds per square inch (41,300 kiloPascals) and a first temperature from about -57 degrees Celsius to about 31 degrees Celsius.

[0324] According to Aspect 247, the present disclosure relates to the foamed article of Aspect 246, wherein the second concentration is less than 1 weight percent, optionally less than 0.1 weight percent, or optionally wherein liquid carbon dioxide is substantially insoluble in the barrier material at a first pressure from about 0.05 pounds per square inch (0.345 kiloPascals) to about 6000 pounds per square inch (41,300 kiloPascals) and a first temperature from about -57 degrees Celsius to about 31 degrees Celsius.

[0325] According to Aspect 248, the present disclosure relates to the foamed article of any one of Aspects 239-247, wherein the barrier material comprises one or more ethylene-vinyl alcohol copolymers, optionally wherein the one or more ethylene-vinyl alcohol copolymers are thermoplastic, optionally wherein the one or more ethylene-vinyl alcohol thermoplastic copolymers comprise one or more thermoplastic elastomeric copolymers; optionally wherein the barrier polymer component consists of one or more ethylene-vinyl alcohol copolymers, optionally wherein the one or more ethylene-vinyl alcohol copolymers are thermoplastic, optionally wherein the one or more ethylene-vinyl alcohol thermoplastic copolymers comprise one or more thermoplastic elastomeric copolymers.

[0326] According to Aspect 249, the present disclosure relates to the foamed article of any one of Aspects 240-248, wherein the additional material is a thermoplastic material, optionally wherein the additional material is an additional thermoplastic elastomeric material.

[0327] According to Aspect 250, the present disclosure relates to the foamed article of any one of Aspects 240-248, wherein the foamed article comprises a foamed material, wherein the foamed material is a first foamed material, and the foamed article further comprises a second foamed material, wherein the second foamed material comprises or consists essentially of the additional material.

[0328] According to Aspect 251, the present disclosure relates to the foamed article of Aspect 250, wherein the density of the first foamed material differs from the density of the second foamed material by at least 5%, at least 10%, or at least 20% in the foamed article.

[0329] According to aspect 252, the present disclosure relates to the foamed article of any one of aspects 250 or 251, wherein the second foamed material is a second physically expanded foam.

[0330] According to aspect 253, the present disclosure relates to the foamed article of any one of aspects 250-252, wherein the second physically expanded foam is the product of placing an unfoamed article comprising a solid additional material in liquid carbon dioxide, infusing the solid additional material with the liquid carbon dioxide, and expanding the infused solid additional material by phase changing the infused carbon dioxide into a gas under conditions that do not soften the solid additional material, thereby forming a foamed additional material of the foamed article.

[0331] According to aspect 254, the present disclosure relates to the foamed article of any one of aspects 240-253, wherein the additional material is a recycled material comprising one or more recycled polymers, optionally wherein the one or more recycled polymers comprises one or more recycled thermoplastics, optionally wherein the one or more recycled thermoplastics comprises one or more recycled thermoplastic elastomers; optionally wherein the recycled material comprises a recycled material polymer component consisting of one or more recycled thermoplastics, optionally wherein the recycled material polymer component consists of one or more recycled thermoplastic elastomers.

[0332] According to aspect 255, the present disclosure relates to the foamed article of aspect 254, wherein the recycled material comprises one or more recycled first thermoplastic elastomers, optionally wherein the one or more recycled first thermoplastic elastomers comprises one or more regrind first thermoplastic elastomers, optionally wherein the one or more recycled first thermoplastic elastomers or regrind first thermoplastic elastomers comprises a thermoplastic elastomer according to any one of aspects 201-254.

[0333] According to aspect 256, the present disclosure relates to the foamed article of aspect 254 or 255, wherein the recycled material further comprises one or more recycled second thermoplastics, optionally wherein the one or more recycled second thermoplastics comprises one or more regrind second thermoplastics, optionally wherein the one or more recycled second thermoplastics or regrind second thermoplastics comprises a thermoplastic according to any one of aspects 201-255.

[0334] According to Aspect 257, the present disclosure relates to the foamed article of Aspect 256, wherein the recycled material comprises one or more recycled thermoplastic polyurethane elastomers or regrind thermoplastic polyurethane elastomers, one or more recycled thermoplastic ethylene-vinyl alcohol copolymers or regrind thermoplastic ethylene-vinyl alcohol copolymers, or both.

[0335] According to Aspect 258, the present disclosure relates to the foamed article of Aspect 256 or 257, wherein the recycled material comprises a blend of one or more recycled thermoplastic elastomers or regrind thermoplastic elastomers and one or more second thermoplastics, or wherein the recycled material comprises a blend of one or more thermoplastic elastomers and one or more recycled thermoplastics or one or more recycled second thermoplastics, optionally wherein the blend is a phase-separated blend, and optionally wherein the phase-separated blend comprises one or more interfaces between the one or more first thermoplastic elastomers and the one or more second thermoplastics.

[0336] According to Aspect 259, the present disclosure relates to the foamed article of any one of Aspects 256-258, wherein the recycled material comprises from about 99% to about 90% by weight of the one or more first thermoplastic elastomers and from about 1% to about 10% by weight of the second thermoplastic, based on the total weight of the recycled material, optionally wherein the recycled material comprises from about 99% to about 93% by weight of the one or more first thermoplastic elastomers and from about 1% to about 7% by weight of the one or more second thermoplastics, or from about 99% to about 95% by weight of the one or more first thermoplastic elastomers and from about 1% to about 5% by weight of the one or more second thermoplastics.

[0337] According to Aspect 260, the present disclosure relates to the foamed article of any one of Aspects 254-259, wherein the recycled material comprises from about 99% to about 50% by weight of the recycled or regrind polymer, based on the total weight of the recycled material, optionally from about 99% to about 75% by weight of the recycled or regrind polymer.

[0338] According to Aspect 261, the present disclosure relates to the foamed article of any one of Aspects 254-258, wherein liquid carbon dioxide is soluble in the recycled material at a concentration of from about 1% to about 30% by weight, optionally from about 5% to about 20% by weight, based on the total weight of the recycled material, at a first pressure of from about 0.05 pounds per square inch (0.345 kilopascals) to about 6000 pounds per square inch (41,300 kilopascals) and a first temperature of from about -57 degrees Celsius to about 31 degrees Celsius.

[0339] According to aspect 262, the present disclosure relates to the foamed article of any one of aspects 254-261, wherein liquid carbon dioxide is soluble in the one or more recycled thermoplastic elastomers or regrind thermoplastic elastomers at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, based on the total weight of the one or more recycled thermoplastic elastomers or regrind thermoplastic elastomers at a first pressure of from about 0.05 pounds per square inch (0.345 kiloPascals) to about 6000 pounds per square inch (41,300 kiloPascals) and a first temperature of from about -57 degrees Celsius to about 31 degrees Celsius.

[0340] According to aspect 263, the present disclosure relates to the foamed article of any one of aspects 254-262, wherein liquid carbon dioxide is soluble in the one or more recycled second thermoplastic or regrind second thermoplastic at less than 1 weight percent, optionally less than 0.1 weight percent, based on the total weight of the one or more recycled second thermoplastic or regrind second thermoplastic, or optionally wherein liquid carbon dioxide is substantially insoluble in the one or more recycled second thermoplastic or regrind second thermoplastic at a first pressure of from about 0.05 pounds per square inch (0.345 kiloPascals) to about 6000 pounds per square inch (41,300 kiloPascals) and a first temperature of from about -57 degrees Celsius to about 31 degrees Celsius.

[0341] According to aspect 264, the present disclosure relates to the foamed article of any one of aspects 254-263, wherein the recycled material comprises a recycled foamed article, optionally wherein the recycled foamed article is a regrind foamed article, optionally wherein the recycled foamed article is the foamed article of any one of aspects 201-263.

[0342] According to aspect 265, the present disclosure relates to the foamed article of any one of aspects 254-263, wherein the recycled material comprises a solid material, wherein the solid material is a thermoplastic elastomer material.

[0343] According to aspect 266, the present disclosure relates to the foamed article of any one of aspects 254-265, wherein the recycled material further comprises one or more virgin first thermoplastic elastomer, optionally wherein the one or more virgin first thermoplastic elastomer comprises one or more virgin thermoplastic polyurethane elastomer.

[0344] According to aspect 267, the present disclosure relates to the foamed article of any one of aspects 258-266, wherein the recycled material comprises one or more nucleating agents or one or more interfaces between phase-separated polymers.

[0345] According to Aspect 268, the present disclosure relates to the foamed article of any one of Aspects 254-267, wherein the thermoplastic elastomer material is a recycled material, or comprises a recycled material, or consists essentially of a recycled material.

[0346] According to Aspect 269, the present disclosure relates to the foamed article of any one of Aspects 254-268, wherein the foamed material is a first foamed material, the foamed article comprises a second foamed material, the second foamed material is a further material, and the thermoplastic elastomer material of the first foamed material is a recycled material, or the further material of the second foamed material is a recycled material, or both the thermoplastic elastomer material and the further material are recycled materials.

[0347] According to Aspect 270, the present disclosure relates to the foamed article of any one of Aspects 254-269, wherein the foamed article comprises a barrier layer or a barrier region, and the barrier layer or the barrier region comprises or consists essentially of a barrier material.

[0348] According to Aspect 271, the present disclosure relates to the foamed article of Aspect 270, wherein the barrier material is the further material of any one of Aspects 237-267.

[0349] According to Aspect 272, the present disclosure relates to the foamed article of any one of Aspects 201-271, wherein the foamed article comprises a structural layer or a structural region, and the structural layer or the structural region comprises or consists essentially of a structural material.

[0350] According to Aspect 273, the present disclosure relates to the foamed article of Aspect 272, wherein the structural material is the further material of any one of Aspects 237-267, optionally wherein the structural material comprises a blend of two or more further materials, optionally wherein at least one of the two or more further materials is a recycled material.

[0351] According to Aspect 274, the present disclosure relates to the foamed article of any one of Aspects 201-273, wherein the foamed article comprises one or more connecting layers or connecting regions, each of the one or more connecting layers or connecting regions individually comprises or consists essentially of a connecting material, wherein each of the one or more connecting layers or connecting regions increases a bonding strength between two adjacent layers or adjacent regions, optionally wherein the connecting material is the thermoplastic elastomer material of any one of Aspects 201-273, optionally wherein the thermoplastic elastomer material is a recycled material.

[0352] According to aspect 275, the present disclosure relates to the foamed article of any one of aspects 201-274, wherein the foamed article comprises one or more protective layers, each of the one or more protective layers individually comprising or consisting essentially of a protective material, wherein each of the one or more protective layers is adjacent to the core layer and has a protective layer thickness, wherein the combination of the one or more protective layers and the adjacent core layer has a minimum radius of curvature that is greater than a minimum radius of curvature that causes cracking of the core layer or causes cracking of one or more individual layers within the core layer, optionally wherein the protective material is the solid foamable material of any one of aspects 201-273, optionally wherein the solid foamable material is a recycled material.

[0353] According to aspect 276, the present disclosure relates to the foamed article of any one of aspects 201-275, wherein the foamed material has a density from about 0.01 grams per cubic centimeter to about 3.0 grams per cubic centimeter, optionally wherein the foamed material is a stabilized foamed material having a density from about 0.01 grams per cubic centimeter to about 3.0 grams per cubic centimeter.

[0354] According to aspect 277, the present disclosure relates to the foamed article of any one of aspects 201-276, wherein the foamed material has a volume that is less than 10% greater, optionally less than 5% greater, than the foamable material prior to foaming, optionally wherein the foamed article is a stabilized foamed article.

[0355] According to aspect 278, the present disclosure relates to the foamed article of any one of aspects 201-276, wherein the foamed material has a volume that is more than 20% greater, optionally more than 30% greater, or more than 40% greater, than the foamable material prior to foaming, optionally wherein the foamed article is a stabilized foamed article.

[0356] According to aspect 279, the present disclosure relates to the foamed article of any one of aspects 201-278, wherein the foamed material has a Shore A hardness from about 35 A to about 95 A, optionally from about 55 A to about 90 A.

[0357] According to aspect 280, the present disclosure relates to the foamed article of any one of aspects 201-279, wherein the foamed article is configured as a roll, the roll optionally comprising a spacer or protective layer between adjacent portions of the foamed article.

[0358] According to aspect 281, the present disclosure relates to the foamed article of any one of aspects 201-280, wherein the article is a layered sheet comprising one or more foamed layers.

[0359] According to Aspect 282, the present disclosure relates to the foamed article of any of Aspects 201-281, wherein the foamed article comprises a layered structure comprising a series of three or more layers, the layered structure comprising:

[0360] a first cap layer comprising or consisting essentially of a first cap layer material, the first cap layer comprising a first cap layer outer surface defining a first outer surface of the layered structure, a first cap layer inner surface opposite the first cap layer outer surface, a first cap layer thickness extending from the first cap layer inner surface to the first cap layer outer surface, wherein the first cap layer outer surface defines a first outer surface of the article;

[0361] a second cap layer comprising or consisting essentially of a second cap layer material, the second cap layer comprising a second cap layer outer surface defining a second outer surface of the layered structure, a second cap layer inner surface opposite the second cap layer outer surface, a second cap layer thickness extending from the second cap layer inner surface to the second cap layer outer surface, optionally wherein the second cap layer outer surface defines a second outer surface of the article; and

[0362] one or more core layers, wherein each of the one or more core layers comprises or consists essentially of a core layer material, each of the one or more core layers comprising a core layer first surface, a core layer second surface, and a core layer thickness extending from the core layer first surface to the core layer second surface, wherein each of the one or more core layers is positioned between the first cap layer inner surface and the second cap layer inner surface;

[0363] wherein at least one of the three or more layers of the article comprises or consists essentially of a solid material, and another of the three or more layers of the article comprises or consists essentially of a foamed material.

[0364] According to Aspect 283, the present disclosure relates to the foamed article of Aspect 282, wherein at least one of the first cap layer material or the second cap layer material comprises a foamed material, or both the first cap layer material and the second cap layer material comprise a foamed material, and the core layer material of at least one of the one or more core layers comprises a barrier material, optionally wherein the polymeric components of the first cap layer material and the second cap layer material are substantially the same.

[0365] According to Aspect 284, the present disclosure relates to the foamed article of any of Aspects 282 or 283, wherein at least one of the one or more core layers comprises a plurality of alternating layers, wherein each of the series of alternating layers individually comprises a first alternating layer material or a second alternating layer material, optionally wherein the first alternating layer material and the second alternating layer material individually are a thermoplastic material or a thermoplastic elastomeric material.

[0366] According to aspect 285, the present disclosure relates to the foamed article of any one of aspects 282-284, wherein the first cap layer inner surface is in contact with the core layer first surface, or the second cap layer inner surface is in contact with the core layer second surface, or both.

[0367] According to aspect 286, the present disclosure relates to the foamed article of any one of aspects 282-285, wherein the foamed article is configured to include a series of four or more layers comprising one or more structural layers, each of the one or more structural layers comprising a structural layer material and comprising a structural layer first surface, a structural layer second surface opposite the structural layer first surface, and a structural layer thickness extending from the structural layer first surface to the structural layer second surface;

[0368] optionally wherein at least one of the one or more structural layers is positioned between the first cap layer and the core layer, or is positioned between the second cap layer and the core layer; or

[0369] optionally wherein the one or more structural layers comprises two or more structural layers, and at least a first of the two or more structural layers is positioned between an inner surface of the first cap layer and a first surface of the core layer, and at least a second of the two or more structural layers is positioned between a second surface of the core layer and an inner surface of the second cap layer.

[0370] According to aspect 287, the present disclosure relates to the foamed article of aspect 286, wherein a first surface of a first of the structural layers is in contact with the inner surface of the first cap layer, and a second surface of the first of the structural layers is in contact with a first surface of one of the one or more core layers, or wherein a first surface of a second of the one or more structural layers is in contact with a second surface of one of the one or more core layers, and a second surface of the second of the structural layers is in contact with the inner surface of the second cap layer, or both.

[0371] According to aspect 288, the present disclosure relates to the foamed article of aspect 286 or 287, wherein the structural layer material of at least one of the one or more structural layers comprises or consists essentially of a solid material.

[0372] According to aspect 289, the present disclosure relates to the foamed article of aspect 286 or 287, wherein the structural layer material of at least one of the one or more structural layers comprises or consists essentially of a foamed material.

[0373] According to Aspect 290, the present disclosure relates to the foamed article of any one of Aspects 286-289, wherein the foamed article comprises a first structural layer and a second structural layer, and the structural layer material of at least one of the first structural layer and the second structural layer comprises or consists essentially of a solid material.

[0374] According to Aspect 291, the present disclosure relates to the foamed article of any one of Aspects 286-289, wherein the foamed article comprises a first structural layer and a second structural layer, and the structural layer material of at least one of the first structural layer and the second structural layer comprises or consists essentially of a foamed material.

[0375] According to Aspect 292, the present disclosure relates to the foamed article of any one of Aspects 282-291, wherein the foamed article is configured to comprise a series of five or more layers including one or more connecting layers, each of the one or more connecting layers comprising a connecting layer material and including a connecting layer first surface, a connecting layer second surface opposite the connecting layer first surface, and a connecting layer thickness extending from the connecting layer first surface to the connecting layer second surface;

[0376] optionally wherein at least one of the one or more connecting layers is positioned between one of the one or more structural layers and one of the one or more core layers, or between the first cap layer and one of the one or more structural layers, or between the second cap layer and one of the one or more structural layers, or any combination thereof; or

[0377] optionally wherein the one or more connecting layers comprise two or more connecting layers, and at least a first connecting layer of the two or more connecting layers is positioned between the second surface of the first structural layer and the first layer of the core layer, and at least a second connecting layer of the two or more connecting layers is positioned between the second surface of the core layer and the first surface of the structural layer.

[0378] According to Aspect 293, the present disclosure relates to the foamed article of Aspect 292, wherein a first surface of a first connecting layer of the one or more connecting layers is in contact with a second surface of a first structural layer of the one or more structural layers, and a second surface of the first connecting layer of the one or more connecting layers is in contact with a first surface of the core layer; or wherein a first surface of a second connecting layer of the one or more connecting layers is in contact with a second surface of one of the one or more core layers, and a second surface of the second connecting layer of the one or more connecting layers is in contact with a first surface of a second structural layer of the one or more structural layers, or both.

[0379] According to Aspect 294, the present disclosure relates to the foamed article of any one of Aspects 292 or 293, wherein the tie layer material of at least one of the one or more tie layers comprises or consists essentially of a solid material.

[0380] According to Aspect 295, the present disclosure relates to the foamed article of any one of Aspects 292 or 293, wherein the tie layer material of at least one of the one or more tie layers comprises or consists essentially of a foamed material.

[0381] According to Aspect 296, the present disclosure relates to the foamed article of any one of Aspects 282-295, wherein the layered structure comprises a first cap layer, a first structural layer, a first tie layer, a core layer, a second tie layer, a second structural layer, and a second cap layer, wherein the inner surface of the first cap layer contacts a first surface of the first structural layer, a second surface of the first structural layer contacts a first surface of the first tie layer, a second surface of the first tie layer contacts a first surface of the core layer, a second surface of the core layer contacts a first surface of the second tie layer, a second surface of the second tie layer contacts a first surface of the second structural layer, and a second surface of the second structural layer contacts an inner layer of the second cap layer, optionally wherein the core layer comprises one or more core layers, or comprises more than one microlayer.

[0382] According to Aspect 297, the present disclosure relates to the foamed article of any one of Aspects 282-296, wherein the average thickness of each layer in the series of three or more layers is individually from about 100 micrometers to about 0.5 centimeters or from about 100 micrometers to about 0.1 centimeters.

[0383] According to Aspect 298, the present disclosure relates to the foamed article of any one of Aspects 282-296, wherein each individual layer in the series of three or more layers has an average thickness, and the average thickness of the individual layers comprising a solid material or consisting essentially of a solid material is in the range from about 100 micrometers to about 0.5 centimeters or from about 100 micrometers to about 0.1 centimeters.

[0384] According to Aspect 299, the present disclosure relates to the foamed article of any one of Aspects 282-298, wherein the foamed article is a layered sheet, optionally wherein the layered sheet is a co-extruded layered sheet, or is a laminated layered sheet.

[0385] According to aspect 300, the present disclosure relates to the foamed article of any one of aspects 282-299, wherein at least one layer of the series of three or more layers comprises a plurality of alternating layers, wherein each alternating layer of the series of alternating layers individually comprises either the first alternating layer material or the second alternating layer material, optionally wherein the plurality of alternating layers comprises from about 3 to about 50 individual layers, or from about 3 to about 25 individual layers or from about 3 to about 7 individual layers, and optionally wherein the plurality of alternating layers forms at least one core layer of the one or more core layers of the layered structure.

[0386] According to aspect 301, the present disclosure relates to the foamed article of aspect 300, wherein in the article the first alternating layer material is a thermoplastic material, optionally wherein the thermoplastic material is a thermoplastic elastomer material, optionally wherein the thermoplastic elastomer material is the thermoplastic elastomer material of any one of aspects 9-23 or 208-220.

[0387] According to aspect 302, the present disclosure relates to the foamed article of aspect 301, wherein in the article the first alternating layer material of the plurality of alternating layers is a solid material, optionally wherein the solid material is a solid thermoplastic material, optionally wherein the solid thermoplastic material is a solid thermoplastic elastomer material, optionally wherein the solid thermoplastic elastomer material is the solid thermoplastic elastomer material of any one of aspects 9-23 or 208-220.

[0388] According to aspect 303, the present disclosure relates to the foamed article of any one of aspects 300-302, wherein the second alternating layer material is a thermoplastic material, optionally wherein the thermoplastic material is a further material, optionally wherein the further material is the further material of any one of aspects 37-67 or 237-267, optionally wherein the further material is a barrier material, optionally wherein the barrier material is the barrier material of any one of aspects 39-48, 54-67, 70, 71, or 239-248.

[0389] According to aspect 304, the present disclosure relates to the foamed article of any one of aspects 300-303, wherein the plurality of alternating layers comprises or consists essentially of a plurality of microlayers, and the plurality of microlayers comprises from about 5 to about 1000 microlayers, optionally about 10 to about 1000 microlayers, about 30 to about 500 microlayers, about 50 to about 200 microlayers, or about 20 to about 100 microlayers.

[0390] According to aspect 305, the present disclosure relates to the foamed article of aspect 304, wherein each individual microlayer of the plurality of microlayers has an average thickness of from about 0.01 micrometers to about 2.5 micrometers.

[0391] According to aspect 306, the present disclosure relates to the foamed article of aspect 304 or 305, wherein each layer of the one or more layers comprising a plurality of alternating layers has an average thickness of from about 0.01 micrometers to about 2.5 micrometers or from about 0.1 micrometers to about 1 micrometers.

[0392] According to aspect 307, the present disclosure relates to the foamed article of any of aspects 201-306, wherein the foamed article comprises a textile.

[0393] According to aspect 308, the present disclosure relates to the foamed article of aspect 307, wherein the foamed article is or comprises a sheet, and the textile forms a layer of the sheet.

[0394] According to aspect 309, the present disclosure relates to the foamed article of aspect 308, wherein the textile forms an outer layer of the sheet, or wherein the textile forms an inner layer of the sheet.

[0395] According to aspect 310, the present disclosure relates to the foamed article of aspect 308 or 309, wherein the textile is a spacer textile having a first textile face, a second textile face, and a textile thickness extending from the first textile face to the second textile face, wherein the textile thickness is from about 0.3 centimeters to about 3 centimeters or from about 0.5 centimeters to about 1 centimeter, optionally wherein a fiber density of the first textile face and the second textile face is at least 25% greater, or at least 50% greater, or at least 75% greater than a fiber density between the first textile face and the second textile face.

[0396] According to aspect 311, the present disclosure relates to the foamed article of aspect 308, wherein the article comprises a layered sheet, and the polymeric component of the thermoplastic material of the synthetic fiber or yarn is substantially the same as the polymeric component of the thermoplastic material of one or more layers of the layered sheet, optionally wherein the polymeric component of the thermoplastic material of the synthetic fiber or yarn is substantially the same as the polymeric component of the thermoplastic material of a cover layer or a structural layer of the layered sheet.

[0397] According to aspect 312, the present disclosure relates to the foamed article of aspect 311, wherein the thermoplastic material of the synthetic fiber or yarn is a solid material, optionally wherein the solid material is a recycled material.

[0398] According to aspect 313, the present disclosure relates to the foamed article of aspect 311, wherein the thermoplastic material of the synthetic fiber or yarn is a foamed material, optionally wherein the foamed material comprises or consists essentially of a recycled material.

[0399] According to aspect 314, the present disclosure relates to a method of manufacturing an article, the method comprising:

[0400] attaching a first component to a second component, wherein the first component is a foamed article according to any of aspects 201-313.

[0401] According to aspect 315, the present disclosure relates to a foamed article manufactured by the method of any of aspects 1-192, optionally wherein the foamed article is a foamed article according to any of aspects 201-313.

[0402] According to aspect 316, the present disclosure relates to the foamed article of any of aspects 201-315, wherein the article comprises a first sheet and a second sheet, wherein a first side of the first sheet faces a second side of the second sheet, and wherein the first sheet and the second sheet are joined together to form an internal cavity in a space between the first side of the first sheet and the second side of the second sheet, wherein the joint extends around at least a portion of a perimeter of the internal cavity, optionally wherein the joint abuts only one or more portions of the perimeter of the internal cavity and comprises one or more apertures that can allow fluid to enter the internal cavity, forming an open cavity; or wherein the joint abuts the entire perimeter of the internal cavity, forming a sealed pouch that can hold fluid in the internal cavity at a pressure higher or lower than atmospheric pressure.

[0403] According to aspect 317, the present disclosure relates to the foamed article of aspect 316, wherein the article comprises one or more internal cavities, optionally wherein the one or more internal cavities comprise at least two internal cavities, and optionally wherein each of the one or more internal cavities is an open cavity, or each of the one or more internal cavities is a sealed pouch, or the one or more internal cavities comprises at least one open cavity and at least one sealed pouch.

[0404] According to aspect 318, the present disclosure relates to the foamed article of aspect 316, wherein the first sheet and the second sheet are adhesively joined or are heat joined, optionally wherein the first sheet and the second sheet comprise a heat joint formed by radio frequency (RF) welding.

[0405] According to aspect 319, the present disclosure relates to the foamed article of any of aspects 316-318, wherein the article comprises one or more sealed pouches and at least one layer of the first sheet or the second sheet comprises a foamed material, optionally wherein the first sheet and the second sheet comprise one or more barrier layers comprising or consisting essentially of a barrier material and the depth of the at least one layer comprising a foamed material is less than the depth of the one or more barrier layers, wherein the depth is determined from an outer surface of the sheet.

[0406] According to aspect 320, the present disclosure relates to the foamed article of aspect 319, wherein the first side of the first sheet and the second side of the second sheet comprise or consist essentially of a solid material, optionally wherein one or more layers of the first sheet or the second sheet comprise or consist essentially of a foamed material, optionally wherein the one or more layers comprising or consisting essentially of a foamed material are positioned in the first sheet and the second sheet at a depth that is less than a depth of the one or more barrier layers.

[0407] According to aspect 321, the present disclosure relates to the foamed article of any of aspects 316-320, wherein the foamed article comprises one or more open cavities.

[0408] According to aspect 322, the present disclosure relates to the foamed article of aspect 321, wherein one or more additional layers of the first sheet or the second sheet or both comprise or consist essentially of a foamed material.

[0409] According to aspect 323, the present disclosure relates to the foamed article of any of aspects 316-322, wherein the internal cavity is a sealed bladder, optionally wherein the sealed bladder comprises a fluid, optionally wherein the fluid is a pressurized fluid.

[0410] According to aspect 324, the present disclosure relates to the foamed article of aspect 323, wherein the fluid comprises nitrogen or air.

[0411] According to aspect 325, the present disclosure relates to the foamed article of aspect 323 or 324, wherein the sealed bladder has an initial internal pressure from about 20 pounds per square inch (137.9 kiloPascals) to about 22 pounds per square inch (151.7 kiloPascals).

[0412] According to aspect 326, the present disclosure relates to the foamed article of aspect 325, wherein the sealed bladder has an internal pressure of at least about 70% to about 80% of the initial internal pressure after 2 years of use.

[0413] According to aspect 327, the present disclosure relates to a component comprising the foamed article of any of aspects 323-326, wherein the component is an open cavity or a sealed bladder according to any of aspects 176-193.

[0414] According to aspect 328, the present disclosure relates to the component of aspect 327, wherein the sealed bladder has a nitrogen transmission rate of less than about 10 cubic centimeters per square meter per atmosphere per day, optionally less than about 3 cubic centimeters per square meter per atmosphere per day, or less than about 2 cubic centimeters per square meter per atmosphere per day.

[0415] According to aspect 329, the present disclosure relates to the component of aspect 327 or 328, wherein the sealed bladder is a cushioning element for an apparel item, an article of footwear, or an article of sports equipment.

[0416] According to aspect 330, the present disclosure relates to the sealed bladder of aspect 329, wherein the cushioning element is a cushioning element for an article of footwear, optionally wherein the cushioning element is a midsole or a component of a midsole for an article of footwear.

[0417] According to aspect 331, the present disclosure relates to an apparel item comprising the bladder of any of aspects 316-330.

[0418] According to aspect 332, the present disclosure relates to an article of footwear comprising the bladder of any of aspects 316-330.

[0419] According to aspect 332, the present disclosure relates to an article of sports equipment comprising the bladder of any of aspects 316-330.

[0420] Method for manufacturing a foamed article

[0421] In one aspect, provided herein is a method for manufacturing a foamed article. The method includes placing an article and carbon dioxide in a container, wherein the article includes a solid foamable material, and wherein the foamable material is a thermoplastic elastomer material including one or more thermoplastic elastomers. After the placing, the method further includes maintaining the container at a first pressure and a first temperature, wherein the first pressure and the first temperature are a pressure and a temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining includes holding the article and the liquid carbon dioxide in the container for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the article. As used herein, "infuse" and "infused" carbon dioxide is understood to mean carbon dioxide that is dissolved in, contained in, or otherwise adsorbed and / or absorbed in the solid foamable material. In some aspects, after the maintaining and holding, the method optionally includes exposing the article to a second pressure and a second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material. In any of these aspects, after the maintaining and holding and the optional exposing of the article, the method includes subjecting the article to a third pressure and a third temperature at which the carbon dioxide infused into the solid foamable material phase changes into a gas, thereby expanding the solid foamable material into a foamed material and forming a foamed article. The foamed material has a porous foam structure. In one aspect, the foamed material has a porous closed-cell structure. In another aspect, the foamed material has a porous open-cell structure. In some aspects, subjecting the article to the third temperature and the third pressure and causing the carbon dioxide to phase change into a gas also serves to cool the foamable material and / or the foamed material.

[0422] Placed in a container. In one aspect, the step of placing carbon dioxide in the container includes introducing carbon dioxide in the form of a solid, liquid, gas, or supercritical fluid into the container prior to the step of maintaining and holding the carbon dioxide in the form of a liquid. In another aspect, introducing the carbon dioxide includes charging the container with carbon dioxide gas at pressure and temperature conditions that are the liquid / vapor equilibrium of carbon dioxide.

[0423] In one aspect, when the article is a sheet, the article can be configured as a roll, optionally including spacers or protective layers between adjacent portions of the foamed article. In some aspects, the article can be a layered sheet including one or more foamed layers. Further, in this aspect, the step of placing includes setting the roll into the container, and wherein the steps of subjecting and expanding include unrolling the article prior to or during the subjecting, or prior to or during the expanding. In some aspects, the step of placing further includes setting a porous spacer between adjacent portions of the article prior to or during the placing, and wherein the steps of maintaining and retaining include flowing carbon dioxide through the porous spacer to the adjacent portions of the article. In other aspects, the article or sheet is not configured as a roll, but can be a sheet, a strand or fibril, a fabric, a bladder, or any other foamable structure such as, for example, those disclosed herein.

[0424] In some aspects, the foamable article can be a foamable bladder or a component of a foamable bladder. In other words, the foamable articles disclosed herein can be used to form a bladder or a component of a bladder, and these bladders or components of bladders can be foamed using the foaming processes disclosed herein. In other aspects, the foamed article can be a foamed bladder or a component of a foamed bladder, wherein the bladder or component of a bladder is foamed using the foaming processes disclosed herein prior to, during, or after forming the bladder or component of a bladder.

[0425] Maintained and kept at a first temperature and a first pressure.After the step of placing the article and carbon dioxide in the container, the article and carbon dioxide in the container are maintained at a first pressure and a first temperature. The first pressure and the first temperature are a pressure and a temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material. This step includes holding the article and the liquid carbon dioxide in the container for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material. During this step, the liquid carbon dioxide contacts the article and infuses into one or more materials present in the article, including the solid foamable material. To infuse the carbon dioxide into the solid foamable material of the article, the carbon dioxide in contact with the article must exist in a form that is soluble in the solid foamable material and will infuse into the solid foamable material. Upon infusion into the solid foamable material, the infused carbon dioxide also needs to exist in a phase that is capable of phase changing into a gas during the foaming process, and also must exist in the solid foamable material in a sufficient concentration to expand at least a portion of the solid foamable material into a foam having a cellular structure. While solid carbon dioxide will expand directly from a solid into a gas under certain conditions, when solid carbon dioxide is placed in contact with the solid foamable materials disclosed herein, under most conditions, the solid carbon dioxide does not infuse into the solid foamable material at a rate or at a concentration sufficient for it to be used as a physical blowing agent for large scale manufacturing. While supercritical carbon dioxide can also phase change and expand into a gas, and supercritical carbon dioxide is generally highly soluble in many polymeric materials, extreme temperatures and pressures are required to maintain carbon dioxide in a supercritical state, which greatly increases the equipment and energy requirements of the process. However, it has been discovered that liquid carbon dioxide is soluble in the solid foamable materials disclosed herein at a sufficient concentration to act as a physical blowing agent.

[0426] In one aspect, the method further includes, after the step of maintaining and holding, prior to the optional exposing step or prior to the step of undergoing and expanding, venting any remaining carbon dioxide from the container. Further, in this aspect, venting the carbon dioxide from the container includes converting the liquid carbon dioxide to carbon dioxide gas prior to or during venting.

[0427] In one aspect, at the first pressure and the first temperature, the carbon dioxide is soluble in the solid foamable material at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, from about 5 weight percent to about 10 weight percent, or from about 10 weight percent to about 20 weight percent.

[0428] In another aspect, the step of maintaining and holding includes maintaining the first pressure from about 0.05 pounds per square inch (about 0.345 kilopascals) to about 6000 pounds per square inch (about 41,300 kilopascals). In another aspect, the first pressure is from about 15 pounds per square inch (103.4 kilopascals) to about 5500 pounds per square inch (37,900 kilopascals), optionally about 100 pounds per square inch (689.5 kilopascals) to about 5000 pounds per square inch (34,500 kilopascals), from about 500 pounds per square inch (3,450 kilopascals) to about 2000 pounds per square inch (about 13,790 kilopascals), or from about 1000 pounds per square inch (6895 kilopascals) to about 1500 pounds per square inch (10,300 kilopascals).

[0429] In yet another aspect, the step of maintaining and holding can include maintaining the first temperature from about -57 degrees Celsius to about 31 degrees Celsius, optionally from about -40 degrees Celsius to about 25 degrees Celsius, or from about -40 degrees Celsius to about 0 degrees Celsius. In one aspect, the step of maintaining and holding includes holding the article at the first pressure and the first temperature for a duration from about 20 seconds to about 72 hours, optionally from about 20 seconds to about 24 hours, from about 1 minute to about 24 hours, or from about 1 minute to about 1 hour.

[0430] Optionally, in any of these aspects, the temperature of the foamable material is maintained at a temperature below the softening temperature of the foamable material during the step of maintaining and holding and the performance of the steps of subjecting and expanding of the methods disclosed herein. For example, the thermoplastic elastomeric material can be maintained at a temperature at least 10 degrees Celsius or at least 20 degrees Celsius below the Vicat softening temperature of the foamable material. While additional processing steps that can cause thermal softening of portions or regions of the solid foamable material or the foamed material can be performed on the foamed article, in these aspects, these steps involving thermal softening of the solid foamable material or melting of the foamed material are performed prior to the step of maintaining and holding or after the steps of subjecting and expanding. Avoiding thermal softening of the foamable material can reduce or prevent thermal degradation of the foamable material.

[0431] In an aspect, the article includes a solid first foamable material and a second material, where the second material is a second foamable material. Further, in this aspect, the step of maintaining and holding includes holding the article and the liquid carbon dioxide in the container for a duration sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid first foamable material but not into the solid second foamable material. Further, in this aspect, the step of subjecting and expanding includes expanding the first foamable material into a first foamed material while maintaining the solid second foamable material as a substantially unfoamed second foamable material.

[0432] In aspects, the foamable article can include a foamable region or foamable layer that includes a first foamable material. In some aspects, the foamable article further includes a second region or layer that includes a second material (where the foamable region or foamable layer that includes the foamable material is a first foamable region or a first foamable layer). The second material can be a second foamable material as disclosed herein, or can be a second non-foamable material. In another aspect, the foamed article can include a foamed region or foamed layer that includes a foamed material, and in some aspects, the foamed article can include a second foamed region or second foamed layer that includes a second foamable material, or can include a second unfoamed region or second unfoamed layer that includes a second unfoamed material, as disclosed herein.

[0433] In another aspect, the article includes a solid first foamable material, and further includes an additional material, where the additional material is an additional foamable material. Further, in this aspect, the steps of maintaining and retaining include retaining the article and the liquid carbon dioxide in a container for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid first foamable material and to infuse into the solid additional foamable material. In another aspect, the method includes an optional exposing step, and the exposing includes exposing the article to a second pressure and a second temperature at which carbon dioxide remains infused within the solid additional foamable material, but at which carbon dioxide diffuses out of the solid first foamable material. Further, in this aspect, the steps of undergoing and expanding include expanding the solid foamable material into a second foamed material, while maintaining the solid first foamable material as a substantially unfoamed first foamable material.

[0434] Optional exposure to a second pressure and a second temperature.In some aspects, after the maintaining and preserving, the method optionally includes exposing the article to a second pressure and a second temperature at which carbon dioxide remains infused into at least a portion of the solid foamable material. In some aspects, the optional step can involve increasing or decreasing the temperature of the foamed article, for example, in order to bring the foamed article to a higher temperature or a lower temperature. In other aspects, the optional step can involve increasing or decreasing the pressure at which the foamed article is maintained, for example, in order to expose the foamed article to a higher pressure or a lower pressure. In yet other aspects, the optional exposure step can include exposing the infused article to a pressure that is increased or decreased compared to the first pressure, and / or a temperature that is increased or decreased compared to the first temperature. The optional exposure step can include exposing the infused article to a second pressure and a second temperature at which the infused carbon dioxide remains substantially infused into the infused article. For example, the second pressure and the second temperature can be a pressure and a temperature at which little, if any, carbon dioxide diffuses out of the infused article over the duration of time during which the infused article is exposed to the second pressure and / or the second temperature. In one aspect, the exposing can include storing the infused article in a conventional freezer at atmospheric pressure at a temperature at which the infused carbon dioxide has a low rate of diffusion out of the infused article. Alternatively, the optional exposure step can include exposing the infused article to a second pressure and a second temperature at which an amount of the infused carbon dioxide diffuses out of the infused article. For example, when the rate of diffusion of carbon dioxide out of a thermoplastic material is known for a particular second pressure and a second temperature, the duration of time required for an amount of carbon dioxide to diffuse out of a particular portion of the infused article can be determined, and the infused article can be held at the second pressure and the second temperature for the determined duration of time in order to reduce the concentration of carbon dioxide in the portion or region of the infused article. For example, based on allowing some or all of the carbon dioxide to diffuse out of a first region or portion, the exposure step can be used to first create a region or portion of the infused article that will expand into a relatively denser foam or that will remain substantially unfoamed compared to other regions or portions of the infused article during the foaming step. In this manner, it has been found that a good controlled variability in the degree to which an article is foamed can be achieved without the need for expensive, complex equipment or tools.

[0435] In one aspect, the optional exposure step includes exposing the article to a second pressure of from about 1 atmosphere (101 kiloPascals) to about 85 atmospheres (8613 kiloPascals), optionally from about 1 atmosphere (101 kiloPascals) to about 40 atmospheres (4053 kiloPascals) or from about 1 atmosphere (101 kiloPascals) to about 20 atmospheres (2026.5 kiloPascals).

[0436] In some aspects, the optional exposing step comprises exposing the article to a second temperature that is less than the softening point of the solid foamable material by more than about 30 degrees Celsius, optionally less than the softening point of the solid foamable material by more than about 50 degrees Celsius or less than the softening point of the solid foamable material by more than about 100 degrees Celsius.

[0437] In any of these aspects, the optional exposing step comprises exposing the article to the second pressure and the second temperature for a duration of from about 30 minutes to about 4 weeks, optionally from about 1 hour to about 1 week or from about 1 hour to about 24 hours.

[0438] In some aspects, the optional exposing step can occur in a container. In other aspects, the optional exposing step further comprises removing the carbon dioxide-infused article from the container prior to exposing the article to the optional second pressure and the second temperature.

[0439] Exposure to a third pressure and a third temperature to expand the solid foamable material. As stated above, the method comprises subjecting the article to a third pressure and a third temperature at which the carbon dioxide infused into the solid foamable material phase changes into a gas, thereby expanding the solid foamable material into a foamed material and forming a foamed article. The third pressure can be a higher or lower pressure than the first pressure or the optional second pressure, and the third temperature can be a higher or lower temperature than the first temperature or the optional second temperature, so long as the third pressure and the third temperature are conditions under which the infused carbon dioxide present in the infused article phase changes into a gas and at a rate sufficient to expand at least a portion of the solid foamable material of the article. In many aspects, the third pressure can be at or near atmospheric pressure, and the third temperature can be at or near room temperature, or can be a high temperature that is below the softening temperature of the solid foamable material, i.e., conditions that can be achieved using inexpensive equipment and low energy consumption.

[0440] In one aspect, the subjecting and expanding step comprises subjecting the article to a third pressure of from about 13 pounds per square inch (89.6 kiloPascals) to about 16 pounds per square inch (110.3 kiloPascals), optionally from about 13 pounds per square inch (89.6 kiloPascals) to about 15 pounds per square inch (103.4 kiloPascals) or from about 14 pounds per square inch (96.5 kiloPascals) to about 15 pounds per square inch (103.4 kiloPascals).

[0441] In some aspects, the subjecting and expanding step comprises subjecting the article to a third temperature of from about 20 degrees Celsius to about 150 degrees Celsius, optionally from about 20 degrees Celsius to about 100 degrees Celsius, from about 25 degrees Celsius to about 70 degrees Celsius, from about 50 degrees Celsius to about 70 degrees Celsius, or about 60 degrees Celsius.

[0442] In any of these aspects, the step of experiencing and expanding includes subjecting the article to a third pressure and a third temperature for a duration of from about 2 seconds to about 5 minutes, optionally from about 5 seconds to about 2 minutes or from about 30 seconds to about 1 minute.

[0443] In some aspects, the step of experiencing and expanding can occur in a vessel. In other aspects, the step of experiencing further includes removing the carbon dioxide-infused article from the vessel prior to subjecting the article to the third pressure and the third temperature.

[0444] In one aspect, the step of subjecting the article to the third temperature and the third pressure includes introducing the article into a fluid bath, optionally wherein the fluid bath is a water bath. In some aspects, the fluid bath has a temperature of from about 20 degrees Celsius to about 90 degrees Celsius, optionally from about 40 degrees Celsius to about 80 degrees Celsius or from about 50 degrees Celsius to about 70 degrees Celsius. In another aspect, the article is maintained in the fluid bath for a duration of from about 15 seconds to about 5 minutes, optionally from about 30 seconds to about 3 minutes or from about 1 minute to about 2 minutes during the experiencing.

[0445] In alternative aspects, the step of experiencing includes subjecting the article to an energy source or a heat source, optionally wherein the energy source or the heat source includes steam, microwave energy, infrared (IR) energy or radio frequency (RF) energy. Further, in this aspect, the step of subjecting the article to the energy source or the heat source increases the temperature of at least a portion of the foamable material of the article to a temperature of from about 60 degrees Celsius to about 150 degrees Celsius, optionally from about 70 degrees Celsius to about 100 degrees Celsius or from about 75 degrees Celsius to about 90 degrees Celsius. In one aspect, the experiencing lasts for a duration of from about 2 seconds to about 5 minutes, optionally from about 15 seconds to about 3 minutes or from about 1 minute to about 2 minutes.

[0446] In another aspect, the step of experiencing and expanding includes expanding the foamable material into a foamed material until the foamed material has a density of from about 0.01 grams per cubic centimeter to about 3.0 grams per cubic centimeter, optionally from about 0.01 grams per cubic centimeter to about 0.1 grams per cubic centimeter, from about 0.01 grams per cubic centimeter to about 0.05 grams per cubic centimeter, from about 0.01 grams per cubic centimeter to about 0.025 grams per cubic centimeter, from about 0.05 grams per cubic centimeter to about 0.1 grams per cubic centimeter, from about 0.1 grams per cubic centimeter to about 3.0 grams per cubic centimeter, from about 0.2 grams per cubic centimeter to about 2.0 grams per cubic centimeter, from about 0.3 grams per cubic centimeter to about 1.5 grams per cubic centimeter, from about 0.3 grams per cubic centimeter to about 1.2 grams per cubic centimeter or from about 0.4 grams per cubic centimeter to about 1.0 grams per cubic centimeter.

[0447] In still another aspect, after the step of subjecting and expanding, the foamed material has an expansion ratio from about 3: 1 to about 120: 1 relative to the solid foamable material prior to subjecting and expanding, optionally from about 3: 1 to about 100: 1, or from 3: 1 to about 50: 1 or from about 5: 1 to about 10: 1 relative to the thermoplastic elastomeric material in unfoamed condition. In one aspect, during expansion, at least a portion of the article comprising the solid foamable material expands in length, width, and height as the solid foamable material expands into the foamed material.

[0448] In one aspect, after expansion, the size of the foamed article is larger in at least one dimension compared to the size of the article prior to placement, optionally wherein the foamed article is at least 5% larger, optionally at least 10% larger, at least 15% larger, or at least 20% larger in one or more of length, width, and height.

[0449] In some aspects, the article is a layered sheet, and the step of subjecting and expanding foams at least one layer of the sheet. Further, in this aspect, after subjecting and expanding, the thickness of the foamed layered sheet is at least 5% larger, optionally at least 10% larger, at least 15% larger, or at least 20% larger than the thickness of the layered sheet in its unfoamed state.

[0450] Optional exposure to a fourth temperature and a fourth pressure. In some aspects, the method further comprises the optional step of, after subjecting and expanding, bringing the foamed article to a fourth temperature and a fourth pressure, and maintaining the foamed article at or below the fourth temperature, the fourth pressure, or both, for a period of time. This optional step can involve raising or lowering the temperature of the foamed article, for example, in order to bring the foamed article to room temperature. Similarly, in some aspects, this optional step can involve increasing or decreasing the pressure at which the foamed article is maintained, for example, to bring the foamed article to atmospheric pressure and / or room temperature.

[0451] In one aspect, the optional step of bringing comprises bringing the foamed article to a fourth pressure of from about 0.03 atmospheres (3.04 kiloPascals) to about 2 atmospheres (202.65 kiloPascals), optionally from about 0.5 atmospheres (50.7 kiloPascals) to about 1.5 atmospheres (152 kiloPascals), or about 1 atmosphere (101.3 kiloPascals).

[0452] In another aspect, the optional reaching step includes reaching a fourth temperature for the foamed article from about 30 degrees Celsius to about 70 degrees Celsius, optionally from about 40 degrees Celsius to about 60 degrees Celsius or from about 45 degrees Celsius to about 55 degrees Celsius. In some aspects, in the optional reaching step, the fourth temperature is at or below the glass transition temperature of the solid foamable material or is from about 10 degrees Celsius less than the glass transition temperature of the solid foamable material to about 10 degrees Celsius greater than the glass transition temperature of the solid foamable material, as measured by the melting temperature, glass transition temperature, and melting enthalpy test protocol. In one aspect, the glass transition temperature of the solid foamable material is less than 0 degrees Celsius, optionally less than -10 degrees Celsius, less than -20 degrees Celsius, less than -30 degrees Celsius, or less than -40 degrees Celsius.

[0453] In any of these aspects, the optional reaching step includes reaching the fourth pressure and the fourth temperature for the foamed article for a duration from about 15 minutes to about 1 hour, optionally from about 20 minutes to about 45 minutes or from about 20 minutes to about 30 minutes.

[0454] Optional stabilization at a fifth temperature and a fifth pressure.In still other aspects, the method further comprises stabilizing the foamed article at a fifth pressure and a fifth temperature after being subjected to and expanded or after being optionally reached. The fifth pressure and the fifth temperature can be a pressure and a temperature at which carbon dioxide diffuses out of the foamed material of the foamed article while the foamed material is maintained in a foam structure, thereby forming a stabilized foamed article. In some aspects, stabilizing comprises maintaining the foamed article at the fifth pressure and the fifth temperature for a duration sufficient to remove substantially all of the carbon dioxide from the foamed material. The fifth pressure can be at or near atmospheric pressure, or can be a pressure at which the rate of air diffusion into the foam and / or the rate of carbon dioxide diffusion out of the foam is greater than at atmospheric pressure. The fifth temperature can be at or near room temperature, or can be a temperature at which the rate of air diffusion into the foam and / or the rate of carbon dioxide diffusion out of the foam is greater than at room temperature. Stabilizing the foamed article can also comprise releasing stresses in the foamed article, such as stresses in the foamed thermoplastic elastomeric material or stresses present in the solid material in the foamed article. In such aspects, the fifth pressure and / or the fifth temperature can be atmospheric pressure and / or room temperature, or can be a pressure and / or a temperature at which stresses in the foamed article are released at a rate faster than at atmospheric pressure or room temperature. In one example, stabilizing can be performed at atmospheric pressure and at a temperature that is at least 5 degrees Celsius above room temperature and below the softening temperature of the foamed material. Stabilizing can be performed using conventional heating equipment such as a convection oven, a microwave oven, or an infrared oven, or a heating tunnel. Stabilizing can be particularly useful when the foamed material is present in the form of a sheet, and / or when the foamed article comprises a layered structure comprising a layer of foamed material adjacent to a layer of solid (unfoamed) material, as the foamed material can release stresses in the solid material that were created during the foaming process.

[0455] In one aspect, the optional stabilizing step comprises stabilizing at a fifth pressure of about atmospheric pressure. In another aspect, the optional stabilizing step comprises stabilizing at a fifth temperature that is greater than the glass transition temperature of the foamed material, as measured by the melt temperature, glass transition temperature, and melt enthalpy test protocol. Further, in this aspect, the optional stabilizing step comprises stabilizing at a fifth temperature from about 30 degrees Celsius to about 70 degrees Celsius, optionally from about 40 degrees Celsius to about 60 degrees Celsius, or about 50 degrees Celsius. In one aspect, the optional stabilizing step comprises stabilizing the foamed article at the fifth temperature for from about 15 minutes to about 60 minutes, optionally from about 30 minutes to about 45 minutes.

[0456] In one aspect, the optional step of stabilizing the foamed article at a fifth pressure and a fifth temperature includes placing the foamed article in an oven. In some aspects, stabilizing the foamed article at a fifth pressure and a fifth temperature releases stresses in the foamed article. In another aspect, stabilizing the foamed article at a fifth pressure and a fifth temperature removes substantially all residual carbon dioxide in the foamed article. In another aspect, the stabilization can remove carbon dioxide gas if the carbon dioxide gas remains in individual cells of the foam. In further aspects, the stabilization can remove injected carbon dioxide if the carbon dioxide remains injected into the foamed material or unfoamed material. In still another aspect, stresses can be introduced when the foamable material transforms into a foamed material while remaining in combination with unfoamed material; further, in this aspect, the stabilization can release these stresses.

[0457] In some aspects, the shrinkage of the foamed article can be a concern, or can be desirable. The step of stabilizing the foamed article at a fifth pressure and a fifth temperature can be used to reduce or control the level of shrinkage of the foamed article after foaming. For example, the rate of shrinkage under certain conditions can be used to determine the time, temperature, and pressure to obtain a desired level of shrinkage of the foamed article. In aspects, the stabilization can reduce or release stresses that would otherwise result in an undesirable level of shrinkage.

[0458] In any of these aspects, the method can include a step of stabilizing, and after the stabilizing, the size of the stabilized foamed article is larger in at least one dimension compared to the size of the article prior to the placing, optionally wherein the stabilized foamed article is at least 5% larger, at least 10% larger, at least 15% larger, or at least 20% larger in one or more of length, width, and height.

[0459] Additional processing of the foamable material and foamed material and article.In aspects, the foamable material can be formed using a variety of processes, optionally. In one aspect, the solid foamable material can be formed using an extrusion process prior to the step of placing. In one aspect, the solid foamable material can be formed using an injection molding process prior to the step of placing. In another aspect, the solid foamable material can be formed using a thermoforming process and / or a vacuum forming process prior to the step of placing. In one aspect, the thermoforming process and / or the vacuum forming process can use pressure and / or heat energy to conform the foamable material to the shape of a mold. In one aspect, the mold can include one or more curved surfaces. In another aspect, the mold can be an open mold or a closed mold. In some aspects, the mold can be configured to form a single surface of the foamable material or multiple surfaces of the foamable material. Alternatively or additionally, an additive manufacturing process such as extrusion, deposition printing, and / or selective sintering can be used to form and / or shape the foamable material prior to the step of placing.

[0460] In one aspect, the method further comprises thermoforming the foamed article, optionally wherein the foamed article is a stabilized foamed article. In some aspects, the foamed article is a sheet, optionally a layered sheet, optionally wherein the layered sheet includes at least one unfoamed cap layer, and optionally wherein the layered sheet includes one or more foamed core layers and two unfoamed cap layers. In some aspects, the article can be a thermoformed article. In any of these aspects, the foamed article can be a component of an apparel article, a footwear article, or a sporting equipment article.

[0461] Foaming a selected layer of the article In one aspect, the article includes a first cap layer, one or more core layers, and optionally a second cap layer. In further aspects, the step of maintaining and retaining injects carbon dioxide into the first cap layer, or injects carbon dioxide into the first cap layer and at least one of the one or more core layers, or injects carbon dioxide into the first cap layer and each of the one or more core layers, or injects carbon dioxide into the first cap layer, each of the one or more core layers, and the second cap layer.

[0462] In one aspect, the method includes the step of exposing, and the exposing releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in at least one of the one or more core layers, or releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in each of the one or more core layers, or releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in each of the one or more core layers, and the second cap layer, or releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in the second cap layer, optionally retaining the injected carbon dioxide in at least one of the one or more core layers, or releases substantially all of the injected carbon dioxide from the first cap layer and each of the one or more core layers while retaining the injected carbon dioxide in the second cap layer.

[0463] In one aspect, the article further includes one or more structural layers, and the step of maintaining and retaining injects carbon dioxide into the first cap layer, or injects carbon dioxide into the first cap layer and at least one of the one or more structural layers, or injects carbon dioxide into the first cap layer, at least one of the one or more structural layers, or injects carbon dioxide into the first cap layer, at least one of the one or more structural layers, and at least one of the one or more core layers, or injects carbon dioxide into the first cap layer, at least one of the one or more structural layers, and each of the one or more core layers, or injects carbon dioxide into the first cap layer, each of the one or more structural layers, each of the one or more core layers, and the second cap layer.

[0464] In still another aspect, the disclosed method includes the step of exposing, and the exposing releases substantially all of the injected carbon dioxide from the first cap layer while retaining the injected carbon dioxide in at least one of the one or more structural layers, or from the first cap layer and a first of the one or more structural layers while retaining the injected carbon dioxide in a second of the one or more structural layers, or from the first cap layer, one or more of the at least one structural layer, and a first of the one or more core layers while retaining the injected carbon dioxide in a second of the one or more core layers, a second of the one or more structural layers, and a second cap layer, or from the first cap layer, at least a first of the one or more structural layers, and at least a first of the one or more core layers while retaining the injected carbon dioxide in at least a first of the one or more core layers, a second cap layer, and optionally a second of the one or more structural layers, or from the first cap layer, each of the one or more structural layers, and each of the one or more core layers while retaining the injected carbon dioxide in a second cap layer.

[0465] In any of these aspects, the article can further include one or more tie layers, and the step of maintaining and retaining injects carbon dioxide into the first cap layer, at least one of the one or more structural layers, and at least one of the one or more tie layers, or into the first cap layer, at least one of the one or more structural layers, at least one of the one or more tie layers, and at least one of the one or more core layers, or into the first cap layer, at least one of the one or more structural layers, at least one of the one or more tie layers, and each of the one or more core layers, or into the first cap layer, each of the one or more structural layers, each of the one or more tie layers, each of the one or more core layers, and a second cap layer.

[0466] In another aspect, the method can include the step of exposing, and the exposing releases substantially all of the injected carbon dioxide from the first cap layer and a first structural layer of the one or more structural layers, while retaining the injected carbon dioxide in the one or more tie layers, or from the first cap layer, a first structural layer of the one or more structural layers, a first tie layer of the one or more tie layers, and a first core layer of the one or more core layers, while retaining the injected carbon dioxide in a second core layer of the one or more core layers, a second tie layer of the one or more tie layers, a second structural layer of the one or more structural layers, and the second cap layer.

[0467] In some aspects, the steps of subjecting and expanding do not expand and foam at least a portion of the tie material of at least one tie layer of the one or more tie layers, leaving the at least one tie layer substantially unfoamed in the foamed article; optionally wherein the tie material of the at least one tie layer comprises or consists essentially of a barrier material as described below.

[0468] In one aspect, the steps of subjecting and expanding do not expand and foam substantially all of the tie material of each tie layer of the one or more tie layers, leaving each tie layer of the one or more tie layers substantially unfoamed in the foamed article; optionally wherein the tie material of each tie layer of the one or more tie layers comprises or consists essentially of a barrier material as described below.

[0469] Foaming a bladder In one aspect, the foamable article includes a first sheet and a second sheet, and a second side of the first sheet faces a second side of the second sheet, and the first sheet and the second sheet are joined together to form an internal cavity in a space between the second side of the first sheet and the second side of the second sheet, wherein the joint extends around at least a portion of a perimeter of the internal cavity, optionally wherein the joint abuts only one or more portions of the perimeter of the internal cavity and includes one or more apertures that are capable of allowing fluid to enter the internal cavity, forming an open cavity; or wherein the joint abuts the entire perimeter of the internal cavity, forming a sealed pouch that is capable of retaining fluid in the internal cavity at a pressure that is higher or lower than atmospheric pressure. In another aspect, the first side of the first sheet and / or the first side of the second sheet can be an outermost surface of the foamable article.

[0470] In any of these aspects, the method can further include the step of closing one or more apertures in the perimeter of the interior cavity, forming a sealed bladder, optionally wherein the step of closing includes forming an adhesive or thermal bond between the second side of the first sheet and the second side of the second sheet. In further aspects, the method further includes the step of inflating the sealed bladder with a fluid.

[0471] In one aspect, the step of inflating occurs prior to the step of placing, or after the steps of subjecting and expanding. In alternative aspects, the method includes the step of reaching, and the step of inflating occurs after the step of reaching. In alternative aspects, the method includes the step of stabilizing, and the step of inflating occurs after the step of stabilizing.

[0472] In another aspect, during the step of subjecting and expanding, the first side of the first sheet and the second side of the second sheet remain unfoamed within the sealed bladder, optionally wherein one or more layers of the first sheet or the second sheet or both are foamed during the step of subjecting and expanding, optionally wherein the one or more foamed layers are positioned in the first sheet and the second sheet at a depth that is less than the depth of the one or more barrier layers.

[0473] In one aspect, the methods disclosed herein can be adjusted and controlled to produce a desired level of expansion of a foamed article (e.g., sheet, bladder, and the like). Further, in this aspect, a single unfoamed article or material, such as a single unfoamed component, can be expanded in a controlled manner such that it can be expanded into two or more different sized foamed articles or components. In one exemplary aspect, a single size unfoamed bladder as disclosed herein can be foamed and stabilized under different conditions to produce foamed airbags suitable for use as cushioning elements in two, three, or more different sized shoes.

[0474] Foamed article

[0475] In one aspect, disclosed herein is a foamed article comprising a foamed material that is a physically expanded foam formed from a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers. In another aspect, the foamed material is the product of placing an unfoamed article comprising a solid foamable material in liquid carbon dioxide, infusing the solid foamable material with carbon dioxide, and expanding the infused solid foamable material by expanding the infused carbon dioxide without thermally softening the solid foamable material, such as by phase changing the infused carbon dioxide into a gas without softening the solid foamable material, thereby expanding the solid foamable material into the foamed material of the foamed article. In some aspects, the foamed article is a stabilized foamed article comprising a stabilized foamed material, wherein the stabilized foamed material is free of, or substantially free of, the infused carbon dioxide.

[0476] In another aspect, in the foamed articles described herein, the foamed material is a first foamed material, the foamed article includes a second foamed material, the second foamed material is an additional material as disclosed herein, and the thermoplastic elastomeric material of the first foamed material is a recycled material, or the additional material of the second foamed material is a recycled material, or both the thermoplastic elastomeric material and the additional material are recycled materials.

[0477] In another aspect, when the first pressure is from about 0.05 pounds per square inch (0.345 kiloPascal) to about 6000 pounds per square inch (about 41,300 kiloPascal), optionally about 15 pounds per square inch (103.4 kiloPascal) to about 5500 pounds per square inch (37,900 kiloPascal), about 100 pounds per square inch (689.5 kiloPascal) to about 5000 pounds per square inch (34,500 kiloPascal), from about 500 pounds per square inch (3,450 kiloPascal) to about 2000 pounds per square inch (about 13,790 kiloPascal), or from about 1000 pounds per square inch (6895 kiloPascal) to about 1500 pounds per square inch (10,300 kiloPascal), and the first temperature can be from about -57 degrees Celsius to about 31 degrees Celsius, optionally from about -40 degrees Celsius to about 25 degrees Celsius, or from about -40 degrees Celsius to about 0 degrees Celsius, the carbon dioxide is soluble in the foamed material, or the solid foamable material, or both, at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, from about 5 weight percent to about 10 weight percent, or from about 10 weight percent to about 20 weight percent.

[0478] In one aspect, the foamed material of the foamed article is substantially opaque. In another aspect, the foamed material has a split tear value from about 2.5 kilograms per centimeter to about 3.0 kilograms per centimeter, optionally from about 2.5 kilograms per centimeter to about 2.8 kilograms per centimeter, from about 2.5 kilograms per centimeter to about 2.75 kilograms per centimeter, or from about 2.75 kilograms per centimeter to about 3.0 kilograms per centimeter, as measured using the Split Tear Test Protocol. In another example, a foamed article is formed having an Asker C hardness from about 10 to about 50, or from about 15 to about 50, from about 15 to about 45, from about 20 to 45, or from about 20 to about 40, as measured using the Asker C Hardness Test Protocol.

[0479] Layers of foamable material and foamed articles and arrangements thereof

[0480] In one aspect, prior to undergoing a foaming process as disclosed herein, the articles disclosed herein can comprise or consist essentially of a single layer of a solid foamable material, as illustrated, for example, in Figure 8A In this exemplary embodiment, the article 401 comprises a solid foamable material 412a having a first side 412a' and a second side 412a" and a thickness 410a prior to undergoing a foaming process. During the foaming process, at least a portion of the single layer of solid foamable material 412a expands to have a foam structure, thereby increasing its volume. The increase in volume of the foamed material increases at least one dimension (length, width, or thickness) of the foamed article. In examples where the length and width of the article are significantly greater than its thickness, the change in volume after foaming will have a greater impact on the thickness of the article. After undergoing the foaming process, the single layer has an increased thickness 410a in the foamed article as compared to its thickness prior to foaming.

[0481] In another aspect, prior to undergoing a foaming process as disclosed herein, the articles disclosed herein can comprise a plurality of layers, at least one layer of the plurality of layers comprising a solid foamable material according to the present disclosure, as illustrated, for example, in Figure 8B In this exemplary embodiment, the article 402 comprises a cap layer 412a having a thickness 410a and a core layer 416 having a thickness 414.

[0482] In accordance with Figure 8BIn one such aspect of the example, the cap layer 412a can include or consist essentially of a first solid foamable material. In such aspects, the core layer 416 can also include or consist essentially of a second solid foamable material, or can include or consist essentially of a barrier material. In any of these aspects, the cap layer 412a can have a first surface 412a' and a second surface 412a", and the core layer can have a first surface 416a and a second surface 416b. In some aspects, the second surface 412a" of the cap layer 412a and the first surface 416a of the core layer 416 can be adjacent to or otherwise in contact with one another. In some aspects, the first surface 412a' of the cap layer 412a can optionally be an outer surface of the article 402.

[0483] During the foaming process, at least a portion of the first solid foamable material of the cap layer 412a, and optionally at least a portion of the second solid foamable material of the core layer 416 if the core layer 416 includes or consists essentially of a second solid foamable material, expands to have a foam structure, thereby increasing its volume. The increase in volume of the foamed material increases at least one dimension (length, width, or thickness) of the foamed article. In examples in which the length and width of the article are significantly greater than its thickness, and / or in which the first solid foamable material and / or the second solid foamable material is constrained in the length dimension and / or the width dimension, such as by being bonded to another material, the change in volume after foaming will have a greater effect on the thickness of the article.

[0484] After undergoing the foaming process, in the foamed article, the thickness 410a of the cap layer 412a is increased compared to its thickness prior to foaming. In aspects in which the core layer 416 includes a second foamable material, the second foamable material can also expand and foam, increasing the thickness 414 of the core layer 416 compared to its thickness prior to foaming. Alternatively, the core layer 416 can not foam during the foaming process, and thus its thickness 414 will remain substantially the same before and after undergoing the foaming process. In one such aspect in which the core layer 416 remains unfoamed, the core layer 416 includes or consists essentially of a barrier material, and thus does not expand and foam during the foaming process. In an alternative such aspect in which the core layer 416 remains unfoamed, the core layer 416 can include a second foamable material, but the second foamable material is not infused with carbon dioxide during the maintaining and retaining step, or the infused carbon dioxide diffuses out of the core layer 416 prior to undergoing and expanding during the expanding step.

[0485] Structural layerIn another aspect, the foamed article includes a structural layer, and the structural layer comprises or is substantially composed of a structural material. In one aspect, the structural material may be another material as disclosed herein, optionally wherein the structural material comprises a blend of two or more other materials, optionally wherein at least one of the two or more other materials is a recycled material.

[0486] In another aspect, prior to undergoing the foaming process disclosed herein, the article disclosed herein may include multiple layers, at least one of which comprises a solid foamable material according to the disclosure, such as, for example, in Figure 8C As illustrated in the figure. In this exemplary embodiment, article 403 includes a cover layer 412a having a thickness 410a, a structural layer 420a having a thickness 418a, and a core layer 416 having a thickness 414.

[0487] According to Figure 8C In one aspect of this example, the capping layer 412a may comprise or be substantially composed of a first solid foamable material. In another aspect, the structural layer 420a may also comprise or be substantially composed of a third solid foamable material, or may comprise or be substantially composed of a barrier material. In yet another aspect, the core layer 416 may comprise or be substantially composed of a second solid foamable material, or may comprise or be substantially composed of a barrier material. In any of these aspects, the capping layer 412a may have a first surface 412a′ and a second surface 412a″, the structural layer may have a first surface 420a′ and a second surface 420a″, and the core layer may have a first surface 416a and a second surface 416b. In some aspects, the second surface 412a″ of the cover layer 412a and the first surface 420a′ of the structural layer 420a may be adjacent to each other or in contact with each other in other ways. In other aspects, the second surface 420a″ of the structural layer 420a and the first surface 416a of the core layer 416 may be adjacent to each other or in contact with each other in other ways. In some aspects, the first surface 412a′ of the cover layer 412a may optionally be the outer surface of the article 403.

[0488] In aspects, at least a portion of the first solid foamable material of the cap layer 412a, and, in aspects in which the structural layer 420a comprises or consists essentially of a third solid foamable material and the core layer 416 comprises or consists essentially of a second solid foamable material, optionally at least a portion of the third solid foamable material of the structural layer 420a and / or at least a portion of the second solid foamable material of the core layer 416, expands to have a foam structure, thereby increasing its volume, during the foaming process. The increase in volume of the foamed material increases at least one dimension (length, width, or thickness) of the foamed article. In instances in which the length and width of the article are significantly greater than its thickness, and / or in which the first, second, and / or third solid foamable materials are constrained in the length and / or width dimensions, such as by being bonded to another material, the change in volume after foaming will have a greater impact on the thickness of the article.

[0489] After undergoing the foaming process, in the foamed article, the thickness 410a of the cap layer 412a is increased compared to its thickness prior to foaming. In aspects in which the structural layer 420a comprises a third foamable material, the third foamable material can also expand and foam, causing the thickness 418a of the structural layer 420a to increase compared to its thickness prior to foaming. Alternatively, the structural layer 420a can not foam during the foaming process, and thus its thickness 418a will remain substantially the same before and after undergoing the foaming process. In aspects in which the core layer 416 comprises a second foamable material, the second foamable material can also expand and foam, causing the thickness 414 of the core layer 416 to increase compared to its thickness prior to foaming. Alternatively, the core layer 416 can not foam during the foaming process, and thus its thickness 414 will remain substantially the same before and after undergoing the foaming process. In one such aspect in which the structural layer 420a and / or the core layer 416 remains unfoamed, the structural layer 420a and / or the core layer 416 comprises or consists essentially of a barrier material, and thus does not expand and foam during the foaming process. In alternative aspects, such as when the structural layer 420a remains unfoamed, the structural layer 420a can comprise a third foamable material, but the third foamable material is not infused with carbon dioxide during the maintaining and retaining step, or the infused carbon dioxide diffuses out of the structural layer 420a prior to undergoing and expanding in the expanding step. In another aspect, such as when the core layer 416 remains unfoamed, the core layer 416 can comprise a second foamable material, but the second foamable material is not infused with carbon dioxide during the maintaining and retaining step, or the infused carbon dioxide diffuses out of the core layer 416 prior to undergoing and expanding in the expanding step.

[0490] Tie layerIn still another aspect, the foamed article includes one or more tie layers, each of the one or more tie layers individually including or consisting essentially of a tie material, wherein each of the one or more tie layers or tie regions individually includes or consists essentially of a tie material, wherein each of the one or more tie layers or tie regions increases the bond strength between two adjacent layers or regions, optionally wherein the tie material is a thermoplastic elastomeric material as disclosed herein, and optionally wherein the thermoplastic elastomeric material is a recycled material as described herein.

[0491] In another aspect, the articles disclosed herein can include a plurality of layers prior to undergoing a foaming process as disclosed herein, at least one of the plurality of layers including a solid foamable material according to the present disclosure, as illustrated for example in Figure 8D In this example embodiment, the article 404 includes a cap layer 412a having a thickness 410a, a structural layer 420a having a thickness 418a, a tie layer 424a having a thickness 422a, and a core layer 416 having a thickness 414.

[0492] In accordance with Figure 8DIn one such aspect of the example, the cap layer 412a can include or consist essentially of a first solid foamable material. In such aspects, the structure layer 420a can also include or consist essentially of a third solid foamable material, or can include or consist essentially of a barrier material. In such aspects, the tie layer 424a can also include or consist essentially of a fourth solid foamable material, or can include or consist essentially of a barrier material. In such aspects, the core layer 416 can include or consist essentially of a second solid foamable material, or can include or consist essentially of a barrier material. In any of these aspects, the cap layer 412a can have a first surface 412a' and a second surface 412a", the structure layer can have a first surface 420a' and a second surface 420a", the tie layer 424a can have a first surface 424a' and a second surface 424a", and the core layer can have a first surface 416a and a second surface 416b. In some aspects, the second surface 412a" of the cap layer 412a and the first surface 420a' of the structure layer 420a can be adjacent to or otherwise in contact with one another. In further aspects, the second surface 420a" of the structure layer 420a and the first surface 424a' of the tie layer 424a can be adjacent to or otherwise in contact with one another. In still further aspects, the second surface 424a" of the tie layer 424a and the first surface 416a of the core layer can be adjacent to or otherwise in contact with one another. In some aspects, the first surface 412a' of the cap layer 412a can optionally be an outer surface of the article 404.

[0493] In aspects, during the foaming process, at least a portion of the first solid foamable material of the cap layer 412a, and, where the structural layer 420a comprises or consists essentially of a third solid foamable material, the tie layer 424a comprises or consists essentially of a fourth solid foamable material, and / or the core layer 416 comprises or consists essentially of a second solid foamable material, at least a portion of the third solid foamable material of the structural layer 420a and / or at least a portion of the fourth solid foamable material of the tie layer 424a and / or at least a portion of the second solid foamable material of the core layer 416 optionally expands to have a foam structure, thereby increasing its volume. The increase in volume of the foamed material increases at least one dimension (length, width, or thickness) of the foamed article. In instances where the length and width of the article are significantly greater than its thickness, and / or where the first, second, third, and / or fourth solid foamable materials are constrained in the length and / or width dimensions, such as by being bonded to another material, the change in volume after foaming will have a greater impact on the thickness of the article.

[0494] After undergoing the foaming process, in the foamed article, the thickness 410a of the cap layer 412a is increased compared to before foaming. In aspects where the structural layer 420a comprises a third foamable material, the third foamable material can also expand and foam, causing the thickness 418a of the structural layer 420a to increase compared to its thickness before foaming. Alternatively, the structural layer 420a can not foam during the foaming process, and thus its thickness 418a will remain substantially the same before and after undergoing the foaming process. In aspects where the tie layer 424a comprises a fourth foamable material, the fourth foamable material can also expand and foam, causing the thickness 422a of the tie layer 424a to increase compared to its thickness before foaming. Alternatively, the tie layer 424a can not foam during the foaming process, and thus its thickness 422a will remain substantially the same before and after undergoing the foaming process. In aspects where the core layer 416 comprises a second foamable material, the second foamable material can also expand and foam, causing the thickness 414 of the core layer 416 to increase compared to its thickness before foaming. Alternatively, the core layer 416 can not foam during the foaming process, and thus its thickness 414 will remain substantially the same before and after undergoing the foaming process. In one such aspect where the structural layer 420a and / or the tie layer 424a and / or the core layer 416 remains unfoamed, the structural layer 420a and / or the tie layer 424a and / or the core layer 416 comprises or consists essentially of a barrier material, and thus does not expand and foam during the foaming process. In alternative aspects such as where the structural layer 420a remains unfoamed, the structural layer 420a can comprise a third foamable material, but the third foamable material is not injected with carbon dioxide during the maintaining and retaining step, or the injected carbon dioxide diffuses out of the structural layer 420a before undergoing and expanding in the expanding step. In another aspect such as when the tie layer 424a remains unfoamed, the tie layer 424a can comprise a fourth foamable material, but the fourth foamable material is not injected with carbon dioxide during the maintaining and retaining step, or the injected carbon dioxide diffuses out of the tie layer 424a before undergoing and expanding in the expanding step. In another aspect such as when the core layer 416 remains unfoamed, the core layer 416 can comprise a second foamable material, but the second foamable material is not injected with carbon dioxide during the maintaining and retaining step, or the injected carbon dioxide diffuses out of the core layer 416 before undergoing and expanding in the expanding step.

[0495] Double-sided article. In some aspects, the articles disclosed herein can comprise a plurality of layers, at least one of the plurality of layers comprising a solid foamable material according to the present disclosure, as for example in Figure 9AThe article 405 is illustrated in cross-section. In this example embodiment, the article 405 includes two cover layers, 412a having a thickness 410a and 412b having a thickness 410b, and a core layer 416 having a thickness 414. In one aspect, the article can be double-sided. Further, in this aspect, the double-sided article can include a symmetrical arrangement of layers on both sides of the core layer 416.

[0496] In accordance with Figure 9A In one such aspect of examples in accordance with the present disclosure, the cover layers 412a and 412b can include or consist essentially of a first solid foamable material. In such aspects, the core layer 416 can include or consist essentially of a second solid foamable material, or can include or consist essentially of a barrier material.

[0497] In any of these aspects, the cover layer 412a can have a first surface 412a' and a second surface 412a", and the cover layer 412b can have a first surface 412b' and a second surface 412b". In another aspect, the core layer 416 can have a first surface 416a and a second surface 416b. In some aspects, the second surface 412a" of the cover layer 412a and the first surface 416a of the core layer 416 can be adjacent to or otherwise in contact with each other. In one aspect, the second surface 416b of the core layer 416 and the second surface 412b" of the cover layer 412b can be adjacent to or otherwise in contact with each other. In some aspects, the first surface 412a' of the cover layer 412a and / or the first surface 412b' of the cover layer 412b can independently be optionally an outer surface of the article 405.

[0498] In aspects, during the foaming process, at least a portion of the first solid foamable material of the cover layer 412a and / or the cover layer 412b, and, where the core layer 416 includes or consists essentially of a second solid foamable material, optionally at least a portion of the second solid foamable material of the core layer 416, expands to have a foam structure, thereby increasing its volume. The increase in volume of the foamed material increases at least one dimension (length, width, or thickness) of the foamed article. In examples where the length and width of the article are significantly greater than its thickness, and / or where the first solid foamable material, the second solid foamable material, and / or the third solid foamable material are constrained in the length dimension and / or the width dimension, such as by being bonded to another material, the change in volume after foaming will have a greater impact on the thickness of the article.

[0499] After undergoing the foaming process, in the foamed article, the thickness 410a of the cap layer 412a and / or the thickness 410b of the cap layer 412b is increased compared to prior to foaming. In aspects where the core layer 416 includes a second foamable material, the second foamable material can also expand and foam, causing the thickness 414 of the core layer 416 to increase compared to its thickness prior to foaming. Alternatively, the core layer 416 can not foam during the foaming process, and thus its thickness 414 will remain substantially the same before and after undergoing the foaming process.

[0500] In one aspect, when the exemplary structure 405 forms one wall of a sealed chamber or bladder, the surface 412a' is exposed on the outermost surface of the sealed chamber or bladder, and at least a portion of the cap layer 412a foams during the foaming process disclosed herein, while the surface 412b' is located on the inner surface of the sealed chamber or bladder, and the cap layer 412b can not foam during the foaming process disclosed herein.

[0501] In some aspects, the articles disclosed herein can include a plurality of layers, at least one of the plurality of layers including a solid foamable material according to the present disclosure, as for example illustrated in Figure 9B In this exemplary embodiment, the article 406 includes two cap layers, 412a having a thickness 410a and 412b having a thickness 410b, two structural layers, 420a having a thickness 418a and 420b having a thickness 418b, and a core layer 416 having a thickness 414. In one aspect, the article can be double-sided. Further, in this aspect, the double-sided article can include a symmetrical arrangement of layers on both sides of the core layer 416.

[0502] In one such aspect according to the examples of Figure 9B In such aspects, the structural layers 420a and 420b can also include or consist essentially of a third solid foamable material, or can include or consist essentially of a barrier material. In such aspects, the core layer 416 can include or consist essentially of a second solid foamable material, or can include or consist essentially of a barrier material.

[0503] In any of these aspects, the cap layer 412a can have a first surface 412a' and a second surface 412a", and the cap layer 412b can have a first surface 412b' and a second surface 412b". In another aspect, the structural layer 420a can have a first surface 420a' and a second surface 420a", and the structural layer 420b can have a first surface 420b' and a second surface 420b". In still another aspect, the core layer 416 can have a first surface 416a and a second surface 416b. In some aspects, the second surface 412a" of the cap layer 412a and the first surface 420a' of the structural layer 420a can be adjacent to or otherwise in contact with each other. In further aspects, the second surface 420a" of the structural layer 420a and the first surface 416a of the core layer can be adjacent to or otherwise in contact with each other. In one aspect, the second surface 416b of the core layer 416 and the second surface 420b" of the structural layer 420b can be adjacent to or otherwise in contact with each other. In still another aspect, the first surface 420b' of the structural layer 420b and the second surface 412b" of the cap layer 412b can be adjacent to or otherwise in contact with each other. In some aspects, the first surface 412a' of the cap layer 412a and / or the first surface 412b' of the cap layer 412b can independently be optionally an outer surface of the article 406.

[0504] In aspects, during the foaming process, at least a portion of the first solid foamable material of the cap layer 412a and / or the cap layer 412b, and, where the structural layer 420a and / or the structural layer 420b comprises or consists essentially of a third solid foamable material, and / or where the core layer 416 comprises or consists essentially of a second solid foamable material, optionally at least a portion of the third solid foamable material of the structural layer 420a and / or the structural layer 420b and / or at least a portion of the second solid foamable material of the core layer 416, expands to have a foam structure, thereby increasing its volume. The increase in volume of the foamed material increases at least one dimension (length, width, or thickness) of the foamed article. In instances where the length and width of the article are significantly greater than its thickness, and / or where the first, second, and / or third solid foamable materials are constrained in the length and / or width dimensions, such as by being bonded to another material, the change in volume after foaming will have a greater impact on the thickness of the article.

[0505] After undergoing the foaming process, in the foamed article, the thickness 410a of the cap layer 412a and / or the thickness 410b of the cap layer 412b is increased compared to before foaming. In aspects where the structural layer 420a and the structural layer 420b comprise a third foamable material, the third foamable material can also expand and foam, causing the thickness 418a of the structural layer 420a and / or the thickness 418b of the structural layer 420b to increase compared to their thicknesses before foaming. Alternatively, the structural layer 420a and / or the structural layer 420b can not foam during the foaming process, and thus their thicknesses 418a and / or 418b will remain substantially the same before and after undergoing the foaming process. In aspects where the core layer 416 comprises a second foamable material, the second foamable material can also expand and foam, causing the thickness 414 of the core layer 416 to increase compared to its thickness before foaming. Alternatively, the core layer 416 can not foam during the foaming process, and thus its thickness 414 will remain substantially the same before and after undergoing the foaming process.

[0506] In one aspect, when the exemplary structure 406 forms one wall of a sealed chamber or bladder, the surface 412a' is exposed on the outermost surface of the sealed chamber or bladder, and at least a portion of the cap layer 412a foams during the foaming process disclosed herein, while the surface 412b' is located on the inner surface of the sealed chamber or bladder, and the cap layer 412b can not foam during the foaming process disclosed herein. Further, in this aspect, when the structural layer 420a comprises or consists essentially of a solid foamable material, at least a portion of the structural layer 420a can foam during the foaming process disclosed herein, while the structural layer 420b can not foam during the foaming process disclosed herein.

[0507] In some aspects, the articles disclosed herein can comprise a plurality of layers, at least one of the plurality of layers comprising a solid foamable material according to the present disclosure, as illustrated, for example, in Figure 9C In this exemplary embodiment, the article 407 comprises two cap layers, 412a having a thickness 410a and 412b having a thickness 410b, two structural layers, 420a having a thickness 418a and 420b having a thickness 418b, two tie layers, 424a having a thickness 422a and 424b having a thickness 422b, and a core layer 416 having a thickness 414. In one aspect, the article can be double-sided. Further, in this aspect, the double-sided article can comprise a symmetrical arrangement of layers on both sides of the core layer 416.

[0508] In accordance with Figure 9CIn one such aspect of the examples, the cap layer 412a and the cap layer 412b can comprise or consist essentially of a first solid foamable material. In such aspects, the structure layer 420a and the structure layer 420b can further comprise or consist essentially of a third solid foamable material, or can comprise or consist essentially of a barrier material. In such aspects, the tie layer 424a and the tie layer 424b can comprise or consist essentially of a fourth solid foamable material, or can comprise or consist essentially of a barrier material. In such aspects, the core layer 416 can comprise or consist essentially of a second solid foamable material, or can comprise or consist essentially of a barrier material.

[0509] In any of these aspects, the cap layer 412a can have a first surface 412a' and a second surface 412a", and the cap layer 412b can have a first surface 412b' and a second surface 412b". In another aspect, the structure layer 420a can have a first surface 420a' and a second surface 420a", and the structure layer 420b can have a first surface 420b' and a second surface 420b". In still another aspect, the tie layer 424a can have a first surface 424a' and a second surface 424a", and the tie layer 424b can have a first surface 424b' and a second surface 424b". In still another aspect, the core layer 416 can have a first surface 416a and a second surface 416b. In some aspects, the second surface 412a" of the cap layer 412a and the first surface 420a' of the structure layer 420a can be adjacent to or otherwise in contact with one another. In further aspects, the second surface 420a" of the structure layer 420a and the first surface 424a' of the tie layer 424a can be adjacent to or otherwise in contact with one another. In still further aspects, the first surface 416a of the core layer and the second surface 424a" of the tie layer 424a can be adjacent to or otherwise in contact with one another. In one aspect, the second surface 416b of the core layer 416 and the second surface 424b" of the tie layer 424b can be adjacent to or otherwise in contact with one another. In another aspect, the first surface 424b' of the tie layer 424b and the second surface 420b" of the structure layer 420b can be adjacent to or otherwise in contact with one another. In still another aspect, the first surface 420b' of the structure layer 420b and the second surface 412b" of the cap layer 412b can be adjacent to or otherwise in contact with one another. In some aspects, the first surface 412a' of the cap layer 412a and / or the first surface 412b' of the cap layer 412b can independently be optionally an outer surface of the article 407.

[0510] In aspects, during the foaming process, at least a portion of the first solid foamable material of the cap layer 412a and / or the cap layer 412b, and where the structural layer 420a and / or the structural layer 420b comprises or consists essentially of a third solid foamable material, and / or the connecting layer 424a and / or the connecting layer 424b comprises or consists essentially of a fourth solid foamable material, and / or where the core layer 416 comprises or consists essentially of a second solid foamable material, optionally at least a portion of the third solid foamable material of the structural layer 420a and / or the structural layer 420b and / or at least a portion of the fourth solid foamable material of the connecting layer 424a and / or the connecting layer 424b and / or at least a portion of the second solid foamable material of the core layer 416 expands to have a foam structure, thereby increasing its volume. The increase in volume of the foamed material increases at least one dimension (length, width, or thickness) of the foamed article. In instances where the length and width of the article are significantly greater than its thickness, and / or where the first, second, third, and / or fourth solid foamable materials are constrained in the length and / or width dimensions, such as by being bonded to another material, the change in volume after foaming will have a greater impact on the thickness of the article.

[0511] After undergoing the foaming process, in the foamed article, the thickness 410a of the cap layer 412a and / or the thickness 410b of the cap layer 412b is increased as compared to prior to foaming. In aspects where the structural layer 420a and the structural layer 420b comprise a third foamable material, the third foamable material can also expand and foam, causing the thickness 418a of the structural layer 420a and / or the thickness 418b of the structural layer 420b to increase as compared to their thicknesses prior to foaming. Alternatively, the structural layer 420a and / or the structural layer 420b can not foam during the foaming process, and thus their thicknesses 418a and / or 418b will remain substantially the same before and after undergoing the foaming process. In aspects where the tie layer 424a and the tie layer 424b comprise a fourth foamable material, the fourth foamable material can also expand and foam, causing the thickness 422a of the tie layer 424a and / or the thickness 422b of the tie layer 424b to increase as compared to their thicknesses prior to foaming. Alternatively, the tie layer 424a and / or the tie layer 424b can not foam during the foaming process, and thus their thicknesses 422a and / or 422b will remain substantially the same before and after undergoing the foaming process. In aspects where the core layer 416 comprises a second foamable material, the second foamable material can also expand and foam, causing the thickness 414 of the core layer 416 to increase as compared to its thickness prior to foaming. Alternatively, the core layer 416 can not foam during the foaming process, and thus its thickness 414 will remain substantially the same before and after undergoing the foaming process.

[0512] In one aspect, when the exemplary structure 407 forms one wall of a sealed chamber or bladder, the surface 412a' is exposed on the outermost surface of the sealed chamber or bladder, and at least a portion of the cap layer 412a foams during the foaming process disclosed herein, while the surface 412b' is located on an inner surface of the sealed chamber or bladder, and the cap layer 412b can not foam during the foaming process disclosed herein. Further, in this aspect, when the structural layer 420a and / or the tie layer 424a independently comprise or consist essentially of a solid foamable material, at least a portion of the structural layer 420a and / or the tie layer 424a can foam during the foaming process disclosed herein, while the structural layer 420b and / or the tie layer 424b can not foam during the foaming process disclosed herein.

[0513] Layer and its composition In any of the disclosed aspects, the article can comprise a barrier layer comprising or consisting essentially of a barrier material as disclosed herein. In another aspect, the barrier material can be an additional material as described herein.

[0514] Protective layerIn an aspect, the article can include one or more protective layers, each of the one or more protective layers individually including or consisting essentially of a protective material, wherein each of the one or more protective layers is adjacent to the core layer and has a protective layer thickness, wherein the combination of the one or more protective layers and the adjacent core layer has a minimum radius of curvature that is greater than a minimum radius of curvature that causes cracking of the core layer or causes cracking of one or more individual layers within the core layer, optionally wherein the protective material is a solid foamable material as disclosed herein, optionally wherein the solid foamable material is a recycled material.

[0515] Barrier layer and / or region. In an aspect, the foamed article includes a barrier layer or a barrier region, and the barrier layer or the barrier region includes or consists essentially of a barrier material. Further, in this aspect, the barrier material can be an additional material as disclosed herein.

[0516] Foamable article comprising microlayers

[0517] In an aspect, the article includes a plurality of microlayers. In an aspect, the plurality of microlayers includes from about 5 to about 1000 microlayers, optionally about 10 to about 1000 microlayers, from about 30 to about 500 microlayers, from about 50 to about 200 microlayers, or from about 20 to about 100 microlayers. In an aspect, each individual microlayer of the plurality of microlayers has an average thickness of from about 0.01 micrometers to about 2.5 micrometers, optionally from about 0.01 micrometers to about 1 micrometer, or from about 0.05 micrometers to about 1 micrometer. In another aspect, each layer of the one or more layers including the plurality of alternating layers has an average thickness of from about 100 micrometers to about 0.5 centimeters or from about 100 micrometers to about 0.1 centimeters.

[0518] In an aspect, at least one layer of the series of three or more layers includes a plurality of alternating layers, wherein each alternating layer of the series of alternating layers individually includes a first alternating layer material or a second alternating layer material, optionally wherein the plurality of alternating layers includes from about 3 to about 50 individual layers, or from about 3 to about 25 individual layers, or from about 3 to about 7 individual layers, and optionally wherein the plurality of alternating layers forms at least one core layer of the one or more core layers of the layered structure. In aspects, the plurality of alternating layers can be microlayers as described herein.

[0519] In aspects, the first alternating layer material can be a thermoplastic material, optionally a thermoplastic elastomer material as disclosed herein. In another aspect, the first alternating layer material can be a solid material, optionally a solid thermoplastic material, optionally a solid thermoplastic elastomer material as disclosed herein. In alternative aspects, the thermoplastic material can optionally be a barrier material, and optionally the barrier material is a barrier material as described elsewhere herein.

[0520] In another aspect, the second alternating layer can be a thermoplastic material, optionally a further material, optionally wherein the further material is a barrier material as disclosed herein.

[0521] In some aspects, the article can be configured as a series of layers, the series of layers including at least one layer of foamable material in contact with a second material. In some aspects, the article is a sheet including more than one layer or more than one alternating layer, the more than one layer or more than one alternating layer including at least one layer of foamable material and at least one layer of a second material.

[0522] In one aspect, the article includes more than one microlayer. In one aspect, the more than one microlayer includes from about 5 to about 1000 microlayers, optionally about 10 to about 1000 microlayers, from about 30 to about 500 microlayers, from about 50 to about 200 microlayers, or from about 20 to about 100 microlayers. In one aspect, each individual microlayer of the more than one microlayer has an average thickness of from about 0.01 micrometers to about 2.5 micrometers, optionally from about 0.01 micrometers to about 1 micrometer, or from about 0.05 micrometers to about 1 micrometer. In another aspect, each layer of the one or more layers including the more than one alternating layer has an average thickness of from about 100 micrometers to about 0.5 centimeters or from about 100 micrometers to about 0.1 centimeters.

[0523] In another aspect, the core layer has an average thickness of from about 100 micrometers to about 0.5 centimeters, optionally from about 100 micrometers to about 0.1 centimeters.

[0524] In one aspect, thermoplastic barrier films and / or sheets can be flexible due to their inherent thinness, but can not be sufficiently elastic for some applications. In this aspect, the alternating more than one first and second microlayers having different compositions (e.g., thermoplastic elastomer layers and thermoplastic barrier films and / or sheets) can provide a mix of properties (e.g., elasticity, flexibility, low gas transmission, and return to original shape after removal of a deforming force) needed for applications in areas such as footwear, athletic apparel, and sporting goods.

[0525] Foamable articles including textiles

[0526] In an aspect, the article includes or is a textile. In some aspects, when the article includes a sheet, the textile can form a layer of the sheet. In an aspect, the textile can form an inner layer of the sheet. In another aspect, the textile can form an outer layer of the sheet.

[0527] In an aspect, the textile can be a spacer textile having a first textile face, a second textile face, and a textile thickness extending from the first textile face to the second textile face, wherein the textile thickness is from about 0.3 centimeters to about 3 centimeters or from about 0.5 centimeters to about 1 centimeter, optionally wherein a fiber density of the first textile face and the second textile face is at least 25% greater, at least 50% greater, or at least 75% greater than a fiber density between the first textile face and the second textile face.

[0528] In another aspect, the textile can be constructed from fibers or yarns, wherein the fibers or yarns of the textile include or consist essentially of synthetic fibers or yarns formed from or consisting essentially of a thermoplastic material, optionally wherein the thermoplastic material of the synthetic fibers or yarns includes or consists essentially of a thermoplastic elastomeric material. In another aspect, the melting temperature of the thermoplastic material of the synthetic fibers or yarns is within 20 degrees Celsius of the melting temperature of the thermoplastic material forming the outer layer of the article.

[0529] In an aspect, the article includes a layered sheet, and the polymer component of the thermoplastic material of the synthetic fibers or yarns is substantially the same as the polymer component of the thermoplastic material of one or more layers of the layered sheet, and optionally the polymer component of the thermoplastic material of the synthetic fibers or yarns is substantially the same as the polymer component of the thermoplastic material of a cover layer or structural layer of the layered sheet.

[0530] In an aspect, the thermoplastic material of the synthetic fibers or yarns is a solid foamable material, and optionally the solid foamable material can be a recycled material. In an alternative aspect, the thermoplastic material of the synthetic fibers or yarns can be a foamed material, optionally wherein the foamed material includes or consists essentially of a recycled material.

[0531] In another aspect, the article can include or be a sheet. In another aspect, the sheet can be from about 300 micrometers thick to about 1 centimeter thick, optionally from about 500 micrometers thick to about 1 centimeter thick or from about 500 micrometers thick to about 750 micrometers thick.

[0532] Sealed pockets and cavities

[0533] In one aspect, disclosed herein is a foamed article made by the methods disclosed herein. In one aspect, the foamed article includes a first sheet and a second sheet, and a second side of the first sheet faces a second side of the second sheet, and the first sheet and the second sheet are bonded together to form an internal cavity in a space between the second side of the first sheet and the second side of the second sheet, wherein the bond extends around at least a portion of a perimeter of the internal cavity, optionally wherein the bond abuts only one or more portions of the perimeter of the internal cavity and includes one or more apertures that can allow fluid to enter the internal cavity, forming an open cavity, or wherein the bond abuts the entire perimeter of the internal cavity, forming a sealed pouch that can hold fluid in the internal cavity at a pressure higher or lower than atmospheric pressure. In another aspect, a first side of the first sheet and / or a first side of the second sheet can be an outermost surface of the foamed article.

[0534] In some aspects, the article includes one or more internal cavities, optionally at least two internal cavities, wherein each of the one or more internal cavities is an open cavity, or each of the one or more internal cavities is a sealed pouch, or the one or more internal cavities includes at least one open cavity and at least one sealed pouch.

[0535] In another aspect, the first sheet and the second sheet are adhesively bonded or are heat bonded, optionally wherein the first sheet and the second sheet include a heat bond formed by radio frequency (RF) welding.

[0536] In aspects, the article includes one or more sealed pouches, and at least one layer of the first sheet or the second sheet includes a foamed material, optionally wherein the first sheet and the second sheet include one or more barrier layers that include or consist essentially of a barrier material, and a depth of the at least one layer that includes a foamed material is less than a depth of the one or more barrier layers, wherein the depth is determined from an outer surface of the sheet.

[0537] In another aspect, the second side of the first sheet and the second side of the second sheet include or consist essentially of a solid material, and optionally one or more layers of the first sheet or the second sheet include or consist essentially of a foamed material, optionally wherein the one or more layers that include or consist essentially of a foamed material are positioned in the first sheet and the second sheet at a depth that is less than a depth of the one or more barrier layers.

[0538] In one aspect, the foamed article includes one or more open cavities. In another aspect, one or more additional layers of the first sheet or the second sheet or both include or consist essentially of a foamed material. In still another aspect, the internal cavity can be a sealed bladder, and optionally the sealed bladder includes a fluid, which can optionally be a pressurized fluid. In one aspect, the fluid can be nitrogen or air. In still another aspect, the sealed bladder can have an initial internal pressure, when inflated, of from about 20 pounds per square inch (137.9 kiloPascals) to about 22 pounds per square inch (151.7 kiloPascals), optionally about 21 pounds per square inch (144.8 kiloPascals) to about 22 pounds per square inch (151.7 kiloPascals). In one aspect, the sealed bladder can have an internal pressure of at least 70% to about 80% of the initial internal pressure, optionally about 70% to about 75% or about 75% to about 80% of the initial internal pressure, after 2 years of use.

[0539] In one aspect, the component can have a nitrogen transmission rate of less than about 10 cubic centimeters per square meter per atmosphere per day (about 0.099 cubic centimeters per square meter per kiloPascal per day), optionally less than about 5 cubic centimeters per square meter per atmosphere per day (about 0.049 cubic centimeters per square meter per kiloPascal per day), less than about 3 cubic centimeters per square meter per atmosphere per day (about 0.030 cubic centimeters per square meter per kiloPascal per day), or less than about 2 cubic centimeters per square meter per atmosphere per day (about 0.020 cubic centimeters per square meter per kiloPascal per day), optionally wherein the component is a sealed bladder.

[0540] In one aspect, disclosed herein is a component, wherein the component is an open cavity or a sealed bladder as disclosed herein. In another aspect, the component is a sealed bladder and has a nitrogen transmission rate of less than about 10 cubic centimeters per square meter per atmosphere per day, optionally less than about 3 cubic centimeters per square meter per atmosphere per day or less than about 2 cubic centimeters per square meter per atmosphere per day.

[0541] In another aspect, the sealed bladder or component can be a cushioning element for an apparel article, an article of footwear, or an article of sports equipment. In one aspect, the cushioning element can be a cushioning element for an article of footwear, optionally wherein the cushioning element is a midsole or a component of a midsole for an article of footwear.

[0542] In some aspects, the foamed article may be a thermoformed foamed article. In another aspect, the foamed article may be a sheet, optionally wherein the sheet is a layered sheet comprising one or more foamed layers, optionally wherein the layered sheet comprises at least one unfoamed capping layer, optionally wherein the layered sheet comprises one or more foamed inner layers and two unfoamed capping layers. In some aspects, the sheet may be from about 300 micrometers thick to about 1 centimeter thick, optionally from about 500 micrometers thick to about 1 centimeter thick, or from about 500 micrometers thick to about 750 micrometers thick.

[0543] In any of these aspects, the foamed item can be a component of clothing, footwear, or sports equipment.

[0544] In the conventional manufacturing of items such as footwear in specific sizes, different equipment is required for thermoforming or otherwise shaping components for use in different shoe sizes. In one aspect, because the foamed articles disclosed herein can be thermoformed prior to foaming and retain their initial geometry and morphology after foaming, fewer pieces of equipment must be purchased and maintained to produce foamed components for a range of shoe sizes. In another aspect, because existing stock of a single size can be foamed under controlled conditions to produce foamed articles of desired sizes in response to consumer demand, a smaller inventory of foamable components must be maintained.

[0545] In one aspect, the article includes an initial geometry or morphology prior to foaming, and wherein the foamed article substantially retains its initial geometry or morphology compared to the article prior to the placement step, but at least a portion of the foamed article expands in one or more of the width, length, and height dimensions. In another aspect, because the polymer material expands in all dimensions, less polymer material is required to manufacture a foamed article of the same size, resulting in lighter parts and the use of lower amounts of thermoplastic elastomer material.

[0546] This article also discloses clothing items, footwear items, and sports equipment items, including the bag disclosed herein.

[0547] The properties of foamed materials and foamed items

[0548] In an aspect, the foamed material, the foamed article, or both has a density from about 0.01 grams per cubic centimeter to about 3.0 grams per cubic centimeter, optionally from about 0.01 grams per cubic centimeter to about 0.1 grams per cubic centimeter, from about 0.01 grams per cubic centimeter to about 0.05 grams per cubic centimeter, from about 0.01 grams per cubic centimeter to about 0.025 grams per cubic centimeter, from about 0.05 grams per cubic centimeter to about 0.1 grams per cubic centimeter, from about 0.1 grams per cubic centimeter to about 3.0 grams per cubic centimeter, from about 0.2 grams per cubic centimeter to about 2.0 grams per cubic centimeter, from about 0.3 grams per cubic centimeter to about 1.5 grams per cubic centimeter, from about 0.3 grams per cubic centimeter to about 1.2 grams per cubic centimeter, or from about 0.4 grams per cubic centimeter to about 1.0 grams per cubic centimeter in the foamed article.

[0549] In an aspect, the foamed article is substantially opaque after foaming. In further aspects, the opacity of the foamed article eliminates the need to add pigments to the thermoplastic elastomer material in order to whiten it.

[0550] In an aspect, the foamed material, the foamed article, or both has a split tear value from about 2.5 kilograms per centimeter to about 3.0 kilograms per centimeter, optionally about 2.5 kilograms per centimeter to about 2.7 kilograms per centimeter, about 2.5 kilograms per centimeter to about 2.6 kilograms per centimeter, about 2.7 kilograms per centimeter to about 3.0 kilograms per centimeter, or about 2.8 kilograms per centimeter to about 3.0 kilograms per centimeter as measured using the split tear test protocol.

[0551] Method of manufacturing an article comprising a foamed article

[0552] In an aspect, disclosed herein is a method for manufacturing an article, the method comprising attaching a first component to a second component, wherein the first component is a foamed article manufactured by the methods disclosed herein. In some aspects, the first component can be a first component of an apparel article, the second component can be a second component of the apparel article, and the article to be manufactured is an apparel article.

[0553] In other aspects, the first component can be a first component of an article of footwear, the second component can be a second component of the article of footwear, and the article to be manufactured is an article of footwear. Further, in these aspects, the first component can be a cushioning element and the second component can be a sole component or an upper component.

[0554] In still other aspects, the first component can be a first component of an article of sports equipment, the second component can be a second component of the article of sports equipment, and the article to be manufactured is an article of sports equipment.

[0555] Foamable material

[0556] The solid foamable material of the articles as described herein is a thermoplastic elastomeric material, meaning that the material is a polymeric material that has thermoplastic properties as well as elastomeric properties. The solid foamable material is a polymeric material that includes or consists essentially of one or more first thermoplastic elastomers. In some aspects, the solid foamable material includes one or more additional thermoplastic polymers, where the one or more additional thermoplastic polymers can be thermoplastic elastomers, or can be thermoplastic but not elastomeric. In some aspects, the solid foamable material includes additional non-polymeric ingredients. In many of the disclosed foamed articles described herein, the foamed material is a thermoplastic elastomeric material, meaning that after expansion, the foamed material retains thermoplastic properties and elastomeric properties.

[0557] In any of the disclosed aspects, the foamable material can be described as including a polymeric component, where the polymeric component includes all polymers present in the foamable material. In this regard, the polymeric component can consist essentially of one or more first thermoplastic elastomers, meaning that in such aspects, substantially all of the polymers present in the foamable material are thermoplastic elastomers. In one aspect, the one or more first thermoplastic elastomers of the foamable material include one or more thermoplastic elastomeric polyolefin homopolymers or copolymers, one or more thermoplastic elastomeric polyamide homopolymers or copolymers, one or more thermoplastic elastomeric polyester homopolymers or copolymers, one or more thermoplastic elastomeric polyether homopolymers or copolymers, one or more thermoplastic elastomeric polycarbonate homopolymers or copolymers, one or more thermoplastic elastomeric polyacrylate homopolymers or copolymers, one or more thermoplastic elastomeric polyurethane homopolymers or copolymers, one or more thermoplastic elastomeric styrene homopolymers or copolymers, or any combination thereof. Similarly, the polymeric component of the foamable material can consist essentially of one or more thermoplastic elastomeric polyolefin homopolymers or copolymers, one or more thermoplastic elastomeric polyamide homopolymers or copolymers, one or more thermoplastic elastomeric polyester homopolymers or copolymers, one or more thermoplastic elastomeric polyether homopolymers or copolymers, one or more thermoplastic elastomeric polycarbonate homopolymers or copolymers, one or more thermoplastic elastomeric polyacrylate homopolymers or copolymers, one or more thermoplastic elastomeric polyurethane homopolymers or copolymers, one or more thermoplastic elastomeric styrene homopolymers or copolymers, or any combination thereof.

[0558] In one aspect, one or more first thermoplastic elastomers of the foamable material include one or more thermoplastic elastomer polyolefin homopolymers or copolymers, one or more thermoplastic elastomer polyamide homopolymers or copolymers, one or more thermoplastic elastomer polyester homopolymers or copolymers, one or more thermoplastic elastomer polyurethane homopolymers or copolymers, one or more thermoplastic elastomer styrene homopolymers or copolymers, or any combination thereof. Similarly, the polymeric component of the foamable material may consist substantially of one or more thermoplastic elastomer polyolefin homopolymers or copolymers, one or more thermoplastic elastomer polyamide homopolymers or copolymers, one or more thermoplastic elastomer polyester homopolymers or copolymers, one or more thermoplastic elastomer polyurethane homopolymers or copolymers, one or more thermoplastic elastomer styrene homopolymers or copolymers, or any combination thereof.

[0559] In one aspect, thermoplastic materials, including thermoplastic elastomers, are advantageous for use in the articles described herein because they can be recycled and reformed into new articles, thus reducing waste and promoting recycling. In another aspect, both foamed and unfoamed thermoplastic materials can be recycled for use in the articles and methods described herein.

[0560] In one aspect, when one or more first thermoplastic elastomers comprise or are substantially composed of one or more thermoplastic elastomer polyolefin homopolymers or copolymers, the one or more first thermoplastic elastomers comprise or are substantially composed of: thermoplastic elastomer polypropylene homopolymers or copolymers; thermoplastic polyethylene homopolymers or copolymers, including thermoplastic elastomer ethylene-vinyl acetate copolymers; thermoplastic elastomer polybutene homopolymers or copolymers; or any combination thereof. The polymeric component of the foamable material may consist substantially of one or more thermoplastic elastomer polyolefin homopolymers or copolymers.

[0561] In one aspect, one or more thermoplastic elastomer polyolefin homopolymers or copolymers may comprise one or more thermoplastic elastomer ethylene-vinyl acetate copolymers or be substantially composed of one or more thermoplastic elastomer ethylene-vinyl acetate copolymers. The polymer component of the foamable material may be substantially composed of one or more thermoplastic elastomer ethylene-vinyl acetate copolymers. Furthermore, in this aspect, the thermoplastic ethylene-vinyl acetate copolymer may comprise a vinyl acetate content from about 25 weight percent to about 50 weight percent, optionally from about 25 weight percent to about 40 weight percent, from about 25 weight percent to about 30 weight percent, or from about 35 weight percent to about 50 weight percent.

[0562] In another aspect, the foamable material can include one or more thermoplastic ethylene-vinyl alcohol copolymers. The polymeric component of the foamable material can include one or more thermoplastic ethylene-vinyl alcohol copolymers. Further, in this aspect, the thermoplastic ethylene-vinyl alcohol copolymers can include an ethylene vinyl alcohol content from about 25 weight percent to about 50 weight percent, optionally an ethylene vinyl alcohol content from about 25 weight percent to about 40 weight percent, an ethylene vinyl alcohol content from about 25 weight percent to about 30 weight percent, or an ethylene vinyl alcohol content from about 35 weight percent to about 50 weight percent.

[0563] In another aspect, the one or more first thermoplastic elastomers of the foamable material include or consist essentially of one or more thermoplastic elastomeric polyamide homopolymers or copolymers. The polymeric component of the foamable material can consist essentially of one or more thermoplastic elastomeric polyamide homopolymers or copolymers. The one or more thermoplastic elastomeric polyamide homopolymers or copolymers can include or consist essentially of a thermoplastic elastomeric polyether block polyamide (PEBA) copolymer elastomer.

[0564] The one or more first thermoplastic elastomers can include or consist essentially of one or more thermoplastic elastomeric polyester homopolymers or copolymers. The polymeric component of the foamable material can consist essentially of one or more thermoplastic elastomeric polyester homopolymers or copolymers. The thermoplastic elastomeric polyester homopolymers can include or consist essentially of one or more polyester terephthalates. The thermoplastic elastomeric polyester homopolymers or copolymers can include or consist essentially of one or more thermoplastic elastomeric copolyesters.

[0565] The one or more first thermoplastic elastomers can include or consist essentially of one or more thermoplastic elastomeric polyether homopolymers or copolymers. The polymeric component of the foamable material can consist essentially of one or more thermoplastic elastomeric polyether homopolymers or copolymers.

[0566] The one or more first thermoplastic elastomers can include or consist essentially of one or more thermoplastic elastomeric polyether homopolymers or copolymers. The polymeric component of the foamable material can consist essentially of one or more thermoplastic elastomeric polyether homopolymers or copolymers.

[0567] The one or more first thermoplastic elastomers can include or consist essentially of one or more thermoplastic elastomer polycarbonate homopolymers or copolymers. The polymeric component of the foamable material can consist essentially of one or more thermoplastic elastomer polycarbonate homopolymers or copolymers.

[0568] The one or more first thermoplastic elastomers can include or consist essentially of one or more thermoplastic elastomer polyacrylate homopolymers or copolymers, including polyacrylics, polymethacrylates, and the like. The polymeric component of the foamable material can consist essentially of one or more thermoplastic elastomer polyacrylate homopolymers or copolymers.

[0569] Thermoplastic elastomer polyurethane homopolymers and copolymers have been found to be particularly useful in the methods and articles described herein. In aspects, the one or more first thermoplastic elastomers include or consist of one or more thermoplastic elastomer polyurethane homopolymers or copolymers, where a thermoplastic polyurethane homopolymer is understood to mean a polymer chain that includes only urethane segments, and a polyurethane copolymer is understood to mean a polymer chain that includes urethane segments as well as other types of segments, such as ester segments or ether segments or the like and combinations thereof. When the one or more first thermoplastic elastomers include one or more thermoplastic elastomer polyurethane homopolymers or copolymers, the one or more thermoplastic elastomers can include or consist essentially of a thermoplastic elastomer polyester-polyurethane copolymer, a thermoplastic elastomer polyether-polyurethane copolymer, a thermoplastic elastomer polycarbonate-polyurethane copolymer, or combinations thereof. In some aspects, the one or more first thermoplastic elastomers of the foamable material include or consist essentially of one or more thermoplastic elastomer polyester-polyurethane copolymers, optionally wherein the polymeric component of the foamable material consists of one or more thermoplastic elastomer polyester-polyurethane copolymers.

[0570] Thermoplastic polyurethanes can be produced via the reaction of a diisocyanate with a difunctional compound reactive toward isocyanate groups. Typically, the difunctional compound has two hydroxyl groups (diol), and can have a molar mass from 62 Daltons (the molar mass of ethylene glycol) to about 10,000 Daltons, or from about 100 Daltons to about 5000 Daltons, or from about 500 Daltons to about 5000 Daltons, or from about 500 Daltons to about 2500 Daltons, or from about 2500 Daltons to about 10,000 Daltons, or from about 5000 Daltons to about 10,000 Daltons, or from about 5000 Daltons to about 7500 Daltons or from about 7500 Daltons to about 10,000 Daltons, although difunctional compounds having other isocyanate-reactive groups (e.g., secondary amines) can be used in small amounts typically, and limited molar fractions of trifunctional isocyanate-reactive compounds and monofunctional isocyanate-reactive compounds can be used. In one example, the polyurethane is linear. The inclusion of difunctional compounds having a molar mass of about 400 Daltons or greater introduces soft segments into the polyurethane. Increasing ratios of soft segments to hard segments in the polyurethane can cause the polyurethane to become increasingly flexible, and eventually elastomeric. In one example, the one or more thermoplastic elastomeric materials include a thermoplastic polyurethane elastomer or a combination of thermoplastic polyurethane elastomers.

[0571] Suitable thermoplastic polyurethane elastomers include thermoplastic polyester- polyurethanes, polyether-polyurethanes, and polycarbonate-polyurethanes. Non-limiting examples of these include polyurethanes polymerized using the following as diol reactants: polyester diols prepared from diols and dicarboxylic acids or anhydrides; polylactone polyester diols (e.g., polycaprolactone diols); polyester diols prepared from hydroxy acids as monocarboxylic acids containing one hydroxyl group; polytetrahydrofuran diols; polyether diols prepared from ethylene oxide or combinations of ethylene oxide; and polycarbonate diols such as polyhexamethylene carbonate diols and poly(hexa-methylene-co-pentamethylene) carbonate diols. Thermoplastic polyurethane elastomers can be prepared by the reaction of one, one or more polyisocyanates, and optionally one or more monomeric chain-extending compounds, of these polymeric diols (polyester diols, polyether diols, polylactone diols, polytetrahydrofuran diols, or polycarbonate diols). Chain-extending compounds are compounds having two or more functional groups reactive toward isocyanate groups, e.g., two functional groups. In one example, the thermoplastic polyurethane elastomer is substantially linear (i.e., all or substantially all of the reactants are difunctional).

[0572] In still another aspect, the one or more first thermoplastic elastomers comprise or consist essentially of one or more thermoplastic elastomeric styrene homopolymers or copolymers. The polymeric component of the foamable material can consist essentially of one or more thermoplastic elastomeric styrene homopolymers or copolymers. The one or more thermoplastic elastomeric styrene homopolymers or copolymers can comprise or consist essentially of one or more styrene butadiene styrene (SBS) block copolymer elastomers, one or more styrene ethylene butylene styrene (SEBS) copolymer elastomers, one or more styrene acrylonitrile (SAN) copolymer elastomers, or any combination thereof.

[0573] In any of these aspects, the one or more first thermoplastic elastomers comprise or consist essentially of one or more recycled first thermoplastic elastomers. Similarly, the polymeric component of the foamable material can comprise or consist essentially of recycled thermoplastic polymers. In one aspect, the polymeric component of the foamable material comprises or consists essentially of one or more recycled thermoplastic elastomeric polymers. In another aspect, the polymeric component of the foamable material comprises one or more recycled thermoplastic polymers. In yet another aspect, the polymeric component of the foamable material comprises or consists essentially of one or more recycled thermoplastic elastomeric polymers and one or more thermoplastic non-elastomeric polymers. In still another aspect, the polymeric component of the foam consists essentially of one or more thermoplastic elastomeric polyurethanes and one or more thermoplastic polyolefins.

[0574] In one aspect, the foamable material comprises a mixture of a polymeric component and a non-polymeric component consisting of one or more non-polymeric additives, optionally wherein the foamable material comprises from about 0.005% by weight to about 20% by weight of the non-polymeric component based on the total weight of the foamable material, optionally about 0.5% by weight to about 10% by weight, about 1% by weight to about 5% by weight, or about 1% by weight to about 2% by weight of the non-polymeric additives based on the total weight of the foamable material.

[0575] Other materials that can be part of the composition used to form the foamable material include, but are not limited to: colorants, including pigments and dyes; fillers such as clays, including nanoclays and halloysite clays; nanotubes; nucleating agents; emulsifiers; mold release agents, including surfactant-based mold release agents; antioxidants; stabilizers; crosslinking agents; and / or the like.

[0576] The foamable material can be a relatively soft material. In some examples, the foamable material has a Shore A hardness from about 35 A to about 95 A. In other examples, the foamable material has a Shore A hardness from about 70 A to about 95 A, optionally about 35 A to about 70 A, about 50 A to about 70 A, or about 55 A to about 90 A, as measured using the Shore A Hardness Test Protocol.

[0577] In any of these aspects, the foamable material does not melt and / or is not melted during the execution of the maintaining and holding step or the experiencing and expanding step of the methods disclosed herein. In accordance with the present disclosure, carbon dioxide is used to infuse at least a portion of the solid foamable material of the article, and the solid foamable material remains a solid during the infusion. The infused solid foamable material of the article remains in a solid state until it is expanded by the phase change of the infused carbon dioxide into a gas at the point at which the foamed material is given a cellular structure without melting or being in a melted state the foamable material. While additional processing steps can be performed on the foamed article that can cause the solid foamable material or portions or regions of the foamed material to melt, it is understood that any steps involving melting the solid foamable material or melting the foamed material are performed prior to the maintaining and holding step or after the experiencing and expanding step. In some aspects, the foamed material of the foamed article is a physically expanded solid material formed without melting the solid material. Avoiding melting the thermoplastic elastomeric material during the foaming process reduces the "thermal history" of the thermoplastic elastomeric material, i.e., the number of heating and cooling cycles to which the thermoplastic elastomeric material is exposed, which reduces or prevents thermal degradation of the thermoplastic elastomeric material.

[0578] Blend.In one aspect, the foamable material can include or consist essentially of a blend of one or more first thermoplastic elastomers and a second material. In some aspects, the second material includes or consists essentially of one or more second polymers, optionally wherein the one or more second polymers include or consist essentially of one or more second thermoplastics. In such aspects, the polymeric component of the foamable material includes or consists essentially of one or more first thermoplastic elastomers and one or more second thermoplastics.

[0579] In another aspect, the one or more second thermoplastics can include or consist essentially of one or more thermoplastic polyolefin homopolymers or copolymers, one or more thermoplastic polyamide homopolymers or copolymers, one or more thermoplastic polyester homopolymers or copolymers, one or more thermoplastic polyether homopolymers or copolymers, one or more thermoplastic polycarbonate homopolymers or copolymers, one or more thermoplastic polyacrylate homopolymers or copolymers, one or more thermoplastic polyurethane homopolymers or copolymers, one or more thermoplastic styrenic homopolymers or copolymers, or any combination thereof. In some aspects, the one or more second thermoplastic polyolefin homopolymers or copolymers include or consist essentially of a thermoplastic polypropylene homopolymer or copolymer, a thermoplastic polyethylene homopolymer or copolymer, a thermoplastic polybutylene homopolymer or copolymer, or any combination thereof. In one aspect, the one or more second thermoplastics include or consist essentially of one or more thermoplastic polyethylene copolymers, including one or more thermoplastic ethylene-vinyl alcohol copolymers or one or more thermoplastic ethylene-vinyl acetate copolymers. In one aspect, the polymeric component of the foamable material consists essentially of a blend of one or more first thermoplastic elastomers and one or more second thermoplastics, optionally wherein the blend is foamed during the step of subjecting and expanding. In such aspects, the one or more second thermoplastics can include one or more thermoplastic polyolefin homopolymers or copolymers. In another aspect, the polymeric component of the foamable material consists essentially of a blend of one or more first thermoplastic elastomer polyurethane homopolymers or copolymers and one or more second thermoplastic ethylene-vinyl alcohol copolymers. Further, in this aspect, the polymeric component can consist essentially of one or more first thermoplastic elastomer polyester-polyurethane homopolymers or copolymers and one or more second thermoplastic ethylene-vinyl alcohol copolymers.

[0580] In an aspect, the blend can include one or more recycled first thermoplastic elastomers, one or more recycled second thermoplastics, or both. The one or more recycled first thermoplastic elastomers can include one or more recycled thermoplastic elastomeric polyurethane copolymers, such as one or more recycled thermoplastic elastomeric polyurethane-polyester copolymers or one or more recycled thermoplastic elastomeric polyurethane-polyether copolymers. The one or more recycled second thermoplastics can include one or more recycled thermoplastic polyolefins, such as one or more recycled polyethylene copolymers.

[0581] Recycled material. In an aspect, the recycled material useful in the methods disclosed herein can include a foamable material as an unfoamed material (i.e., the foamable material has not previously been foamed). For example, the recycled material can be obtained by recycling an unfoamed foamable material, such as scrap or waste material (e.g., by regrinding or another method). In another aspect, the recycled foamable material can be obtained by recycling an article containing a foamable material prior to the article having been foamed (e.g., by recycling a defective article that has been discarded prior to foaming).

[0582] In an aspect, the blend includes a phase-separated blend of one or more first thermoplastic elastomers and one or more second thermoplastics. In some aspects, the phase-separated blend includes one or more phase-separated regions that include an interface between the one or more first thermoplastic elastomers and the one or more second thermoplastics. Without wishing to be bound by theory, the one or more first thermoplastic elastomers and the one or more second thermoplastics can phase separate, or when the one or more first thermoplastic elastomers include at least one copolymer having hard segments and soft segments, the hard segments and / or soft segments can have an affinity for the second thermoplastic; thus, in some aspects, the phase-separated blend can include some polymer entanglement in addition to the interface between portions of the one or more first thermoplastic elastomers and the one or more second thermoplastics. The presence of one or more interfaces, such as the presence of interfaces between the phase-separated regions or between different polymeric materials within the article, can act as nucleation sites for bubble formation during the steps of experiencing and expanding, and thus the presence of such nucleation sites in the article can increase the uniformity of the pore structure in the foamed material.

[0583] The blend can comprise at least 50 weight percent of the one or more first thermoplastic elastomers and less than 50 weight percent of the one or more second thermoplastics, based on the total weight of the blend. The blend can comprise at least 70 weight percent of the one or more first thermoplastic elastomers and less than 30 weight percent of the one or more second thermoplastics, based on the total weight of the blend. The blend can comprise at least 80 weight percent of the one or more first thermoplastic elastomers and less than 20 weight percent of the one or more second thermoplastics, based on the total weight of the blend. In exemplary aspects, the blend comprises about 95% by weight of the one or more first thermoplastic elastomers and about 5% by weight of the one or more second thermoplastics, based on the total weight of the blend.

[0584] In some aspects, the solubility of carbon dioxide can vary among different polymeric materials making up the foamable material, such as when the foamable material is a blend of a first thermoplastic elastomer material with a second non-elastomeric thermoplastic material or a blend of a regrind material and a virgin material, due to the different thermal histories of the regrind material and the virgin material. In some aspects, the solubility of carbon dioxide is greater in the one or more thermoplastic elastomers than in the one or more non-elastomeric thermoplastics. In one aspect, carbon dioxide is soluble in the one or more first thermoplastic elastomers at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, from about 5 weight percent to about 10 weight percent, or from about 10 weight percent to about 20 weight percent, based on the total weight of the one or more first thermoplastic elastomers present in the foamable material. In another aspect, carbon dioxide is soluble in the one or more second thermoplastics at a concentration of less than 1 weight percent, optionally less than 0.5 weight percent, less than 0.25 weight percent, or less than 0.1 weight percent, based on the total weight of the one or more second thermoplastics present in the foamable material. In some aspects, carbon dioxide is substantially insoluble in the one or more second thermoplastics. The solubility of carbon dioxide in the one or more first thermoplastic elastomers and the one or more second thermoplastics can be determined gravimetrically by injecting carbon dioxide into separate samples of the first thermoplastic elastomer and the second thermoplastic at a first temperature.

[0585] Foamed material

[0586] In aspects, a foamed material is disclosed herein. In one aspect, the foamed material can be the product of expanding any of the foamable materials described above. In another aspect, the foamed material can be a thermoplastic material. In still another aspect, the foamed material can be partially or completely crosslinked. In one aspect, when the foamed material is crosslinked, the crosslinking can crosslink the foamed material completely or partially. In some aspects, when the foamed material is partially crosslinked, it can retain some thermoplastic properties such that the foam can be heat-softened. In alternative aspects, the foamed material can be crosslinked to the point where it becomes a thermoset foamed material.

[0587] In one aspect, the foamed material can be crosslinked during or after the steps of expansion and foaming. In another aspect, the crosslinking can be actinically initiated. In one exemplary aspect, the crosslinking can be initiated using heat radiation, light (e.g., UV radiation), electron beam, or any combination thereof.

[0588] In some aspects, the foamable material further comprises a crosslinking agent, such as, for example, a heat-initiated crosslinking agent or a light-initiated crosslinking agent.

[0589] In one aspect, the foamed material has a Shore A hardness from about 35 A to about 95 A. In other examples, the foamed material has a Shore A hardness from about 70 A to about 95 A, optionally about 35 A to about 70 A, about 50 A to about 70 A, or about 55 A to about 90 A, as measured using the Shore A Hardness Test Protocol.

[0590] In another aspect, the foamed material can have an Asker C hardness from about 10 to about 50, optionally about 15 to about 5, about 15 to about 45, about 20 to about 45, or about 20 to about 40, as measured using the Asker C Hardness Test Protocol.

[0591] In some aspects, the article prior to foaming can be optically clear and colorless. After foaming, the article can be opaque, depending on the placement and thickness of the foamed material.

[0592] Additional Materials

[0593] In one aspect, the article includes an additional material, i.e., another material in addition to the solid foamable material. Optionally, the additional material can be an additional thermoplastic material, optionally an additional thermoplastic elastomeric material, optionally wherein the additional thermoplastic elastomeric material is an additional (i.e., second) foamable material. In another aspect, the additional material can be an additional foamable material, and during the expanding step, the additional foamable material expands into an additional foamed material. In a further aspect, in the foamed article, the density of the first foamed material differs from the density of the additional foamed material by at least 5%, optionally at least 10%, or at least 20%.

[0594] In one aspect, the article includes an additional material, wherein the additional material is a material separate from the foamable material. In one aspect, the additional material and the foamable material can be bonded to one another or can be in contact with one another. In another aspect, the additional material and the foamable material can have some polymer chains mixed at the interface (e.g., if the foamable material and the additional material are thermally bonded). In another aspect, the additional material includes or consists essentially of one or more polymers, and includes an additional material polymer component consisting of all polymers present in the additional material. In an optional aspect, the additional material includes or consists essentially of a second material, optionally wherein the second material is a thermoplastic material. Still additionally, in this aspect, the additional material can optionally include an additional material polymer component mixed with an additional material non-polymer component consisting of all non-polymer components present in the additional material.

[0595] In some aspects, the article includes one or more first portions of the foamable material and one or more second portions of the additional material, wherein the one or more first portions are different from the one or more second portions.

[0596] In one aspect, the additional material is separate from the foamable material and / or is not a component of the foamable material. Further, in this aspect, the additional material can be present in the article as a distinct element separate from the foamable material but can be in contact with at least a portion of the foamable material. In other aspects, the additional material can be a component of the foamable material, e.g., as part of a blend that also includes the first material.

[0597] In one aspect, the additional material includes a barrier material including one or more barrier polymers, the barrier material including a barrier polymer component consisting of all polymers present in the barrier material. In some aspects, the additional material remains substantially unfoamed during the expanding step.

[0598] In some aspects, the additional material can be a recycled material comprising one or more recycled polymers, optionally wherein the one or more recycled polymers comprise one or more recycled thermoplastics, optionally wherein the one or more recycled thermoplastics comprise one or more recycled thermoplastic elastomers, optionally wherein the recycled material comprises a recycled material polymer component consisting of one or more recycled thermoplastics, optionally wherein the recycled material polymer component consists of one or more recycled thermoplastic elastomers. In some aspects, the recycled material comprises one or more recycled first thermoplastic elastomers. Optionally, in another aspect, the one or more recycled first thermoplastic elastomers comprise one or more regrind first thermoplastic elastomers. Optionally, further in this aspect, the one or more recycled first thermoplastic elastomers or regrind first thermoplastic elastomers comprise a thermoplastic elastomer as described herein.

[0599] In another aspect, the recycled material further comprises one or more recycled second thermoplastics. Optionally, in aspects, the one or more recycled second thermoplastics comprise one or more regrind second thermoplastics. Optionally, further in this aspect, the one or more recycled second thermoplastics or regrind second thermoplastics comprise a thermoplastic according to any of the preceding aspects. In some aspects, the recycled material comprises one or more recycled thermoplastic polyurethane elastomers or regrind thermoplastic polyurethane elastomers or one or more recycled thermoplastic ethylene-vinyl alcohol copolymers or both.

[0600] In one aspect, the recycled material can comprise a blend of one or more recycled thermoplastic elastomers or regrind thermoplastic elastomers and one or more second thermoplastics, or can comprise a blend of one or more thermoplastic elastomers and one or more recycled thermoplastics or one or more recycled second thermoplastics. Optionally, in one aspect, the blend can be a phase-separated blend, optionally wherein the phase-separated blend comprises one or more interfaces between the one or more first thermoplastic elastomers and the one or more second thermoplastics.

[0601] In another aspect, the recycled material can comprise from about 99% to about 90% by weight of the one or more first thermoplastic elastomers and from about 1% to about 10% by weight of the second thermoplastic plastic, optionally from about 99% to about 93% by weight of the one or more first thermoplastic elastomers and from about 1% to about 7% by weight of the one or more second thermoplastic plastic, or from about 99% to about 95% by weight of the one or more first thermoplastic elastomers and from about 1% to about 5% by weight of the one or more second thermoplastic plastic, based on the total weight of the recycled material.

[0602] In some aspects, the recycled material comprises from about 99% to about 50% by weight of the recycled polymer or regrind polymer, optionally from about 99% to about 75% by weight of the recycled polymer or regrind polymer, based on the total weight of the recycled material.

[0603] In any of these aspects, the carbon dioxide is soluble in the recycled material at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, based on the total weight of the recycled material. In another aspect, the carbon dioxide is soluble in the one or more recycled thermoplastic elastomers or regrind thermoplastic elastomers at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent, based on the total weight of the one or more recycled thermoplastic elastomers or regrind thermoplastic elastomers. In still another aspect, the carbon dioxide can be soluble in the one or more recycled second thermoplastic plastic or regrind second thermoplastic plastic at less than 1 weight percent, optionally less than 0.5 weight percent, less than 0.25 weight percent, or less than 0.1 weight percent, based on the total weight of the one or more recycled second thermoplastic plastic or regrind second thermoplastic plastic, or optionally wherein the carbon dioxide is substantially insoluble in the one or more recycled second thermoplastic plastic or regrind second thermoplastic plastic.

[0604] In aspects, the recycled material comprises a recycled foamed article produced by the methods disclosed herein, optionally wherein the recycled foamed article is a re- ground foamed article. In some aspects, the recycled material comprises a foamable material, wherein the foamable material is an unfoamed material. In another aspect, the recycled material further comprises one or more virgin first thermoplastic elastomers, optionally wherein the one or more virgin first thermoplastic elastomers comprise one or more virgin thermoplastic polyurethane elastomers. In still another aspect, the recycled material comprises one or more nucleating agents or nucleation sites for foaming the recycled material, optionally wherein the one or more nucleation sites comprise one or more interfaces between phase-separated polymers.

[0605] In one aspect, the barrier material has a hardness that is at least 10 Shore A units greater than the foamable material, optionally at least 20 Shore A units greater than the foamable material, at least 30 Shore A units greater than the foamable material, or at least 40 Shore A units greater than the foamable material, as measured using the Shore A Hardness Test Protocol.

[0606] In any of these aspects, the additional material can be a barrier material having a nitrogen gas transmission rate of less than or equal to 10 cubic centimeters per square meter per 24 hours, or less than or equal to 1 cubic centimeter per square meter per 24 hours. In some aspects, although the second material can be slightly stretched or deformed during the foaming process, the gas transmission rate, gas barrier properties, and durability of the layer remain substantially unchanged after foaming.

[0607] In another aspect, the barrier material has a nitrogen gas transmission rate that is at least 50%...

Claims

1. A method for making a foamed article, the method comprising: placing an article and carbon dioxide in a container, wherein the article comprises a solid foamable material that is a thermoplastic elastomer material comprising one or more first thermoplastic elastomers; after the placing step, maintaining the container at a first pressure and a first temperature, wherein the first pressure and first temperature are a pressure and temperature at which the carbon dioxide is a liquid and liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining comprises holding the article and the liquid carbon dioxide in the container for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the article; after the maintaining and holding steps, optionally exposing the infused article to a second pressure and a second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material; after the maintaining and holding steps and optional exposing step, subjecting the article to a third pressure and a third temperature at which the liquid carbon dioxide infused into the solid foamable material phase changes to a gas, thereby expanding the solid foamable material into a foamed material and forming the foamed article; wherein the article comprises a first sheet and a second sheet, wherein a first side of the first sheet faces a second side of the second sheet, and wherein the first sheet and the second sheet are bonded together to form more than one internal cavity in a space between the first side of the first sheet and the second side of the second sheet, wherein a bond extends around at least a portion of a perimeter of each internal cavity, wherein for each internal cavity, (a) the bond abuts only one or more portions of the perimeter of the internal cavity and comprises one or more apertures that can allow fluid to enter the internal cavity, forming an open cavity, or (b) the bond abuts around an entire perimeter of the internal cavity, forming a sealed pocket that can hold fluid in the internal cavity at a pressure higher or lower than atmospheric pressure.

2. The method of claim 1, wherein the solid foamable material has a Shore A hardness from 35 A to 95 A.

3. The method of claim 1 or 2, wherein the article comprises the sealed pocket, and during the subjecting and expanding step, the first side of the first sheet and the second side of the second sheet remain unfoamed within the sealed pocket.

4. The method of claim 1 or 2, wherein the first sheet, or the second sheet, or both the first sheet and the second sheet have a layered structure.

5. The method of claim 4, wherein the article comprises the sealed pocket, and during the subjecting and expanding step, one or more layers of the first sheet or the second sheet or both foam within the sealed pocket.

6. The method of claim 1, wherein the article includes one or more open cavities, and during the step of maintaining and retaining, the carbon dioxide enters the one or more open cavities, wherein the carbon dioxide is injected into the material forming the first side of the first sheet or the material forming the second side of the second sheet or both; and wherein during the step of subjecting and expanding, the injected carbon dioxide material within the one or more open cavities expands and foams to form the foamed material.

7. The method of claim 2, wherein the article includes one or more open cavities, and during the step of maintaining and retaining, the carbon dioxide enters the one or more open cavities, wherein the carbon dioxide is injected into the material forming the first side of the first sheet or the material forming the second side of the second sheet or both; and wherein during the step of subjecting and expanding, the injected carbon dioxide material within the one or more open cavities expands and foams to form the foamed material.

8. The method of claim 1, wherein at least one of the plurality of internal cavities is an open cavity that includes one or more holes in a perimeter of the internal cavity; during the step of maintaining and retaining, the carbon dioxide enters the open cavity and is injected into a solid foamable material contained in the open cavity; and during the step of subjecting and expanding, the solid foamable material contained in the open cavity expands and foams into the foamed material.

9. The method of claim 2, wherein at least one of the plurality of internal cavities is an open cavity that includes one or more holes in a perimeter of the internal cavity; during the step of maintaining and retaining, the carbon dioxide enters the open cavity and is injected into a solid foamable material contained in the open cavity; and during the step of subjecting and expanding, the solid foamable material contained in the open cavity expands and foams into the foamed material.

10. The method of claim 8, wherein during the step of maintaining and retaining, the carbon dioxide entering the open cavity is either liquid carbon dioxide or both liquid carbon dioxide and carbon dioxide vapor, and the liquid carbon dioxide or both the liquid carbon dioxide and carbon dioxide vapor enters the open cavity through the one or more holes in the perimeter of the internal cavity.

11. The method of claim 9, wherein during the step of maintaining and retaining, the carbon dioxide entering the open cavity is either liquid carbon dioxide or both liquid carbon dioxide and carbon dioxide vapor, and the liquid carbon dioxide or both the liquid carbon dioxide and carbon dioxide vapor enters the open cavity through the one or more holes in the perimeter of the internal cavity.

12. The method of any of claims 8-11, wherein during the step of maintaining and holding, the carbon dioxide enters the open cavity and infuses into the solid foamable material of the first side of the first sheet or the second side of the second sheet or both; and during the step of undergoing and expanding, the infused solid foamable material of the first side or the second side or both expands and foams into the foamed material.

13. The method of claim 12, wherein the foamed material defines at least a portion of the first side of the first sheet, or at least a portion of the second side of the second sheet, or both.

14. The method of claim 12, wherein the foamed material is present in an inner layer of the first sheet or the second sheet or both.

15. The method of claim 13, wherein the foamed material is present in an inner layer of the first sheet or the second sheet or both.

16. The method of any of claims 6-11 and 13-15, wherein during the step of maintaining and holding, the carbon dioxide enters the open cavity and infuses into a solid foamable material in contact with or bonded to the first side of the first sheet or the second side of the second sheet or both; and during the step of undergoing and expanding, the solid foamable material in contact with or bonded to the first side or the second side or both expands and foams into the foamed material.

17. The method of claim 12, wherein during the step of maintaining and holding, the carbon dioxide enters the open cavity and infuses into a solid foamable material in contact with or bonded to the first side of the first sheet or the second side of the second sheet or both; and during the step of undergoing and expanding, the solid foamable material in contact with or bonded to the first side or the second side or both expands and foams into the foamed material.

18. The method of any of claims 6-11, 13-15, and 17, wherein the open cavity comprises more than one fiber, more than one yarn, more than one particle, or any combination thereof, and the more than one fiber, the more than one yarn, the more than one particle, or any combination thereof comprises the solid foamable material in contact with or bonded to the first side or the second side or both.

19. The method of claim 12, wherein the open cavity comprises more than one fiber, more than one yarn, more than one particle, or any combination thereof, and the more than one fiber, the more than one yarn, the more than one particle, or any combination thereof comprises the solid foamable material in contact with or bonded to the first side or the second side or both.

20. The method of claim 16, wherein the open cavity comprises more than one fiber, more than one yarn, more than one particle, or any combination thereof, and the more than one fiber, the more than one yarn, the more than one particle, or any combination thereof comprises the solid foamable material in contact or bonded with the first side or the second side, or both.

21. The method of any of claims 6-11, 13-15, 17, and 19-20, further comprising, after the steps of subjecting and expanding, closing and sealing the one or more holes in the perimeter of the inner cavity, thereby forming the sealed pocket, wherein the sealed pocket comprises the foamed material.

22. The method of claim 12, further comprising, after the steps of subjecting and expanding, closing and sealing the one or more holes in the perimeter of the inner cavity, thereby forming the sealed pocket, wherein the sealed pocket comprises the foamed material.

23. The method of claim 16, further comprising, after the steps of subjecting and expanding, closing and sealing the one or more holes in the perimeter of the inner cavity, thereby forming the sealed pocket, wherein the sealed pocket comprises the foamed material.

24. The method of claim 18, further comprising, after the steps of subjecting and expanding, closing and sealing the one or more holes in the perimeter of the inner cavity, thereby forming the sealed pocket, wherein the sealed pocket comprises the foamed material.

25. The method of claim 21, further comprising, prior to or during the step of closing and sealing the one or more holes, inflating the inner cavity with a fluid.

26. The method of any of claims 22-24, further comprising, prior to or during the step of closing and sealing the one or more holes, inflating the inner cavity with a fluid.

27. The method of any of claims 6-11, 13-15, 17, 19-20, and 22-25, wherein the first sheet, or the second sheet, or both the first sheet and the second sheet has a layered structure.

28. The method of claim 3, wherein the first sheet, or the second sheet, or both the first sheet and the second sheet has a layered structure.

29. The method of claim 12, wherein the first sheet, or the second sheet, or both the first sheet and the second sheet has a layered structure.

30. The method of claim 16, wherein the first sheet, or the second sheet, or both the first sheet and the second sheet has a layered structure.

31. The method of claim 18, wherein the first sheet, or the second sheet, or both the first sheet and the second sheet has a layered structure.

32. The method of claim 21, wherein the first sheet, or the second sheet, or both the first sheet and the second sheet has a layered structure.

33. The method of claim 26, wherein the first sheet, or the second sheet, or both the first sheet and the second sheet have a layered structure.

34. The method of claim 4, wherein the first sheet has a second side opposite the first side of the first sheet, the second side of the first sheet is bounded by a first sheet outer layer, and in the foamed article, the first sheet outer layer remains unfoamed; or wherein the second sheet has a first side opposite the second side of the second sheet, the first side of the second sheet is bounded by a second sheet outer layer, and in the foamed article, the second sheet outer layer remains unfoamed; or wherein in the foamed article, both the first sheet outer layer and the second sheet outer layer remain unfoamed.

35. The method of claim 27, wherein the first sheet has a second side opposite the first side of the first sheet, the second side of the first sheet is bounded by a first sheet outer layer, and in the foamed article, the first sheet outer layer remains unfoamed; or wherein the second sheet has a first side opposite the second side of the second sheet, the first side of the second sheet is bounded by a second sheet outer layer, and in the foamed article, the second sheet outer layer remains unfoamed; or wherein in the foamed article, both the first sheet outer layer and the second sheet outer layer remain unfoamed.

36. The method of any of claims 5 and 28-33, wherein the first sheet has a second side opposite the first side of the first sheet, the second side of the first sheet is bounded by a first sheet outer layer, and in the foamed article, the first sheet outer layer remains unfoamed; or wherein the second sheet has a first side opposite the second side of the second sheet, the first side of the second sheet is bounded by a second sheet outer layer, and in the foamed article, the second sheet outer layer remains unfoamed; or wherein in the foamed article, both the first sheet outer layer and the second sheet outer layer remain unfoamed.

37. A foamed article made by the method of any of claims 1-36.

38. The foamed article of claim 37, wherein the foamed article is or comprises an open cell or a sealed bladder.

39. The foamed article of claim 38, wherein the foamed article is or comprises the sealed bladder, and the sealed bladder is a cushioning element.

40. The foamed article of claim 39, wherein the cushioning element is a cushioning element for an article of apparel, an article of footwear, or an article of sports equipment. ​ ​ ​ ​ ​ ​ 41. A foamed article comprising a first sheet and a second sheet, wherein a first side of the first sheet faces a second side of the second sheet, and wherein the first sheet and the second sheet are bonded together to form a plurality of internal cavities in a space between the first side of the first sheet and the second side of the second sheet, wherein a bond extends around at least a portion of a perimeter of each internal cavity, wherein for each internal cavity, (a) the bond abuts only one or more portions of the perimeter of the internal cavity and includes one or more apertures that can allow fluid to enter the internal cavity, forming an open cavity, or (b) the bond abuts around an entire perimeter of the internal cavity, forming a sealed pocket that can hold fluid in the internal cavity at a pressure higher or lower than atmospheric pressure, wherein the foamed article comprises a foamed material; the foamed material is a physically expanded foam formed from a thermoplastic elastomer material comprising one or more first thermoplastic elastomers; and wherein the foamed material is the product of placing an unfoamed article comprising a solid foamable material in liquid carbon dioxide, infusing the solid foamable material with the liquid carbon dioxide, and expanding the infused solid foamable material by phase changing the infused carbon dioxide into a gas without softening the solid foamable material, thereby forming the foamed material.

42. The foamed article of claim 41, wherein the foamed material has a Shore A hardness from 35 A to 95 A. ​

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