System and method for thermoforming articles

Abstract

The invention relates to a system and method for thermoforming an article. Systems and processes for thermoforming articles (110) and systems and processes for preparing articles for thermoforming are disclosed. A system for thermoforming may include one or more heating and cooling stations (300, 310). The system for thermoforming may also include an article movement mechanism (500) that may be coupled to the article and rotate the article within the heating chamber (212, 214, 216, 218, 220), within the cooling chamber (310), or within both. A system for preparing an article for thermoforming may include a container including a port (921) and a negative pressure generating system coupled to the port. The system for preparing an article for thermoforming may also include a compressed material (910) forming an interior portion (226, 312, 911, 926) for receiving the article. The negative pressure generating system may cause the compressed material to expand to allow the article to be inserted into the interior portion of the compressed material.

Description

[0001] This application is a Divisional of application number 201980027894.4, filed on April 24, 2019, having the title "System and method for thermoforming articles". TECHNICAL FIELD The present disclosure relates to systems and methods for thermoforming articles and systems and methods for preparing articles for thermoforming. BACKGROUND Thermoforming articles can include heating an article to a particular temperature or above a particular temperature, and then cooling the article to a particular temperature or below a particular temperature. During this heating and cooling, in certain processes, the article can be formed into a particular shape or structure. BRIEF DESCRIPTION OF DRAWINGS Illustrative aspects of the application are described below with reference to the accompanying drawings, which are incorporated herein by reference, and in which: Figure 1 depicts a top perspective view of a thermoforming system having a heating station including a plurality of heating chambers, a cooling station, a dryer, a loading / unloading station, and an article movement mechanism, in accordance with aspects of the present application; Figure 2 depicts a top perspective view of a heating chamber with a portion removed to reveal an article of footwear positioned within the heating chamber and coupled to the article movement mechanism, in accordance with aspects of the present application; Figure 3 depicts a top perspective view of a cooling station with a portion removed to reveal an article of footwear positioned within the cooling chamber, and wherein the cooling chamber is coupled to a second cooling source, in accordance with aspects of the present application; Figure 4 depicts a top perspective view of a dryer with a portion removed to reveal an article of footwear positioned within the dryer, in accordance with aspects of the present application; Figure 5A depicts a top perspective view of an insole placed on a last, in accordance with aspects of the present application; Figure 5B depicts a top perspective view of a chassis positioned on a sole portion of the insole positioned on a last, in accordance with aspects of the present application; Figure 5C depicts a top perspective view of a heel counter positioned on a heel portion of the insole of Figure 5B , in accordance with aspects of the present application; Figure 5D depicts a top perspective view of a shoe cover positioned on the insole, the chassis, and the heel counter from Figure 5C , in accordance with aspects of the present application; Figure 5EDepicted is a top perspective view of a membrane according to aspects of the present invention positioned from Figure 5D On the shoe covers; Figure 6 Depicts a top perspective view of a compression shoe cover positioned from a Figure 5E On the upper component; Figure 7A Depicted is a diagram from an aspect of the present invention Figure 6 A partial side cross-sectional view of a compression shoe cover and upper assembly; Figure 7B Depicts Figure 7A , specifically illustrating the layers of a compression overshoe, membrane, overshoe, heel counter, and liner according to aspects of the present invention; Figure 8A depicts a side view of a compression assembly system according to aspects of the present invention, particularly showing a negative pressure container partially cut away to reveal compressed material positioned within the negative pressure container; Figure 8B Describes aspects of the present invention Figure 8A a side view of a compression assembly system of FIG. 1 , wherein the compressed material is in an expanded configuration or position and has expanded to the size of the negative pressure container; Figure 8C Describes aspects of the present invention Figure 8B A side view of a compression assembly system, wherein the upper of the shoe last is inserted into the compression material when the compression material is in an expanded configuration or position; Figure 8D Describes aspects of the present invention Figure 8C a side view of a compression assembly system wherein the upper of the last is inserted within the compression material and the compression material is transitioned from an expanded configuration and positioned adjacent to an article; Figure 9 depicts a top perspective view of a portion of an article moving mechanism according to aspects of the present invention, particularly showing a shoe upper of a last positioned within a compression material coupled to a coupling member of the article moving mechanism; Figure 10 depicts a flow chart of a method for preparing an article for thermoforming according to aspects of the present invention; and Figure 11 A flow chart of a method for thermoforming an article according to aspects of the present invention is depicted. Detailed Description of the Invention The subject matter of aspects of the application is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies.

[0002] Aspects herein relate to methods and systems for thermoforming an article and / or for preparing an article for thermoforming. Certain thermoforming systems can include heating an article and then cooling the article while forming the article into a desired shape. Certain current thermoforming systems can only provide inefficient or non-uniform exposure of an article to various temperatures required during the heating and / or cooling of the thermoforming. Further, certain current thermoforming processes can result in defects of the thermoformed article, for example, caused by misalignment or creasing of the material used to help shape or form the thermoformed article, which can result in wrinkles or other defects on the surface of the thermoformed article.

[0003] Systems and methods disclosed herein can alleviate one or more of the above-mentioned problems. For example, systems for preparing an article for thermoforming and subsequent thermoforming of the article are disclosed. Generally, systems and methods disclosed herein can help insert an article into a shaping compression material. In such aspects, a vacuum or negative pressure can be applied to such shaping compression material to apply a compression force to all or a portion of the article during a thermoforming process. In certain aspects, a compression material or vacuum bag that is similar in shape to the article and / or substantially similar in size to the article can be used, which can limit wrinkles and other defects formed on the surface of the thermoformed article. However, due to minimal size and / or shape differences between the lasted upper and the compression material, it can be manually difficult to insert the lasted upper into the compression material.

[0004] The systems and methods described herein allow for efficient and aligned insertion of an article into a compression material (e.g., a shaped compression material). For example, in one aspect, a compression material can be placed in a container, and a negative or vacuum pressure can be applied to expand the compression material to the size of the container, allowing for easy insertion of an article into the compression material. In some aspects, identifying symbols on the container and / or the compression material can guide the article for correct aligned insertion into the compression material. In such aspects, once the article is inserted into the expanded compression material, ambient atmospheric pressure (or a pressure higher than the previously applied negative pressure) can be applied to cause the compression material to transition from an expanded configuration to a more neutral configuration while the article is inserted into the compression material. In aspects, a vacuum pressure can then be applied so that the compression material can compress onto the article to allow for thermoforming.

[0005] Further, in certain aspects, the systems and methods disclosed herein can provide efficient and uniform exposure at temperatures that can be needed for each of the steps in the thermoforming process. For example, in aspects, the systems and methods disclosed herein can introduce an article into a heating station and rotate the article within the heating station so that each side of the article is exposed to a heating element present within the heating station, which can allow for more uniform heating of the article. Further, in aspects, the article can be exposed to a vacuum pressure so that the compression material applies a compressive force to the article as it is introduced into and rotated within the heating station. Further, in certain aspects, the article can also be introduced into a cooling station and rotated within the cooling station to allow for efficient cooling of the heated article. In such aspects, the cooling station can include a liquid, and rotation of the heated article can facilitate more rapid conduction of heat from the upper to the liquid, thereby more efficiently cooling the upper. In such aspects, the article can be exposed to a vacuum pressure so that the compression material applies a compressive force to the article as it is introduced into and rotated within the cooling station. In aspects, the vacuum pressure can be a continuous draw while the article is exposed to the heating and cooling stations, or can be a single initial draw prior to exposure to the heating and / or cooling stations, and the compression material can be sealed so as to maintain the compressive force on the article throughout the thermoforming process.

[0006] Accordingly, in one aspect, a method for preparing an article for thermoforming is provided. The method can include inserting a compression material into a container, where the compression material can be present in a first position or configuration in the container. In this aspect, at least a portion of the compression material can form an interior portion adapted to receive an article. In some aspects, the method can further include exposing a region between an outer surface of the compression material and an inner surface of the container to a pressure less than atmospheric pressure to transition the compression material from the first position to an expanded position, where, in the expanded position, at least a portion of the compression material is closer to the inner surface of the container than in the first position. In aspects, the method can further include inserting at least a portion of the article into the interior portion of the compression material while the compression material is in the expanded position. In aspects, the article can be present on a forming material. In aspects, the method can further include exposing the region between the outer surface of the compression material and the inner surface of the container to a pressure about at atmospheric pressure such that the compression material transitions from the expanded position to a second position, where, in the second position, at least a portion of the article is in the interior portion of the compression material and at least a portion of the compression material is closer to the article than when the article was inserted into the compression material in the expanded position.

[0007] In another aspect, a system for preparing an article for thermoforming is provided. The system can include a container. In aspects, the container can have an interior volume defined by at least a bottom portion and at least one sidewall extending upwardly from the bottom portion to a top portion. In aspects, the container can include a port. In aspects, the system can further include a negative pressure generating system that can be coupled to the port of the container. In aspects, the system can further include a compression material that can be positioned within the interior volume of the container, where at least a portion of the compression material forms an interior portion adapted to receive an article. In aspects, the negative pressure generating system and the port are cooperatively adapted to expose a region between an outer surface of the compression material and an inner surface of the at least one sidewall to a pressure less than atmospheric pressure such that the compression material expands.

[0008] In yet another aspect, a method for thermoforming an article is provided. The method can include receiving a compression material having an article positioned inside the compression material. In aspects, the method can further include exposing a region between an inner surface of the compression material and an outer surface of the article to a pressure less than atmospheric pressure such that the compression material exerts a compressive force onto the outer surface of the article. In aspects, the method can further include introducing the article to one or more heating stations and rotating the article within the one or more heating stations. Further, in aspects, the method can include introducing the article to a cooling station and rotating the article within the cooling station.

[0009] In yet another aspect, a system for thermoforming articles is provided. The system can include one or more heating stations. In aspects, each of the one or more heating stations can include a heating chamber. In aspects, the system can further include a cooling station including a cooling chamber. In aspects, the system can further include an article movement mechanism. In aspects, the article movement mechanism can include at least one coupling member adapted to couple an article to the article movement mechanism. In aspects, the article movement mechanism can be adapted to rotate the article within the heating chamber, the cooling chamber, or both.

[0010] Turning now to the drawings, Figure 1 A system 100 for thermoforming articles is depicted. It should be understood that while system 100 depicts a portion of an article of footwear, e.g., an upper 110, exposed to system 100, other types of articles or other portions of articles of footwear can be used in system 100 described herein. In aspects, system 100 can be used to thermoform a portion of an article of footwear, e.g., an upper 110, to a desired shape. Figure 1 In aspects depicted in FIG. 1, system 100 includes a heating station 200, a cooling station 300, a dryer 400, a loading / unloading station 600, and an article movement mechanism 500.

[0011] As Figure 1 As can be seen in FIG. 1, article movement mechanism 500 is coupled to upper 110 for transport to the various stations and areas of system 100. In aspects, article movement mechanism 500 can be coupled to upper 110 via a coupling member 520 at one end of a radially extending member 510. The coupling of an article to article movement mechanism 500 will be discussed further below. Figure 1 In aspects depicted in FIG. 1, article movement mechanism 500 is coupled to one article, i.e., upper 110, via a coupling member 520 at one end of a radially extending member 510. The coupling of an article to article movement mechanism 500 will be discussed further below.

[0012] It should be understood that article movement mechanism 500 can be coupled to any number of articles. For example, in one aspect, article movement mechanism 500 can include more than one radially extending member, with each member coupled to an article. In such aspects, system 100 can simultaneously expose multiple articles to a portion of the thermoforming system, e.g., each article exposed to one station or chamber at a certain time. Further, in such aspects, each article can be exposed to each station or chamber for substantially the same amount of time.

[0013] As Figure 1As can be seen in aspects of the system 100, the system 100 is configured such that each station or chamber is positioned circumferentially with the article movement mechanism 500 positioned at the center. In such aspects, this circumferential design can provide for a reduced footprint in the processing area and increased productivity as article movement and / or additional operator contact with the article is reduced. Although not depicted in the figures, the system 100 can include an enclosure for housing the entire system 100 or a portion thereof. For example, in one aspect, the system 100 can include an enclosure that encloses the heating station 200, the cooling station 300, the dryer 400, and the loading / unloading station 600.

[0014] In aspects depicted in Figure 1 In aspects depicted in Figure 1 In aspects depicted in

[0015] In aspects, to expose the upper 110 or other article to the heating station 200, such as by introducing the upper 110 into the heating chamber 212, the article movement mechanism 500 can be rotated about an axis, such as axis 501, and then lower the upper 110 through an opening 222 in the top portion 224 of the first heating chamber 212 of the heating station 200. In such aspects, the article movement mechanism 500 can include any mechanism for moving the upper 110 and / or the radially extending member 510 upward away from the heating chamber 212 and downward toward the heating chamber 212. Further, in aspects, as discussed further below, the article movement mechanism 500 is adapted to rotate the upper 110 or other article while the upper 110 is positioned within the heating chamber 212 or any other heating chamber 214, 216, 218, or 220.

[0016] Figure 2 One specific example of a heating chamber, the heating chamber 212, is depicted in Figure 2As can be seen in FIG, the upper 110 is positioned in the interior portion 226 of the heating chamber 212, for example, by vertical displacement of the radially extending member 510 downwardly toward the heating chamber 212. Figure 2 , when upper 110 or other article is positioned within heating chamber 212, coupling member 520 may at least partially or completely cover opening 222 of top portion 224, which may help retain thermal energy within interior portion 226. In alternative aspects, coupling member 520 may not cover opening 222 of top portion 224.

[0017] exist Figure 2 , the heating chamber 212 can include one or more thermal elements 228. In this aspect, the thermal elements 228 are positioned on the sidewalls 230 of the heating chamber 212. It should be understood that other locations of thermal elements within the heating chamber 212 are also contemplated for use in the system 100 described herein. It should also be understood that more than one thermal element can be used in the heating chamber 212, and that one thermal element 228 is depicted as merely an example. Additionally, Figure 2 The thermal element 228 in the figure is schematically depicted, and such depiction is not intended to limit the type and / or shape of thermal elements that can be used in the system 100 disclosed herein. For example, in one aspect, the thermal element 228 can be an infrared (IR) lamp. In the same or alternative aspects, the thermal element 228 can include a heated fluid, such as air. In aspects not depicted in the figure, the thermal element 228 can include an IR lamp or other heat source, which is adjacent to a fan for distributing the thermal energy emitted by the IR lamp or other heat source.

[0018] In certain aspects, heating station 200 and / or heating chamber 212 are adapted to expose an article, such as upper 110, to a temperature sufficient to cause at least a portion of the material of the article to melt and / or deform. For example, in one aspect, heating station 200 and / or heating chamber 212 are adapted to expose an article, such as upper 110, to a temperature above the melting temperature of the thermoplastic material of upper 110 or the other article. In the same or alternative aspects, heating station 200 and / or heating chamber 212 are adapted to expose an article, such as upper 110, to a temperature within a range of approximately 100° C. to approximately 350° C., approximately 150° C. to approximately 340° C., or approximately 200° C. to approximately 330° C.

[0019] As discussed above, in certain aspects, system 100 can provide for rotation of upper 110 while upper 110 is positioned within heating chamber 212. For example, Figure 2As depicted, at least a portion of the article movement mechanism 500 can rotate about the axis 232 such that the upper 110 can be more evenly heated in the heating chamber 212. For example, in one aspect, the coupling member 520 can rotate about the axis 232 relative to the radially extending member 510 to facilitate rotation of the upper 110 in the interior portion 226 of the heating chamber 212, which can result in each side of the article 110 being directly exposed to the heating element 228. The article movement mechanism 500 will be discussed in greater detail below.

[0020] It should be appreciated that although the heating chamber 212 is discussed in detail above, the description of any or all features of the heating chamber 212 can apply to other heating chambers, such as one or more of the heating chambers 214, 216, 218, and 220.

[0021] As discussed above, the heating station 200 can include a plurality of heating chambers 210. In such aspects, the plurality of heating chambers 210 can be used to incrementally increase the temperature to which the upper 110 is exposed in a sequential manner. For example, in one aspect, the upper 110 is exposed to an increased temperature at each subsequent heating chamber. In such aspects, the upper 110 can be exposed to a temperature that is at least about 2 °C higher, at least about 5 °C higher, or at least about 7 °C higher at a subsequent heating chamber immediately following a previous heating chamber. For example, in one aspect, the upper 110 can be exposed to a temperature that is about 2 °C or about 5 °C higher at the heating chamber 214 than the temperature to which the upper 110 is exposed in the heating chamber 212.

[0022] In certain aspects, after the upper 110 is exposed to the heating station 200, such as to one or more of the plurality of heating chambers 210, the upper 110 is exposed to a cooling station, such as the cooling station 300. Figure 3 One example of a cooling station 300 is depicted. As Figure 3 As can be seen in the depicted aspects, the cooling station 300 includes a cooling chamber 310 and a secondary cooling source 320. In certain aspects, the article movement mechanism 500 (e.g., through rotation of the radially extending member 510) can transfer the upper 110 from the heating station 200 to the cooling station 300.

[0023] In certain aspects, the cooling station 300 can expose the upper 110 to a cooled fluid, such as a cooled liquid. For example, as Figure 3As can be seen, the cooling station 310 can include a liquid 311 in the interior portion 312 of the cooling chamber 310. In such aspects, the liquid 311 can be cooled to facilitate a rapid decrease in temperature of the heated upper 110. In certain aspects, the liquid 311 can be maintained at a particular temperature through circulation of the liquid 311 between the cooling chamber 310 and a secondary cooling source 320, which in aspects can cool the liquid 311. The secondary cooling source 320 can cool the liquid 311 using conventional liquid cooling techniques. In certain aspects, such as Figure 3 As depicted in the figure, the liquid 311 from the cooling chamber 310 can travel via conduit 321 to the secondary cooling source 320, which in aspects can have been heated due to contact with the heated upper 110. Further, in such aspects, the cooled liquid 311 can travel back to the cooling chamber 310 via conduit 322. It should be appreciated that other configurations for maintaining the liquid 311 at a particular temperature can be utilized and are contemplated for use in the systems described herein.

[0024] In aspects, the cooling station 300 can expose the upper 110 to a temperature in a range of about 0°C to about 30°C, about 2°C to about 25°C, about 3°C to about 20°C, or a temperature of about 4°C or about 5°C. In certain aspects, the liquid 311 can include water or one or more other aqueous solvents. In the same or alternative aspects, the liquid 311 can include ethylene glycol or one or more other coolant liquids.

[0025] In certain aspects, circulation of the liquid 311 can provide agitation or circulation within the cooling chamber 310 such that heat from the heated upper 110 is effectively transferred from the upper 110 to the liquid 311. In the same or alternative aspects, the upper 110 can be rotated about an axis 324 to provide agitation of the liquid 311, for example, the coupling member 520 can be rotated about the axis 324 relative to the radially extending member 510 to facilitate rotation of the upper 110 in the interior portion 312 of the cooling chamber 310. The article movement mechanism 500 will be discussed in greater detail below.

[0026] In certain aspects not depicted in the figure, the upper 110 can be exposed to more than one cooling chamber 310. For example, in one aspect, the system 100 can include an additional cooling chamber such that the upper is first exposed to the cooling chamber 310 and then, subsequently, to a second cooling chamber. In such aspects, the second cooling chamber can include any or all of the features of the cooling chamber 310 discussed above.

[0027] As discussed further below, the upper 110 can be positioned inside the compression material. In such aspects, the compression material can be water impermeable or liquid impermeable such that the upper 110 does not absorb the liquid 311 or otherwise attract the liquid 311 onto it or come into contact with the liquid 311 when the upper 110 is submerged in the liquid 311. Further, in such aspects, the compression material can retain the liquid 311 on its outer surface after the upper 110 is removed from the cooling chamber 310, which can be removed by the dryer 400.

[0028] Figure 4 One example of a dryer 400 is depicted. In certain aspects, the upper 110 can be optionally transferred to the dryer 400 after exposure to the cooling station 300, for example, rotated from adjacent the cooling station 300 to the dryer 400 via the radial extension member 510. It should be appreciated that, Figure 4 The dryer 400 depicted in FIG. 6 is merely one example dryer 400, and other drying mechanisms are also contemplated for use in the present system 100. Figure 4 The dryer 400 depicted in FIG. 6 includes one or more air nozzles 410 for providing an air flow to the upper 110 in order to remove at least a portion of the liquid 311 that can be present on the upper 110 or the compression material. In one aspect, the air flow can be at room temperature, for example, air at about 25 °C.

[0029] In certain aspects, the upper 110 can be vertically displaced, for example, via vertical displacement of the radial extension member 510, while the air nozzles 410 provide an air flow over all or a portion of the upper 110. In certain aspects, the dryer 400 can optionally include a reservoir 420 for collecting the liquid 311 removed from the upper 110 or the compression material positioned on the upper 110.

[0030] In one aspect, the upper 110 can be rotated about the vertical axis 522 via rotation of the coupling member 520, as discussed herein. In alternative aspects, the upper 110 can not be rotated about the vertical axis 522 when the upper 110 is exposed to the air flow from the air nozzles 410.

[0031] In certain aspects, once the upper 110 is exposed to the dryer 400 or the cooling station 300, the upper 110 can be transferred to the loading / unloading station 600 for removal from the system 100 and / or for further processing. In such aspects, the upper 110 can be transferred to the loading / unloading station 600 via rotation of the radial extension member 510.

[0032] As discussed above, in aspects, the system 100 can expose the upper 110 or other article to the heating station 200, the cooling station 300, and the dryer 400. In certain aspects, in operation, the upper 110 is loaded into the system 100, for example at the loading / unloading station 600, by coupling the upper 110 to the article movement mechanism 500. The coupling of the article to the article movement mechanism 500 will be discussed in greater detail below. Further, in aspects, once the upper 110 is coupled to the article movement mechanism 500, the article movement mechanism 500 can be rotated about an axis (e.g. axis 501) and then lower the upper 110 through the opening 222 in the top portion 224 of the first heating chamber 212 of the heating station 200. In such aspects, the article movement mechanism 500 can include any mechanism for moving the upper 110 and / or the radially extending member 510 upward away from the heating chamber 212 and downward toward the heating chamber 212. Further, in aspects, the article 110 can be exposed to the heating chamber 214 via the article movement mechanism 500, then exposed to the heating chamber 216, then exposed to the heating chamber 218, and then exposed to the heating chamber 220 (or exposed to any number of heating chambers appropriate for a particular system configuration or process) via the article movement mechanism 500. Further, in certain aspects, the upper 110 is then transferred to the cooling station 300 for cooling the heated upper 110. Optionally, the upper 110 is then transferred to the dryer 400 for removing at least a portion of the liquid 311 present on the upper 110 or compressed material. Further, in such aspects, the upper 110 can be transferred back to the loading / unloading station 600 for removal from the system 100.

[0033] As discussed above, in certain aspects, the article moving mechanism 500 can be used to transfer the upper 110 from one station to the next. Further, as discussed above, the article moving mechanism 500 can include a plurality of radially extending members, with each member coupled to an upper. In such aspects, the article moving mechanism 500 can simultaneously transfer each upper attached to each of the plurality of radially extending members to a subsequent processing station. In other words, in one aspect, the plurality of radially extending members can be fixedly coupled to the central portion 530, which rotates, thereby causing each of the plurality of radially extending members and the articles coupled to each of the plurality of radially extending members to rotate. In such aspects, each article or upper is exposed to each station for a substantially similar amount of processing time. For example, the upper 110 can be exposed to a single cooling station 300 for approximately 30 seconds, while the upper 110 is exposed to each of five heating chambers for 30 seconds each, such that the upper 110 is exposed to the heating station 200 for approximately 150 seconds. In aspects in which there can be six heating chambers, the upper 110 can be exposed to the heating station for approximately 180 seconds, while being exposed to the cooling station for 30 seconds (or 60 seconds in aspects in which there are two cooling chambers). It should be understood that the 30 second time period mentioned above for each station or step is merely one example of a time period for exposure to the plurality of stations or steps discussed above. In alternative aspects, the upper 110 or other article can be exposed to each station or step for approximately 10 seconds, approximately 20 seconds, approximately 28 seconds, approximately 45 seconds, or approximately 60 seconds.

[0034] As discussed above, one example article for use with the system 100 disclosed herein can be an upper 110 for an article of footwear. Figures 5A-5D Various components of the upper 110 are depicted, as well as assembly of the components of the upper 110 on the last 700. It should be understood that, in certain aspects, the upper 110 and the components of the upper 110 mentioned below can be assembled in other manners not depicted in the figures. For example, in one aspect, the components of the upper 110 can be assembled off of the last 700, which can then be applied to the last 700 after assembly.

[0035] Figure 5A A liner 120 is depicted as being placed on the last 700. In certain aspects, the last 700 can be formed of a rigid material capable of withstanding the temperatures and other processing parameters discussed herein with respect to the system 100. In aspects, the liner 120 can include a heel portion 122, a toe portion 124, and a ground-facing portion 126.

[0036] In certain aspects, the liner 120 can be formed from any type of material. In certain aspects, the liner 120 can include a knit textile, a braided textile, a woven textile, and a non-woven textile, a film, a sheet, or a molded article such as an injection molded article, a foam material, or a combination thereof. In the same or alternative aspects, the liner 120 can include a natural material, a synthetic material, or a combination of a natural material and a synthetic material. In one aspect, the liner 120 can include a non-woven textile. In aspects, the liner 120 can include multiple pieces of one or more materials secured together, for example, by bonding or stitching. In one or more aspects, the liner 120 can optionally include a plurality of eyelets 128. In aspects, the liner 120 is positioned on the last 700 by inserting the last 700 into the cavity 129 of the liner 120.

[0037] Figure 5B A bottom layer 130 is depicted positioned on the ground-facing portion 126 of the liner 120 positioned on the last 700. In one aspect, the bottom layer 130 can be formed from any type of material so long as such material can provide support and stability to the upper 110 and the article of footwear formed from the upper 110. In one aspect, the bottom layer 130 can include a material that can be fused with other portions of the upper in a thermoforming process. In such aspects, the bottom layer can include a thermoplastic material having a melting temperature, a Vicat softening temperature, a heat deflection temperature, or any combination thereof, in a range of about 80 °C to about 135 °C or from about 90 °C to about 120 °C. The melting temperature can be determined according to the test method detailed in ASTM D7138-16. The Vicat softening temperature can be determined according to the test method detailed in ASTM D1525-09, preferably using Load A and Rate A. The heat deflection temperature can be determined according to the test method detailed in ASTM D648-16, using an applied stress of 0.455 MPa. In aspects, all or a portion of the bottom layer 130 can be made from such material or the bottom layer 130 can be coated with such material for fusing to additional portions or portions of the upper 110, such as the liner 120 and / or the sock 150 discussed further below. In one aspect, an adhesive such as a hot melt adhesive can be used to secure at least a portion of the bottom layer 130 to the liner 120.

[0038] Figure 5CA heel stabilizer 140 is depicted as being placed on the heel portion 122 of the liner 120. In certain aspects, the heel stabilizer 140 can provide stability to the heel region of the upper. In certain aspects, an adhesive, such as a hot melt adhesive, can be used to secure at least a portion of the heel stabilizer 140 to the liner 120. In aspects, the heel stabilizer 140 can be formed of any material so long as such material can provide heel support when exposed to the system 100 and processes described herein.

[0039] In aspects, the heel stabilizer 140 can include one or more of the fusible materials discussed above with reference to the underlayer 130. In such aspects, at least a portion of the heel stabilizer 140 can melt or deform and fuse or bond to additional components of the upper 110, such as the liner 120 and / or the sock 150, when exposed to the system 100 and / or processes described herein.

[0040] Figure 5D A sock 150 is depicted as being placed on the liner 120, the underlayer 130, and the heel stabilizer 140 positioned on the last 700. Figure 5D The sock 150 includes a ground-facing portion 152, a heel portion 154, a forefoot portion 156, and a plurality of eyelets 158. In certain aspects, the sock 150 can not include eyelets 158. In one aspect, the sock 150 can be sock-like in that it can substantially cover the forefoot region, the heel region, the ground-facing region of the wearer’s foot by itself.

[0041] In aspects, the sock 150 can include a woven textile, a knit textile, a knitted textile, or a nonwoven textile. In aspects, such a textile can include one or more yarns or fibers that include a yarn or fiber composition that includes a thermoplastic material. In such aspects, the thermoplastic material and / or the yarn or fiber composition can exhibit a melting temperature (or melting point), a Vicat softening temperature, a heat deflection temperature, or a combination thereof, from about 80 °C to about 135 °C, or from about 90 °C to about 120 °C. In an aspect, the thermoplastic material and / or the yarn or fiber composition can exhibit a melting temperature, a Vicat softening temperature, a heat deflection temperature, or a combination thereof, of about 135 °C or less, about 125 °C or less, or about 120 °C or less. In the same or alternative aspects, the sock 150 can include one or more materials that will not melt or deform under the processing conditions disclosed herein. In such aspects, in the case of such a thermoplastic material, such a material can exhibit a melting temperature greater than about 135 °C, greater than about 140 °C, or greater than about 150 °C. Further, in such aspects, additional materials that can be present in the article, such as materials that are different than the thermoplastic material, can not degrade at temperatures less than about 150 °C, about 140 °C, or about 135 °C.

[0042] In aspects, the eyelets 158 on the sock 150 can be aligned with the eyelets 128 present on the liner 120. In aspects, the alignment of the eyelets 158 with the eyelets 128 can be achieved with an alignment mechanism.

[0043] Turning now to Figure 5E , a film 160 has been placed on the exterior of the sock 150 present on the last 700 is depicted. In certain aspects, the film 160 can include a ground-facing portion 162, a heel portion 164, and a toe-covering portion 166. In certain aspects, the film 160 can include a thermoplastic material that can melt and cool to form a film on the upper 110 to, for example, provide support, stability, and / or moisture resistance, by exposure to the system 100 and thermoforming process disclosed herein. In certain aspects, the thermoplastic material can exhibit a melting temperature, a heat deflection temperature, a Vicat softening temperature, or a combination thereof, in a range of 80 °C to about 135 °C, or a range of about 90 °C to about 120 °C, or about 135 °C or less, about 125 °C or less, or about 120 °C or less. It will be appreciated that, Figure 5E The film 160 depicted in

[0044] Figure 6 The above reference to Figures 5A-5EThe assembly upper 110 discussed is positioned on the last 700. As discussed above, the upper 110 can include a material that can melt and flow when exposed to the system 100 and thermoforming process disclosed herein. Further, as discussed above, in certain aspects, one or more of the components of the upper 110 can include a material that fuses or bonds to another material or additional component of the upper 110 when exposed to the system 100 and thermoforming process disclosed herein. In one or more of these aspects, it can be desirable to provide a compression force to the upper 110 to facilitate the fusing or bonding, to limit the flow of the melted thermoplastic material, and / or to help form the upper 110 or a portion thereof into a shaped material, such as the last 700. In such aspects, a compression sock can be used to provide such a compression force to the outer surface 112 of the upper 110.

[0045] Figure 6 One example compression sock 800 applied to the upper 110 positioned on the last 700 is depicted. As can be seen in Figure 6 The compression sock 800 can be sock-like, including a ground-facing portion 802, a heel portion 804, and a forefoot portion 806, as can be seen in

[0046] Figure 7A An uppered upper 110 is depicted, with the compression sock 800 positioned on the uppered upper 110. Figure 7A A close-up view of the heel region of the uppered upper 110 of Figures 5A-5E The arrangement of the various components of the upper 110 discussed above with reference to Figure 7A As can be seen in Figure 7B A close-up view of the heel region of the uppered upper 110 of Figure 7A

[0047] ​As discussed above, in certain aspects, the compression sock 800 can apply a compression force onto the upper 110, thereby pressing the upper 110 against the rigid last 700. In such aspects, the compression force can help limit the flow of the film 160 when melted, such that the film 160 cools and hardens in the desired location on the upper 110. Further, in aspects, the compression force can facilitate the bonding of one or more of the components of the upper 110, such as the heel counter 140 fusing or bonding to the sock 150 and / or the liner 120.

[0048] In certain aspects, an additional level of compression force onto the upper 110 can be desired in addition to the compression force applied by the compression sock 800. In such aspects, the uppered upper 110 covered with the compression sock 800 can have a compression material that compresses onto the outer surface of the compression sock 800 to apply such additional level of compression force to the uppered upper 110. In certain aspects, the compression material can be a vacuum bag. The compression material can be formed of any material so long as such material will not melt or deform throughout the entire process of the system 100 and process disclosed herein. In one aspect, the compression material can be used directly on the upper 110 without the compression sock 800.

[0049] In one or more aspects, the vacuum bag or compression material can be at least partially shaped to resemble the shape of the formed material and / or the article to be thermoformed. For example, Figure 8A A compression material 910 is depicted that includes a portion 912 that is at least partially or substantially shaped to resemble the shape of the last 700 and / or the upper 110, at least because the portion 912 generally includes a sock shape having a ground-facing portion 914, a heel portion 918, and a toe portion 916.

[0050] In certain aspects, it can be desirable for the portion 912 of the compression material 910 to be similar in size or slightly larger in size than the uppered upper 110 inserted therein. However, in such aspects, it can be difficult to effectively insert the uppered upper 110 into the compression material 910 of similar size. In such aspects, a system or mechanism can be utilized to facilitate the assembly of the compression material 910 onto the uppered upper 110.

[0051] Figures 8A-8D A compression assembly system 900 is depicted that can be utilized to facilitate the insertion of the uppered upper 110 into the compression material 910 of similar size and / or shape. As Figure 8AAs can be seen, compression assembly system 900 can include compression material 910 and negative pressure container 920. It should be appreciated that compression assembly system 900 is merely one example system for facilitating assembly of compression material 910 to a lasted upper 110 or other article, and that other system components or designs are also contemplated by the present disclosure.

[0052] As Figure 8A As can be seen, compression material 910 has been inserted into interior portion 926 of negative pressure container 920. As discussed above, because compression material 910 can be similar in size or shape to lasted upper 110, it can be difficult to effectively insert lasted upper 110 into interior portion 911 of compression material 910. Figure 8A The neutral configuration or position of compression material 910 in can make it difficult to effectively insert lasted upper 110 into interior portion 911 of compression material 910. In such aspects, compression material 910 can transition to an inflated configuration to inflate interior portion 911, thereby allowing for more effective insertion of lasted upper 110. For example, as Figures 8A-8D As can be seen, negative pressure container 920 can include port 921 that can provide negative pressure or vacuum pressure to volume 921a between outer surface 913 of compression material 910 and inner surface 928 of negative pressure container 920. In such aspects, at least a portion of compression material 910 can be coupled to a seal or otherwise provide or form a seal at top portions 922a and 922b of negative pressure container 920 to allow for the extraction of vacuum pressure in volume 921a. In certain aspects not depicted in the figures, port 921 can be coupled to a negative pressure generating device to provide vacuum pressure to volume 921a.

[0053] As Figure 8B As can be seen, when volume 921a between outer surface 913 of compression material 910 and inner surface 928 of negative pressure container 920 is exposed to negative pressure or vacuum pressure, compression material 910 can transition to an inflated configuration such that at least a portion of compression material 910 is larger than Figure 8A The neutral configuration of compression material depicted in is closer to side walls 924a and 924b of negative pressure container 920. In one aspect, when volume 921a between outer surface 913 of compression material 910 and inner surface 928 of negative pressure container 920 is exposed to negative pressure or vacuum pressure, compression material 910 can form to the size of negative pressure container 920.

[0054] In certain aspects, in this inflated configuration of compression material 910, such as Figure 8B and Figure 8CThe upper 110, depicted in FIG. 10, positioned on the last 700 can be more easily inserted into the interior portion 911 of the compression material 910. In aspects not depicted in the figure, an identifying symbol on the compression material 910, the negative pressure container 920, or both, can be provided to identify the orientation in which the upper 110 should be placed in the compression material for proper fit. In aspects, the port 921 can provide continuous extraction of vacuum pressure or exposure of the vacuum pressure to the volume 921a as the lasted upper 110 is inserted into the interior portion 911. In alternative aspects, the port 921 can provide an initial non-continuous extraction of vacuum pressure or exposure of the vacuum pressure to the volume 921a and then be sealed to maintain the compression material in an expanded configuration as the lasted upper 110 is inserted into the interior portion 911.

[0055] In certain aspects, once the lasted upper 110 is inserted into the interior portion 911 of the compression material 910, the port 921 can cease providing negative or vacuum pressure to the volume 921a or remove the seal so that the compression material 910 can transition from the expanded configuration depicted in FIG. 10 to the closed configuration or position depicted in FIG. 11. Figure 8B and Figure 8C In certain aspects, once the lasted upper 110 is inserted into the interior portion 911 of the compression material 910, the port 921 can cease providing negative or vacuum pressure to the volume 921a or remove the seal so that the compression material 910 can transition from the expanded configuration depicted in FIG. 10 to the closed configuration or position depicted in FIG. 11. Figure 8D In one aspect, the port 921 can supply pressure to the volume 921a at or about atmospheric pressure, which can cause the compression material 910 to displace away from the sidewalls 924a and 924b and toward the lasted upper 110. Further, in such aspects, the compression material 910 can disengage from the top portions 922a and 922b and be removed for further processing, such as compressing the compression material 910 onto the lasted upper 110 and exposing the lasted upper 110 to the system 100 and / or thermoforming process described herein.

[0056] In certain aspects, once the lasted upper 110 is inserted into the compression material 910, the lasted upper 110 can be coupled to the article movement mechanism 500. Figure 9 A close-up view of one example article movement mechanism 500 including a radial extension member 510 and a coupling member 520 is depicted in FIG. 12. Figure 9 One example of how the lasted upper 110 can be coupled to the article movement mechanism 500 is also depicted in FIG. 12.

[0057] In certain aspects, the portion 910a of the compression material 910 that extends beyond the lasted upper 110 can be coupled to the article movement mechanism 500. From Figure 9As can be seen in the depicted aspects, portions 910a of the compression material 910 can extend through the coupling member 520, with the top portion 522 serving to seal the interior portion 911 of the compression material 910. In aspects not depicted in the figures, a port within the coupling member 520 of the article movement mechanism 500 can provide a vacuum or negative pressure to the interior portion 911 of the compression material 910 in order to cause the compression material 910 to exert a compressive force onto the lasted upper 110. In such aspects, Figure 1 A negative pressure generating device 950 can be coupled to the article movement mechanism 500 in the depicted aspects. The negative pressure generating device 950 can be any type of vacuum pressure device, and can be coupled to the article movement mechanism 500 using any coupling mechanism, with the particular device or coupling mechanism being selected for a particular design or purpose.

[0058] In one aspect, the interior portion 911 of the compression material 910 can be exposed to a vacuum or negative pressure in a continuous manner as the upper 110 is transferred between the stations or chambers of the system 100 described above. In such aspects, the article movement mechanism 500 can provide this continuous negative pressure via the negative pressure generating system 950.

[0059] In alternative aspects, the interior portion 911 of the compression material 910 can be exposed to a vacuum or negative pressure at an initial single step in order to compress the compression material 910 onto the lasted upper 110 and then the coupling member 520 can seal the interior portion 911 of the compression material 910, for example via the top portion 522 or other member, in order to maintain the vacuum pressure within the interior portion 911. In such aspects, the article movement mechanism 500 can provide this initial single exposure to negative pressure via the negative pressure generating system 950. In one aspect, an additional source of negative pressure other than the negative pressure generating system 950 can be used to provide the vacuum pressure to the interior portion 911, and the compression material 910 can be sealed by the coupling member 520 or by an additional sealing mechanism.

[0060] As discussed above, in certain aspects, the upper 110 can be rotated when the upper 110 is positioned within the heating station 200, for example within the heating chamber 212, and / or when the upper 110 is positioned within the cooling station 300, for example within the cooling chamber 310. In addition, as discussed above, in such aspects, the article movement mechanism 500 can rotate the upper 110. As Figure 9 As can be seen, the coupling member 520 can rotate about the vertical axis 501 relative to the radially extending member 510. In one aspect, in order to have a continuous draw of vacuum pressure in the interior portion 911 of the compression material 910, a vacuum can be drawn through a rotational axis, for example the axis 501, from which the compression material 910 and the lasted upper 110 are rotated.

[0061] Further, as can be seen in Figure 9 member 520, the hook 524 can also rotate. In such aspects, a portion of the uppered upper 110 can interface with or be removably coupled to the hook 524 to allow the upper 110 to rotate as the coupling member 520 and hook 524 rotate. In certain aspects, the hook 524 can also provide for efficient loading and unloading of the uppered upper 110, in combination with, for example, easy removal of the compression material 910 from the coupling member 520 by releasing the top portion 522 of the coupling member 520.

[0062] In certain aspects, as discussed above, the compression material 910 can be similar in size and / or shape to the last 700 and / or upper 110. After exposure to the thermoforming process, in certain aspects, it can be desirable to utilize assistance in order to facilitate removal of the compression material 910 from the upper 110. In such aspects, an air stream can be blown into the interior portion 911 of the compression material 910 to help release the compression material 910 from the surface of the upper 110, or to expand the interior portion 911 to make removal of the upper 110 easier. In one aspect, a port associated with the article moving mechanism 500 can provide such an air stream. In alternative aspects, the air stream can be supplied by a separate air nozzle or port that is not associated with the article moving mechanism 500 or other components of the system 100 discussed above.

[0063] Figure 10 A flowchart depicting a method 1000 for preparing an article for thermoforming is depicted. The method 1000 can include the step of inserting a compression material into a container 1010. In aspects, the compression material can include any or all of the features, properties, and parameters of the compression material 910 discussed above with reference to Figures 8A-9 In certain aspects, the container can include any or all of the features, properties, and parameters of the negative pressure container 920 discussed above with reference to Figures 8A-8D In aspects, the compression material is present in the container in a first position. In one aspect, the first position can be similar to the position or configuration of the compression material 910 depicted in Figure 8A In aspects, the compression material can include an interior portion adapted to receive an article.

[0064] Method 1000 can include a step 1020 of exposing the region between the outer surface of the compression material and the inner surface of the container to a pressure that is less than atmospheric pressure. In such aspects, the pressure that is less than atmospheric pressure can transition the compression material from the first position to an expanded position. In such aspects, at least a portion of the compression material can be closer to the inner surface of the container in the expanded position than in the first position. In one or more aspects, in the expanded position, the compression material can assume at least a portion of the dimensions of the container, such as Figure 8B depicted in FIGS. 10A-10B.

[0065] Method 1000 can also include a step 1030 of inserting at least a portion of the article into the interior portion of the compression material. As discussed above, in certain aspects, the article can include an upper positioned on a last. In such aspects, the upper can include any or all of the features, properties, and parameters of the upper 110 discussed above with reference to Figures 5A-7B In some aspects, the entire upper or a portion of the upper can be positioned inside the compression material.

[0066] Method 1000 can include a step 1040 of exposing the region between the outer surface of the compression material and the inner surface of the container to a pressure that is about atmospheric pressure such that the compression material transitions from the expanded position to a second position. In such aspects, in the second position, at least a portion of the article is located in the interior of the compression material and the compression material is closer to the article than when the article was inserted into the compression material in the expanded position. For example, in one aspect, the second position of the compression material can be similar to the position depicted in Figure 8D FIGS. 10A-10B, where the compression material has moved away from the sidewalls of the container and is positioned adjacent to the article.

[0067] Figure 11 A flowchart of a method 1100 for thermoforming an article is depicted. Method 1100 can include a step 1110 of receiving a compression material having an article positioned inside the compression material. In aspects, the compression material can include any or all of the features, properties, and parameters of the compression material 910 discussed above with reference to Figures 8A-9 In certain aspects, the article can include an uppered shoe, such as the uppered shoe 110 discussed above with reference to Figures 5A-7B FIGS. 11A-11B.

[0068] Method 1100 can include a step 1120 of exposing the region between the inner surface of the compression material and the outer surface of the article to a pressure that is less than atmospheric pressure. In such aspects, the compression material can exert a compression force onto the outer surface of the article. In certain aspects, the article movement mechanism 500 and the negative pressure generation system 950 can be used to provide the negative pressure and expose the region to a pressure that is less than atmospheric pressure.

[0069] Method 1100 can include a step 1130 of introducing the article into one or more heating stations. In aspects, the one or more heating stations can include any or all of the features, properties, and parameters of heating station 200 discussed above with reference to Figure 1 and Figure 2 Method 1100 can also include a step 1140 of rotating the article within each of the one or more heating stations. In such aspects, article movement mechanism 500 discussed above with reference to Figure 1 , Figure 2 and Figure 9 may be used to couple the article to article movement mechanism 500 and rotate the article within each of the one or more heating stations.

[0070] Method 1100 can also include a step 1150 of introducing the article into a cooling station. In aspects, the cooling station can include any or all of the features, properties, and parameters of cooling station 300 discussed above with reference to Figure 1 and Figure 3 In an aspect, article movement mechanism 500 discussed above with reference to Figure 1 , Figure 3 and Figure 9 may be used to transfer the article from the one or more heating stations to the cooling station. Method 1100 can also include a step 1160 of rotating the article within the cooling station. In such aspects, article movement mechanism 500 discussed above with reference to Figure 1 , Figure 2 and Figure 9 may be used to rotate the article within the cooling station.

[0071] While specific reference is made to one or more steps in Figure 10 and Figure 11 , it is still contemplated that one or more additional or alternative steps can be implemented while still achieving aspects provided herein. Thus, blocks can be added or omitted while still remaining within the scope of the present disclosure.

[0072] As used herein and in connection with the claims set forth below, the term “any of the clauses” or similar variations of that term is intended to be construed such that the features of the claims / clauses can be combined in any combination. For example, exemplary clause 4 can indicate a method / device of any of clauses 1-3, which is intended to be construed such that the features of clause 1 and clause 4 can be combined, the features of clause 2 and clause 4 can be combined, the features of clause 3 and clause 4 can be combined, the features of clauses 1, 2, and 4 can be combined, the features of clauses 2, 3, and 4 can be combined, the features of clauses 1, 2, 3, and 4 can be combined, and / or other variations. Further, the term “any of the clauses” or similar variations of that term is intended to include “any of the clauses” or other variations of those terms, as indicated by some of the examples provided above.

[0073] The following clauses are aspects contemplated herein.

[0074] Clause 1. A method for preparing an article for thermoforming, the method comprising: inserting a compression material into a container, the compression material existing in a first position in the container, wherein at least a portion of the compression material forms an interior portion adapted to receive an article; exposing an area between an outer surface of the compression material and an inner surface of the container to a pressure that is less than atmospheric pressure to transition the compression material from the first position to an expanded position, wherein in the expanded position at least a portion of the compression material is closer to the inner surface of the container than in the first position; inserting at least a portion of the article into the interior portion of the compression material while the compression material is in the expanded position, wherein the article exists on a forming material; and exposing the area between the outer surface of the compression material and the inner surface of the container to a pressure that is about at atmospheric pressure such that the compression material transitions from the expanded position to a second position, wherein in the second position the at least a portion of the article is located in the interior portion of the compression material and the at least a portion of the compression material is closer to the article than when the article was inserted into the compression material in the expanded position.

[0075] Clause 2. The method of clause 1, wherein the article comprises a portion of an article of footwear.

[0076] Clause 3. The method of clause 2, wherein the portion of an article of footwear comprises an upper.

[0077] Clause 4. The method of clause 3, wherein the forming material comprises a last.

[0078] Clause 5. The method of clause 4, wherein the compression material in the first position is complementary in shape to at least a portion of a shape of the last.

[0079] Clause 6. The method of clause 3, wherein the upper includes a sock having a ground-facing portion.

[0080] Clause 7. The method of clause 3, wherein the upper includes a sock and at least one of an insole or a heel stabilizer positioned inside the sock.

[0081] Clause 8. The method of clause 7, wherein the upper further includes a membrane adjacent to the sock.

[0082] Clause 9. The method of clause 3, wherein a compression sock is positioned on the upper.

[0083] Clause 10. The method of clause 9, wherein the compression sock includes an elastomeric material, wherein the elastomeric material has a melting temperature above 110 °C.

[0084] Clause 11. The method of any one of clauses 1-10, wherein the compression material has a melting temperature, a degradation temperature, or both, above 110 °C.

[0085] Clause 12. The method of any one of clauses 1-11, further comprising, after exposing the area between the outer surface of the compression material and the inner surface of the container to a pressure of about atmospheric pressure, exposing the area between the outer surface of the article and the inner surface of the compression material to a pressure less than atmospheric pressure, such that the compression material exerts a compressive force on the outer surface of the article, thereby forming a compressed article.

[0086] Clause 13. The method of clause 12, further comprising exposing the compressed article to a temperature from about 70 °C to about 250 °C.

[0087] Clause 14. The method of clause 13, further comprising, after exposing the compressed article to a temperature from about 70 °C to about 250 °C, exposing the compressed article to a temperature of about 25 °C or less.

[0088] Clause 15. The method of clause 14, wherein exposing the compressed article to a temperature of about 25 °C or less includes submerging at least a portion of the compressed article in a liquid having a temperature of about 25 °C or less.

[0089] Clause 16. A system for preparing an article for thermoforming, the system comprising: a container having an interior volume defined by at least a bottom portion and at least one sidewall extending upwardly from the bottom portion to a top portion, wherein the container includes a port; a negative pressure generating system coupled to the port of the container; and a compressed material positioned within the interior volume of the container, wherein at least a portion of the compressed material forms an interior portion adapted to receive an article, wherein the negative pressure generating system and the port are cooperatively adapted to expose an area between an outer surface of the compressed material and an inner surface of the at least one sidewall to a pressure less than atmospheric pressure such that the compressed material expands.

[0090] Clause 17. The system of clause 16, wherein the compressed material has a melting temperature, a degradation temperature, or both, that is higher than 110 °C.

[0091] Clause 18. The system of any one of clauses 16-17, wherein the article comprises an upper positioned on a last, and wherein the interior portion of the compressed material is sized to receive the upper positioned on the last.

[0092] Clause 19. The system of clause 18, wherein at least a portion of the compressed material is complementary in shape to the upper, the last, or both.

[0093] Clause 20. The system of any one of clauses 16-19, wherein the port of the container is adapted to expose a volume between the outer surface of the compressed material and the inner surface of the at least one sidewall to a pressure that is about atmospheric pressure.

[0094] From the foregoing, it will be seen that this application is one that is particularly adapted to achieve the objects and purposes set forth above, along with other advantages that will be apparent to those skilled in the art and inherent to the structure.

[0095] It will be understood that certain features and subcombinations are of utility and can be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

[0096] While specific elements and steps are discussed in conjunction with the above, it will be understood that any element and / or step provided herein can be combinable with any other element and / or step, whether or not explicitly stated, and still within the scope of the present disclosure. Since many possible embodiments can be made of the disclosure without departing from the scope thereof, it is to be understood that all matter contained herein or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Claims

1. A method for thermoforming an article, the method comprising: receiving a compression material having an article positioned within the compression material, wherein the article is an upper for an article of footwear, wherein a compression shoe cover is positioned on the upper, and wherein the compression shoe cover comprises an elastomeric material; exposing an area between an inner surface of the compressed material and an outer surface of the article to a pressure less than atmospheric pressure such that the compressed material exerts a compressive force on the outer surface of the article; introducing the articles into one or more heating stations; rotating the article within the one or more heating stations; introducing said articles into a cooling station; as well as The articles are rotated within the cooling station.

2. The method according to claim 1, wherein During the introduction of the article into the one or more heating stations and during the rotation of the article within the one or more heating stations, the area between the inner surface of the compressed material and the outer surface of the article is continuously exposed to the pressure that is less than atmospheric pressure.

3. The method according to claim 1, wherein Exposing the area between the inner surface of the compressive material and the outer surface of the article to the pressure less than atmospheric pressure also includes sealing the article within the compressive material so as to maintain the compressive force on the outer surface of the article without continued exposure to the pressure less than atmospheric pressure.

4. The method according to claim 1, wherein During the introduction of the article into the cooling station and during the rotation of the article within the cooling station, the area between the inner surface of the compressed material and the outer surface of the article is continuously exposed to the pressure that is less than atmospheric pressure.

5. The method according to claim 1, wherein The one or more heating stations include at least two heating chambers, wherein each of the at least two heating chambers includes one or more thermal elements.

6. The method according to claim 5, wherein: The one or more thermal elements are positioned on a portion of at least one side wall of each of the at least two heating chambers such that rotating the article within the one or more heating stations exposes each side of the article to the one or more thermal elements.

7. The method according to claim 1, wherein The cooling station includes a liquid contained in a cooling chamber, wherein introducing the item into the cooling station includes submerging at least a portion of the item in the liquid.

8. The method according to claim 7, wherein: The liquid exhibits a temperature of approximately 25°C or lower.

9. The method according to claim 7, wherein: Rotating the item within the cooling station includes rotating the item while the at least a portion of the item is submerged in the liquid.

10. The method of claim 7, further comprising circulating the liquid between the cooling chamber and a secondary cooling source such that the liquid is maintained at a temperature of approximately 25°C or less.

11. The method according to claim 1, wherein The compressed material has a melting temperature, a degradation temperature, or both, greater than 110°C.

12. The method according to claim 1, wherein The article includes at least a portion of an article of footwear.

13. The method according to claim 12, wherein: The at least a portion of the article of footwear includes an upper.

14. The method according to claim 13, wherein The upper is positioned on a shoe last.

15. The method according to claim 1, wherein The cooling station includes a liquid contained in a cooling chamber, wherein introducing the article into the cooling station includes submerging at least a portion of the article in the liquid, and wherein the article is an upper for an article of footwear.

16. The method according to claim 1, wherein The upper is positioned on a shoe last.

17. The method according to claim 1, wherein The compressed material is similar in shape to the article.

18. The method according to claim 1, wherein The upper includes a shoe cover, and wherein a bottom layer or heel counter is positioned within the upper.

19. The method according to claim 1, wherein The upper includes an overshoe and a lining, wherein the overshoe includes eyelets and the lining includes eyelets, and wherein the eyelets of the overshoe are aligned with the eyelets of the lining.

20. The method according to claim 1, wherein The upper includes a shoe cover and a film positioned on the shoe cover, and wherein the film includes a thermoplastic material exhibiting a melting temperature, a heat distortion temperature, a Vicat softening temperature, or a combination thereof, in a range of approximately 80° C. to approximately 135° C.

Images