System and method for blow molding a plate component of an article of footwear

Abstract

A blow molding system (10, 10a) comprising: an extrusion system (100) including at least one extruder configured to extrude a parison (14, 14a, 16) having an internal cavity; a blow pin (116) configured to extend into the internal cavity (18) of the parison (14, 14a, 16) extruded from the extrusion system (100); and a mold assembly (200, 202, 202a) defining a mold cavity (205, 205a) configured to receive the parison (14, 14a, 16), the mold assembly (200, 202, 202a) including a plurality of mold cavities (208, 210) each facing the mold cavity (205, 205a) and defining a profile of a sole component of an article of footwear.

Description

[0001] Cross-reference to related applications This PCT international application claims priority to U.S. Application Serial No. 18 / 516,666, filed November 21, 2023, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0002] This disclosure generally relates to a system for molding sole plates of footwear articles, and more specifically to a system for simultaneously blow molding multiple sole plates of footwear articles. Background Technology

[0003] This section provides background information in connection with this disclosure and is not necessarily prior art.

[0004] Footwear typically comprises an upper and a sole structure. The upper can be made of any suitable material to receive, secure, and support the foot against the sole structure. The upper may work with laces, straps, or other fasteners to adjust the fit around the foot. The bottom portion of the upper, closest to the foot, is attached to the sole structure.

[0005] A sole construction typically comprises a layered arrangement extending between the ground surface and the upper. One layer of the sole construction includes an outsole that provides abrasion resistance and traction with the ground surface. The outsole may include a sole plate formed of a rigid or semi-rigid material, which provides rigidity and energy distribution across the sole construction. The sole plate may be provided with one or more types of traction elements to maximize contact with the ground surface. In some cases, the traction elements may be attached to the outsole plate or integrally molded with the sole plate.

[0006] Shoe soles are typically manufactured using injection molding. While injection molding is a suitable process, it can be relatively expensive due to the complexity of the molds and molding materials. Additionally, injection molding can limit the types of materials that can be used because some of the materials' chemical properties are incompatible when combined in the process. Attached Figure Description

[0007] The accompanying drawings described herein are for illustrative purposes only, representing the selected configurations and not all possible implementations, and are not intended to limit the scope of this disclosure.

[0008] Figure 1 This is a schematic cross-sectional view showing an example configuration of a blow molding system according to the principles of this disclosure; Figure 2 It is shown Figure 1 A schematic diagram of the cross-section of a blow molding system, in which molding material is extruded as a preform into a mold; Figure 3 It is shown Figure 1 A schematic diagram of the cross-section of a blow molding system, in which the mold assembly is moved into a closed configuration; Figure 4 It is shown Figure 1 A schematic diagram of the cross-section of a blow molding system, in which the preform expands into the mold cavity of the mold; Figure 5 It is shown Figure 1 A schematic diagram of the cross-section of a blow molding system, wherein the mold is opened to remove the molded article; Figure 6 yes Figure 5 A perspective view of the molded article, showing the steps of separating the molded article segments; Figure 7 yes Figure 6 A perspective view of the separated molded sections; Figure 8 yes Figure 7 A perspective view of one of the separated molded sections, showing the sole plate being removed from the molded section; Figure 9 This is a schematic cross-sectional view showing an example configuration of a blow molding system according to the principles of this disclosure; Figure 10 It is shown Figure 9 A schematic diagram of the cross-section of a blow molding system, in which molding material is extruded as a preform into a mold; Figure 11 It is shown Figure 9 A schematic diagram of the cross-section of a blow molding system, in which the mold assembly is moved into a closed configuration; Figure 12 It is shown Figure 9 A schematic diagram of the cross-section of a blow molding system, in which the preform expands into the mold cavity of the mold; Figure 13 It is shown Figure 9 A schematic diagram of the cross-section of a blow molding system, wherein the mold is opened to remove the molded article; Figure 14 yes Figure 13 A perspective view of the molded article, showing the steps of separating the molded article segments; Figure 15 yes Figure 14 A perspective view of the separated molded sections; Figure 16 yes Figure 15 A perspective view of one of the separated molded sections, showing the sole plate being removed from the molded section; Figure 17This is a schematic diagram of a cross-section showing another example configuration of a blow molding system according to the principles of this disclosure; Figure 18 It is shown Figure 17 A schematic diagram of the cross-section of a blow molding system, in which molding material is extruded as a preform into a mold; Figure 19A It is along Figure 18 The line 19-19 was cut off Figure 18 A cross-sectional view of the blow molding system, showing the preform within the mold system; Figure 19B It is along Figure 18 The line 19-19 was cut off Figure 18 A cross-sectional view of the blow molding system, showing the preform expanding within the mold system; and Figure 20 Is using Figure 17 Molded products produced by the blow molding system.

[0009] In all the accompanying drawings, the corresponding reference numerals indicate the corresponding parts. Detailed Implementation

[0010] The exemplary configurations will now be described more fully with reference to the accompanying drawings. These exemplary configurations are provided so that this disclosure will be thorough and will fully convey the scope of this disclosure to those skilled in the art. Specific details, such as examples of particular components, apparatus, and methods, are set forth to provide a thorough understanding of the configurations of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that the exemplary configurations may be embodied in many different forms, and that the specific details and exemplary configurations should not be construed as limiting the scope of this disclosure.

[0011] The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be restrictive. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless the context explicitly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or shown, unless specifically identified as such. Additional or alternative steps may be employed.

[0012] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, it may be directly on, joined to, attached to, or linked to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as “directly on another element or layer,” “directly joined to,” “directly connected to,” “directly attached to,” or “directly linked to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0013] The terms first, second, third, etc., may be used herein to describe various elements, components, areas, layers, and / or segments. These elements, components, areas, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, area, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms do not imply order or sequence. Therefore, without departing from the teachings of the example configuration, the first element, component, area, layer, or segment discussed below may be referred to as the second element, component, area, layer, or segment.

[0014] One aspect of this disclosure provides a blow molding system. The blow molding system includes an extrusion system comprising at least one extruder configured to extrude a preform having an inner cavity. The blow molding system also includes a blow needle configured to extend into the inner cavity of the preform extruded from the extrusion system. The blow molding system further includes a mold assembly defining a mold chamber configured to receive the preform. The mold assembly includes a plurality of mold cavities, each facing the mold chamber and defining the contour of a sole component of a footwear article.

[0015] Embodiments of this disclosure may include one or more of the following optional features. In some instances, at least one extruder includes a first extruder configured to extrude a first layer of the preform and a second extruder configured to extrude a second layer of the preform concentric with the first layer. In some embodiments, the first layer includes a first material, and the second layer includes a second material different from the first material. In some configurations, the first and second materials are selected from at least one of polypropylene, high-density polyethylene, thermoplastic polyurethane, or polyamide. In some further configurations, at least one of the first and second materials includes a recycled material.

[0016] In some instances, the plurality of mold cavities includes a first mold cavity and a second mold cavity, the first mold cavity defining the outline of a first sole plate of the footwear article, and the second mold cavity defining the outline of a second sole plate of the footwear article, the second sole plate having a different configuration from the first sole plate. In some embodiments, the plurality of mold cavities includes a first plurality of first mold cavities and a second plurality of second mold cavities, each of the first plurality of first mold cavities defining the outline of a first sole plate of the footwear article, and each of the second plurality of second mold cavities defining the outline of a second sole plate of the footwear article, the second sole plate having a different configuration from the first sole plate. In some configurations, each of the plurality of mold cavities defines the outline of a sole plate, the sole plate including a full-length sole plate body and a plurality of attachment friction elements.

[0017] In some instances, the sole plate for footwear articles is formed using a blow molding system of any of the examples, configurations, or embodiments described above. In some embodiments, a footwear article including a sole plate is formed.

[0018] Another aspect of this disclosure provides a method for forming a plurality of sole plates for footwear articles. The method includes extruding a preform into a mold cavity of a mold assembly. The mold assembly includes a plurality of mold cavities, each mold cavity facing the mold cavity and defining the profile of a sole plate of the footwear article. The method further includes expanding the preform within the mold cavity, adapting the material forming the preform to the plurality of mold cavities, and forming a molded article comprising the plurality of sole plates.

[0019] Embodiments of this aspect of the present disclosure may include one or more of the following optional features. In some instances, the extruded preform includes a first layer of the extruded preform and a second layer of the preform concentric with the first layer. In some embodiments, the first layer and the second layer of the extruded preform comprise continuously extruding the first layer and intermittently extruding the second layer along the length of the preform. In some instances, the first layer comprises a first material, and the second layer comprises a second material different from the first material. In some configurations, the first and second materials are selected from at least one of polypropylene, high-density polyethylene, thermoplastic polyurethane, or polyamide. In some further configurations, at least one of the first and second materials comprises a recycled material.

[0020] In some instances, the plurality of mold cavities includes a first mold cavity and a second mold cavity, the first mold cavity defining the outline of a first sole plate of the footwear article, and the second mold cavity defining the outline of a second sole plate of the footwear article, the second sole plate having a different configuration from the first sole plate. In some embodiments, the plurality of mold cavities includes a first plurality of first mold cavities and a second plurality of second mold cavities, each of the first plurality of first mold cavities defining the outline of a first sole plate of the footwear article, and each of the second plurality of second mold cavities defining the outline of a second sole plate of the footwear article, the second sole plate having a different configuration from the first sole plate.

[0021] In some configurations, each of the mold cavities defines the outline of a sole plate, which includes a full-length sole plate body and multiple attachment friction elements. In some instances, the method also includes separating multiple sole plates from the molded article.

[0022] This disclosure provides a system and method for blow molding polymer components for footwear articles, and more specifically for multi-layer sole plates for footwear articles. Conventionally, sole plates and other polymer components of footwear are manufactured using injection molding processes or, in some cases, additive manufacturing (e.g., 3D printing). While suitable, these processes can be time- and labor-intensive. Blow molding is a low-cost and efficient manufacturing method that enables the production of lightweight products that can be single-layer or multi-layered, allowing for unique material combinations to be achieved in a single process. Furthermore, molds associated with blow molding systems are generally less expensive than those associated with injection molding processes. As discussed herein, molds used with blow molding processes can include multiple mold plates for simultaneously forming multiple mold plates. The use of extruded materials in blow molding processes also allows for the selective incorporation of recycled contents or foam layers within the central layer of the sole plate, thereby improving sustainability while maintaining desired aesthetic and performance qualities.

[0023] Details of one or more embodiments of this disclosure are set forth in the accompanying drawings and the following description. Other aspects, features, and advantages will become apparent from the specification, drawings, and claims.

[0024] refer to Figures 1 to 5 A blow molding system 10 according to an example of the present disclosure is provided. The blow molding system 10 includes an extrusion system 100 and a mold system 200, configured to produce a blow-molded article 300 including a plurality of sole plates 306, 308 for manufacturing footwear. Therefore, a plurality of sole plates 306, 308 can be formed simultaneously by the blow molding system 10.

[0025] refer to Figure 1The extrusion system 100 includes one or more extruders 102a, 102b, including a first extruder 102a configured to extrude a first die material 12a and a second extruder 102b configured to extrude a second die material 12b. Although the illustrated example is provided with a first extruder 102a and a second extruder 102b for clarity, it should be understood that the extrusion system 100 may include additional extruders as needed. For example, and as described below, the extrusion system 100 may include a third extruder that includes a first material 12a or a third material and is configured to extrude a third layer. In this configuration, a second material 12b may be encapsulated or inserted between two layers of the first material 12a.

[0026] The first extruder 102a includes a first hopper 104a for receiving a first die material 12a in its raw form (such as granules). The first extruder 102a also includes an extruder barrel 105a, which includes a first extruder screw 106a and a heating element 107a for heating the first die material 12a to a molten state. The extruder barrel 105a includes a first nozzle 108a disposed at the end of the first extruder screw 106a for receiving the molten first die material 12a.

[0027] The second extruder 102b includes a second hopper 104b for receiving second die material 12b in its original form (such as granules). The second extruder 102b also includes an extruder barrel 105b, which includes a second extruder screw 106b and a heating element 107b for heating the second die material 12b to a molten state. The extruder barrel 105b includes a second nozzle 108b disposed at the end of the second extruder screw 106b for receiving the molten second die material 12b.

[0028] Each of the nozzles 108a and 108b of the extruders 102a and 102b can communicate with a corresponding manifold 112a and 112b, which provide a passage for the corresponding die materials 12a and 12b to the end die 114 of the extrusion system 100. The manifolds 112a and 112b are configured to sequentially introduce the die materials 12a and 12b into the end die 114, whereby the first die material 12a is supplied upstream of the second die material 12b to the end die 114, such that the second die material 12b is stacked on the outer surface of the first die material 12a to form layers 16a and 16b of a co-extruded parison 14 comprising the two materials 12a and 12b. In other words, the first die material 12a forms the inner layer 16a of the parison 14, and the second die material 12b forms the outer layer 16b of the parison 14. Although the illustrated example of extrusion system 100 is configured for co-extruding two concentric layers 16a, 16b of die materials 12a, 12b, it should be understood that molding systems with other configurations may be used. For example, extrusion system 100 may be configured to co-extrude a preform 14 comprising three or more tubular layers 16a, 16b. Alternatively, extrusion system 100 may be configured to extrude a preform 14 having a single layer 16a of only the first die material 12a.

[0029] Still referencing Figure 1 The extrusion system 100 includes a blow needle 116 located within an end die 114 and extending from an outlet end 115 of the end die 114. The blow needle 116 is configured to extend within a cavity 18 of the preform 14 and into the die system 200. While the illustrated example shows layers 16a, 16b of the preform 14 directly adjacent to the blow needle 116, other extrusion systems 100 may be configured such that layers 16a, 16b of the preform 16 are radially outwardly spaced from the blow needle 116 and can be separated from the blow needle 116 by a portion of the end die 114 (e.g., an annular spacer). The blow needle 116 is configured to receive pressurized fluid (e.g., air) and inject the pressurized fluid into the cavity 18 of the preform 14 to cause the preform 14 to expand within the die assembly 200, as described below. Figure 4 As described.

[0030] As described above, the extrusion system 100 is configured to co-extrude a first material 12a and a second material 12b. While the first material 12a and the second material 12b can be the same, the advantage of the extrusion system 100 is that it allows different materials to be co-extruded as unique layers of the preform 14. The layers 16a, 16b of the preform 14 may include an elastomeric material comprising one or more thermoplastic polymers and / or one or more crosslinkable polymers. In one aspect, the elastomeric material may include one or more thermoplastic elastomer materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, etc.

[0031] As used herein, “polyurethane” refers to copolymers (including oligomers) containing urethane groups (-N(C=O)O-). In addition to urethane groups, these polyurethanes may contain additional groups such as esters, ethers, ureas, urethane esters, biuret, carbodiimides, oxazolidinyl esters, isocyanurates, diuretes, carbonates, etc. In one aspect, one or more polyurethanes can be produced by polymerizing one or more isocyanates with one or more polyols to produce copolymer chains having (-N(C=O)O-) bonds.

[0032] Examples of suitable isocyanates for generating polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), adducts of TDI and trimethylolpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylphenyl dimethylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene 1,5-diisocyanate (NDI), 1,5-tetrahydronaphthalene diisocyanate, p-phenylene diisocyanate (PPDI), 3,3'-dimethyldiphenyl-4,4'-diisocyanate (DDDI), 4,4'-dibenzyl diisocyanate (DBDI), 4-chloro-1,3-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chain is substantially free of aromatic groups.

[0033] In certain aspects, the polyurethane polymer chain is generated from diisocyanates including HMDI, TDI, MDI, H12 aliphatic compounds, and combinations thereof. In one aspect, thermoplastic TPUs may include polyester-based TPUs, polyether-based TPUs, polycaprolactone-based TPUs, polycarbonate-based TPUs, polysiloxane-based TPUs, or combinations thereof.

[0034] On the other hand, the polymer layer can be formed from one or more of the following: EVOH copolymers, poly(vinyl chloride), polyvinylidene ethylene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), high-density polyethylene, polyethylene terephthalate, polyetherimide, polyacrylamide, and other polymeric materials. Blends of these materials, as well as blends with the TPU copolymers described herein and optionally combinations of polyimide and crystalline polymers, are also suitable.

[0035] In some instances, where incompatible first material 12a and second material 12b are selected (e.g., they do not bond naturally to each other in the molten state), the extrusion system 100 may include an intermediate extruder configured to extrude an intermediate adhesive material for bonding the first material 12a to the second material 12b. Thus, the preform 14 may include two or more layers bonded by an adhesive (multilayer extrusion). Additionally or alternatively, the extrusion system 100 may include one or more extruders configured to extrude adhesive material adjacent to the exposed surfaces of the inner layer 16a and / or the outer layer 16b. For example, an adhesive layer may be extruded and applied to the exposed surface of the footbed of the inner layer 16a corresponding to the sole plates 306, 308, whereby the adhesive allows the sole plates 306, 308 to adhere to the upper (e.g., to strobel). Optionally, an adhesive layer may be extruded and applied to the exposed surface of the outer layer 16b corresponding to the ground contact surface of the sole plates 306, 308, whereby the adhesive enables one or more adhesion friction elements to adhere to the ground contact surface of the sole plates 306, 308. In another configuration, the preform 14 may include alternating layers of one or more first copolymer materials and one or more second copolymer materials, wherein the total number of layers in the preform 14 includes at least four (4) layers and / or at least ten (10) layers.

[0036] In some instances, the first material 12a or the second material 12b may include recycled or upgraded remanufactured materials derived from previously extruded recycled waste. Recycled materials should be understood as materials that can be distinguished from "original" materials that were never used in the manufacturing process. In configurations utilizing recycled or remanufactured materials, the preform 14 may be formed with three or more layers 16a, 16b, including inner and outer layers 16a, 16b containing the original first material 12a or second material 12b, and an intermediate layer containing recycled second material inserted between the inner and outer layers 16a, 16b. Therefore, the preform 14 and the resulting sole plates 306, 308 will include a portion of recycled material hidden between the original material layers 16a, 16b. Thus, the resulting sole plates 306, 308 provide the benefits of using sustainable materials while maintaining the external aesthetics associated with the original materials.

[0037] Still referencing Figure 1 The blow molding system 10 also includes a mold system 200, which includes features that can be opened into a configuration ( Figure 1 ) and closed configuration ( Figure 2 A mold assembly 202 operates between the preform 14 and the mold assembly 202. The mold assembly 202 includes a first mold plate 204 and a second mold plate 206, which are configured to abut each other in a closed configuration to define a mold cavity 205 configured to receive a preform 14. The first mold plate 204 defines a first mold cavity 208 corresponding to the outline of a first sole plate 306 to be molded using the blow molding system 10. The second mold plate 206 defines a second mold cavity 210 corresponding to the outline of a second sole plate 308 to be molded using the blow molding system 10. In the illustrated example, the first mold cavity 208 and the second mold cavity 210 are mirror images of each other, whereby the first mold cavity 208 is configured for molding the first sole plate 306 corresponding to a left-foot footwear article, and the second mold cavity 210 is configured for molding the second sole plate 308 corresponding to a right-foot footwear article. Therefore, mold assembly 202 is configured to simultaneously mold a pair of mold plates 204, 206 for a single pair of footwear. In other instances, mold cavities 208, 210 may have the same configuration (e.g., both are for the left foot) or may have different profiles (e.g., different sizes, shapes, and / or arrangements of the attached friction elements). Furthermore, while the illustrated examples show mold plates 204, 206 each defining a single mold cavity 208, 210, mold plates 204, 206 may be configured to include two or more mold cavities in mold cavities 208, 210. Additionally, while the mold cavities 208, 210 in the illustrated examples are provided as “concave” or female mold cavities, mold plates 204, 206 may include “convex” or male mold geometries.

[0038] Mold plates 204 and 206 are configured in a closed configuration ( Figure 3 The mold plates 204 and 206 are joined together to form a peripheral seal 211 around the preform 14. Therefore, when the mold plates 204 and 206 are in a closed configuration, the outer portion of the preform 14 can be compressed between the mold plates 204 and 206. As shown, the mold plates 204 and 206 are also configured to form a peripheral seal 211 between the blow needle 116 and the preform 14 at the inlet of the mold cavity 205 to prevent fluid from escaping from the mold cavity 205 during the blow molding process.

[0039] refer to Figure 2 This illustrates the first step for forming the molded article 300 according to this disclosure. Figure 2 In this configuration, the die assembly 202 is initially provided in an open configuration, whereby die plates 204, 206 are spaced apart to open the die chamber 205. The extrusion system 100 extrudes a preform 14 between the die plates 204, 206 and through the die chamber 205. The preform 14 comprises one or more layers 16a, 16b of materials 12a, 12b. As shown, the distal end of the preform 14 extends beyond the die chamber 205 and is aligned with the ends of the die plates 204, 206.

[0040] exist Figure 3 In this configuration, mold assembly 202 is moved to a closed configuration to form a peripheral seal 211 around the preform 14. As shown, the distal end of the preform 14 is compressed between mold plates 204 and 206 to seal the inner cavity 18 at the distal end of the preform 14. Simultaneously, mold plates 204 and 206 abut at the proximal end of the preform 14 (i.e., adjacent to end mold 114) to form a peripheral seal 211 around the preform 14 and the blow needle 116. Therefore, in Figure 3 In the middle, the preform 14 is sealed at each of its distal and proximal ends, so that fluid can be introduced into the inner cavity 18 of the preform 14 via the conduit 118 of the blow needle 116, so that the preform 14 expands into the mold plates 204, 206.

[0041] exist Figure 4 In this process, compressed air A is introduced into the inner cavity 18 of the preform 14 via a blow needle 116, causing layers 16a, 16b of the material 12a, 12b of the preform 14 to be biased outward and enter the corresponding mold cavities 208, 210. As shown in the figure, the mold cavities 208, 210 of the illustrated example are configured to form a molded article 302 including sole plates 306, 308 with molded adhesion friction elements 314. Specifically, the first mold cavity 208 is configured to form a first sole plate 306 including a first sole plate body 310 and a plurality of adhesion friction elements 314. The second mold cavity 210 is configured to form a second sole plate 308 including a second sole plate body 312 and a plurality of adhesion friction elements 314. Figure 5In the process, the mold assembly 202 is moved to an open configuration, allowing the molded article 300, including the sole plates 306 and 308, to be cooled and removed from the mold cavity 205.

[0042] refer to Figure 6 The image shows a molded article 300 after being removed from the mold chamber 205. In this example, the molded article 300 includes a plurality of molded article segments 302a, 302b corresponding to the number of mold plates 204, 206. Therefore, the molded article 300 may include a first molded article segment 302a and a second molded article segment 302b joined to each other at a molded article seam 304 corresponding to the junction between the mold plates 204, 206. The first molded article segment 302a includes a first sole plate 308 and a mold material flash 322 associated with excess mold material of the preform 14. The second molded article segment 302b includes a second sole plate 310 and a mold material flash 322 associated with excess mold material of the preform 14. As shown, the molded article seam 304 is formed within the mold flash 322 between adjacent segments of the molded article segments 302a, 302b. Alternatively, the cutting tool 20 can be used to separate the molded article segments 302a, 302b from each other along the molded article seam 304. Although the illustrated example shows a manual cutting tool 20 (e.g., a knife), the blow molding system 10 may include an automatic cutting tool, such as a die-cutting device or a computer numerical control (CNC) cutting system. Figure 7 A molded article 300 in a separated state is shown. The molded article 300 includes a first molded article segment 302a and a second molded article segment 302b.

[0043] refer to Figure 8 A first molded article 302a is shown separately for post-molding processing. In this step, the first sole plate 306 is separated from the first molded article segment 302a by removing the die flash 322 from the periphery 316 of the first plate body. As shown, the first sole plate 306 includes each of the layers 16a, 16b of the preform 14, which cooperate to define the structure of the sole plate 306. The illustrated sole plate 306 includes a first sole plate body 312 and a plurality of adhesion friction elements 314, each adhesion friction element including layers 16a, 16b. Similarly, although the illustrated examples of sole plates 310, 312 are provided with two layers 16a, 16b, any number of material layers can be bonded to the sole plates 310, 312 by selecting the corresponding extrusion system 100 for forming the preform 14 with the desired layer configuration. Additionally or alternatively, the thickness T of the layers 16a, 16b is... 16 T 16b The arrangement can be varied, and / or layers 16a and 16b can be intermittently set in independent areas of the sole plates 306 and 308.

[0044] Special Reference Figures 9 to 16 This provides another example of using the blow molding system 10. Considering the... Figures 1 to 8 The blow molding system 10 associated with the components relative to Figures 9 to 16 The blow molding system 10 is fundamentally similar in structure and function, and the same reference numerals are used in the following text and figures to identify the same parts, while the same reference numerals containing letter extensions are used to identify those parts that have been modified.

[0045] As described above, the blow molding system 10 can be configured to intermittently extrude one or more of the layers 16a, 16b to provide variable properties in the sole plate. Figures 9 to 16 In the example, the inner layer 16a of the preform 14a is intermittently extruded to provide an intermediate portion of the preform 14a in which the inner layer 16a is omitted. Therefore, as... Figures 10 to 13 and Figure 16 As shown, the preform 14a forms plates 306a and 308a, wherein the inner layer 16a is omitted from the midfoot region of the bodies 310a and 312a to provide increased flexibility along the midfoot and relatively high stiffness in the forefoot and heel regions associated with the adhesion friction element 314.

[0046] For details, please refer to the following: Figures 17 to 20 This disclosure provides another example of a blow molding system 10a according to this disclosure. Given the fundamental structural and functional similarities between the parts associated with the blow molding system 10a and those associated with the blow molding system 10a, the same reference numerals are used hereinafter and in the accompanying drawings to identify the same parts, while the same reference numerals including letter extensions are used to identify those parts that have been modified.

[0047] refer to Figure 17The blow molding system 10a includes the aforementioned extrusion system 100 and mold system 200a. Mold system 200a includes a mold assembly 202a having a first mold plate 204a and a second mold plate 206a. The first mold plate 204a includes a plurality of first mold segments 212a, each defining a single first mold cavity 208. Conversely, the second mold plate 206a includes a plurality of second mold segments 212b, each defining a single second mold cavity 210. Although the illustrated example shows the first mold segments 212a and the second mold segments 212b integrated into a single mold plate 204a, 206a, respectively, the mold segments 212a, 212b can be provided as separate components. Furthermore, mold assembly 202a may have any number of mold segments 212a, 212b corresponding to the desired number of sole plates 306, 308 to be formed using blow molding system 10a. For example, mold plates 204a and 206b may each include two of mold segments 212a and 212b, three of mold segments 212a and 212b, four of mold segments 212a and 212b, or at least five of mold segments 212a and 212b.

[0048] exist Figure 17 In order to illustrate the corresponding mold cavities 208 and 210 of each mold plate 204a, 206a, the mold assembly 202a is shown in an open configuration. However, it should be understood that the mold plates 204a, 206a will be configured to move along direction D1 to achieve a closed configuration. Figure 18 The preforms 14 and 14 are mated together and provide a peripheral seal along the distal end of the preform 14 and the opposite proximal end of the preform 14, as previously described with respect to the mold system 200.

[0049] exist Figure 18 In this configuration, die assembly 202 is moved into a closed configuration to define a die chamber 205a for receiving the extruded preform 14. Again, for clarity, the ends of die assembly 202 have been omitted, but it should be understood that die assembly 202a is configured to form a seal around the proximal end of the preform 14 and the blow needle 116. As shown, the preform 14 is extruded into the die chamber 205a between die sections 212a, 212b.

[0050] exist Figure 19A In the middle, along Figure 18 The first cross-sectional view of the blow molding system 10a, taken by line 19-19, shows the middle portion of the preform 14 disposed within the mold cavity 205a (i.e., between the sealed distal and proximal ends), whereby the blow needle 116 is positioned within the inner cavity 18 of the preform 14 when the preform 14 is in an unexpanded state. Figure 19BIn this process, pressurized air is supplied to the inner cavity 18 of the preform 14 via a blow needle 116, and layers 16a, 16b of the preform 14 are biased outward against mold sections 212a, 212b. Layers 16a, 16b of the preform 14 are adapted to mold sections 212a, 212b, and more specifically, to mold cavities 208, 210. In doing so, layers 16a, 16b form a molded article 300a, which includes a plurality of molded article sections 302a, 302b having a first sole plate 306 and a second sole plate 308. Specifically, the molded article 300a includes a plurality of first molded article sections 302a formed by a first mold plate 204a and including a plurality (e.g., three) of first sole plates 306. The molded article 300a also includes a plurality of second molded article segments 302b formed by the second mold plate 204b and including a plurality (e.g., three) of second sole plates 308. Each of the molded article segments 302a, 302b includes a preform flash 322, and adjacent molded article segments 302a, 302b are joined together along their respective molded article seams 304a, 304b.

[0051] exist Figure 20 The figure shows a molded article 300a after being removed from mold assembly 202a. As shown, the molded article 300a includes multiple molded article segments 302a, 302b joined together along molded article seams 304a, 304b. Similar to the molded article 300 discussed above, the molded article segments 302a, 302b can be separated from each other along the molded article seams 304a, 304b for post-processing. In the post-processing step, the first sole plate 306 is separated from the first molded article segment 302a by removing the flash 322 from the respective peripheries 316, 318 of the sole plate bodies 310, 312, and the second sole plate 308 is separated from the second molded article segment 302b.

[0052] In the illustrated example, the mold system 200 is configured to form multiple full-length sole plates 306, 308, including a forefoot area, a midfoot area, and a heel area. However, the mold assembly 200 may be configured to form other plate components of footwear articles, such as plates of a portion length. As used herein, the term "plate" refers to a rigid or semi-rigid component used in footwear articles. For example, a plate component formed using the methods and systems of this disclosure may have a stiffness of at least 10 gigapascals (i.e., Young's modulus).

[0053] In the illustrated example, the preform 14 is extruded to have a first thickness T. 16a The continuous inner layer 16a and having a second thickness T 16b The continuous outer layer 16b. Although representative examples show a first thickness T 16a With the second thickness T16b The same, but the thickness T of either layer 16a or 16b is... 16a T 16b It can be combined with the thickness T of any of the layers. 16a T 16b The desired mechanical properties are imparted to the finished sole plates 306, 308. Additionally or alternatively, one or more of the layers 16a, 16b may be intermittently extruded to provide a separate area excluding one of the layers 16a, 16b. For example, the outer layer 16b may be extruded in the areas of the preform corresponding to the forefoot and heel areas of the sole plates 306, 308 to provide increased stiffness in the area associated with the attached friction element 314, while the outer layer 16b may be omitted (i.e., not extruded) in the area of ​​the preform associated with the midfoot area of ​​the sole plates 306, 308 to provide reduced stiffness.

[0054] The following clauses provide an exemplary configuration of a method for forming a fluid-filled chamber for the aforementioned footwear articles.

[0055] Clause 1: A blow molding system comprising: an extrusion system including at least one extruder configured to extrude a preform having an inner cavity; a blow needle configured to extend into the inner cavity of the preform extruded from the extrusion system; and a mold assembly defining a mold chamber configured to receive the preform, the mold assembly including a plurality of mold cavities, each mold cavity facing the mold chamber and defining the contour of a sole component of a footwear article.

[0056] Clause 2: The blow molding system according to Clause 1, wherein the at least one extruder comprises a first extruder configured to extrude a first layer of the preform and a second extruder configured to extrude a second layer of the preform concentric with the first layer.

[0057] Clause 3: The blow molding system according to Clause 2, wherein the first layer comprises a first material and the second layer comprises a second material different from the first material.

[0058] Clause 4: The blow molding system according to Clause 3, wherein the first material and the second material are selected from at least one of polypropylene, high-density polyethylene, thermoplastic polyurethane or polyamide.

[0059] Clause 5: The blow molding system according to Clause 3, wherein at least one of the first material and the second material comprises a recycled material.

[0060] Clause 6: The blow molding system according to Clause 1, wherein the plurality of mold cavities includes a first mold cavity and a second mold cavity, the first mold cavity defining the outline of a first sole plate of the footwear article, the second mold cavity defining the outline of a second sole plate of the footwear article, the second sole plate having a different configuration from the first sole plate.

[0061] Clause 7: The blow molding system according to Clause 1, wherein the plurality of mold cavities includes a first plurality of first mold cavities and a second plurality of second mold cavities, each of the first plurality of first mold cavities defining the outline of a first sole plate of the footwear article, and each of the second plurality of second mold cavities defining the outline of a second sole plate of the footwear article, the second sole plate having a different configuration from the first sole plate.

[0062] Clause 8: The blow molding system according to Clause 1, wherein each of the plurality of mold cavities defines the outline of a sole plate, the sole plate comprising a full-length sole plate body and a plurality of adhesion friction elements.

[0063] Clause 9: A sole plate for footwear articles, said sole plate being formed using a blow molding system according to any one of Clauses 1 to 8.

[0064] Clause 10: A footwear article comprising a sole plate as described in Clause 9.

[0065] Clause 11: A method of forming a plurality of sole plates for footwear articles, the method comprising: extruding a preform into a mold cavity of a mold assembly, the mold assembly including a plurality of mold cavities, each mold cavity facing the mold cavity and defining a profile of the sole plate of the footwear article; and expanding the preform in the mold cavity, the material forming the preform conforming to the plurality of mold cavities, and forming a molded article including the plurality of sole plates.

[0066] Clause 12: The method according to Clause 11, wherein extruding the preform includes extruding a first layer of the preform and a second layer of the preform concentric with the first layer.

[0067] Clause 13: The method according to Clause 12, wherein extruding the first layer and the second layer of the preform comprises continuously extruding the first layer and intermittently extruding the second layer along the length of the preform.

[0068] Clause 14: The method according to Clause 12, wherein the first layer comprises a first material and the second layer comprises a second material different from the first material.

[0069] Clause 15: The method according to Clause 14, wherein the first material and the second material are selected from at least one of polypropylene, high-density polyethylene, thermoplastic polyurethane or polyamide.

[0070] Clause 16: The method according to Clause 14, wherein at least one of the first material and the second material comprises a recycled material.

[0071] Clause 17: The method according to Clause 11, wherein the plurality of mold cavities includes a first mold cavity and a second mold cavity, the first mold cavity defining the outline of a first sole plate of the footwear article, the second mold cavity defining the outline of a second sole plate of the footwear article, the second sole plate having a different configuration from the first sole plate.

[0072] Clause 18: The method according to Clause 11, wherein the plurality of mold cavities includes a first plurality of first mold cavities and a second plurality of second mold cavities, each of the first plurality of first mold cavities defining the outline of a first sole plate of the footwear article, and each of the second plurality of second mold cavities defining the outline of a second sole plate of the footwear article, the second sole plate having a configuration different from the first sole plate.

[0073] Clause 19: The method according to Clause 11, wherein each of the mold cavities defines the outline of a sole plate, the sole plate comprising a full-length sole plate body and a plurality of adhesion friction elements.

[0074] Clause 20: The method according to Clause 11 further includes separating the plurality of sole plates from the molded article.

[0075] The foregoing description has been provided for purposes of illustration and description. This foregoing description is not intended to be exhaustive or limiting of this disclosure. Elements or features of a particular configuration are generally not limited to that particular configuration, but are interchangeable where applicable and can be used in selected configurations, even if not specifically shown or described. The same applies to variations in many respects. Such changes should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A blow molding system, comprising: An extrusion system comprising at least one extruder configured to extrude a preform having an internal cavity; A blow needle, configured to extend into the cavity of the preform extruded from the extrusion system; as well as A mold assembly defining a mold chamber configured to receive the preform, the mold assembly including a plurality of mold cavities, each mold cavity facing the mold chamber and defining the outline of a sole component of a footwear article.

2. The blow molding system of claim 1, wherein the at least one extruder comprises a first extruder configured to extrude a first layer of the preform and a second extruder configured to extrude a second layer of the preform concentric with the first layer.

3. The blow molding system of claim 2, wherein the first layer comprises a first material, and the second layer comprises a second material different from the first material.

4. The blow molding system according to claim 3, wherein the first material and the second material are selected from at least one of polypropylene, high-density polyethylene, thermoplastic polyurethane or polyamide.

5. The blow molding system of claim 3, wherein at least one of the first material and the second material comprises a recycled material.

6. The blow molding system of claim 1, wherein the plurality of mold cavities includes a first mold cavity and a second mold cavity, the first mold cavity defining the outline of a first sole plate of the footwear article, the second mold cavity defining the outline of a second sole plate of the footwear article, the second sole plate having a different configuration from the first sole plate.

7. The blow molding system of claim 1, wherein the plurality of mold cavities includes a first plurality of first mold cavities and a second plurality of second mold cavities, each of the first plurality of first mold cavities defining the outline of a first sole plate of the footwear article, each of the second plurality of second mold cavities defining the outline of a second sole plate of the footwear article, the second sole plate having a configuration different from the first sole plate.

8. The blow molding system of claim 1, wherein each of the plurality of mold cavities defines the outline of a sole plate, the sole plate comprising a full-length sole plate body and a plurality of adhesion friction elements.

9. A sole plate for footwear articles, said sole plate being formed using the blow molding system according to claim 1.

10. A footwear article comprising the sole plate according to claim 9.

11. A method for forming a plurality of sole plates for footwear articles, the method comprising: The preform is extruded into the mold cavity of a mold assembly, the mold assembly including a plurality of mold cavities, each mold cavity facing the mold cavity and defining the contour of the sole plate of the footwear article; and The preform is expanded in the mold cavity, the material forming the preform conforms to the plurality of mold cavities, and a molded article including the plurality of shoe sole plates is formed.

12. The method of claim 11, wherein extruding the preform comprises extruding a first layer of the preform and a second layer of the preform concentric with the first layer.

13. The method of claim 12, wherein extruding the first layer and the second layer of the preform comprises continuously extruding the first layer and intermittently extruding the second layer along the length of the preform.

14. The method of claim 12, wherein the first layer comprises a first material, and the second layer comprises a second material different from the first material.

15. The method of claim 14, wherein the first material and the second material are selected from at least one of polypropylene, high-density polyethylene, thermoplastic polyurethane, or polyamide.

16. The method of claim 14, wherein at least one of the first material and the second material comprises a recycled material.

17. The method of claim 11, wherein the plurality of mold cavities includes a first mold cavity and a second mold cavity, the first mold cavity defining the outline of a first sole plate of the footwear article, the second mold cavity defining the outline of a second sole plate of the footwear article, the second sole plate having a configuration different from the first sole plate.

18. The method of claim 11, wherein the plurality of mold cavities includes a first plurality of first mold cavities and a second plurality of second mold cavities, each of the first plurality of first mold cavities defining the outline of a first sole plate of the footwear article, each of the second plurality of second mold cavities defining the outline of a second sole plate of the footwear article, the second sole plate having a configuration different from the first sole plate.

19. The method of claim 11, wherein each of the mold cavities defines the outline of a sole plate, the sole plate comprising a full-length sole plate body and a plurality of adhesion friction elements.

20. The method of claim 11, further comprising separating the plurality of sole plates from the molded article.

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