System and method for thermoforming an article

Abstract

The present application relates to systems and methods for thermoforming articles. Disclosed are systems (100) and processes for thermoforming articles (130, 131). The system (100) can include a first heating station (200) that can include a first heating zone (201, 205) and a second heating zone (201, 205). The system (100) can also include a first cooling station (300, 400, 500) for reducing the temperature of the heated article (130, 131) to a range of about 50 °C to about 70 °C while exposing the article (130, 131) to atmospheric pressure. The system (100) can also include a second cooling station (300, 400, 500) that can expose the article (130, 131) to a pressure that is higher than atmospheric pressure.

Description

[0001] This application is a divisional application of the application filed on May 17, 2019, with application number 202310191095.9 and invention title "System and method for thermoformed articles".

[0002] The application filed on May 17, 2019, with application number 202310191095.9 and entitled "System and method for thermoformed articles", is a divisional application of the application filed on May 17, 2019, with application number 201980033242.1 and entitled "System and method for thermoformed articles". Technical Field

[0003] This disclosure relates to a system and method for thermoformed articles. Background Technology

[0004] Thermoforming can involve heating the article to a temperature above its melting point and then cooling it to a temperature below its melting point. In some processes, the article can be formed into a specific desired shape or structure during this heating and cooling process. Attached Figure Description

[0005] The illustrative aspects of the invention are described in detail below with reference to the accompanying drawings, which are incorporated herein by reference, and wherein: Figure 1 A top perspective view of a thermoforming system according to various aspects of this document is depicted, the thermoforming system having a heating station, as well as first, second and third cooling stations, a loading / unloading station, and a product moving mechanism; Figure 2 Depicting various aspects based on this article Figure 1 Top perspective view of a thermoforming system, with a portion of the housing removed to show the heating station housing; Figure 3A A close-up side perspective view of the processing area of ​​the first heating zone of the heating station according to various aspects of this article is depicted, wherein the first processing area includes heat elements and air circulation devices; Figure 3B A close-up side perspective view of the processing area of ​​the second heating zone of the heating station according to various aspects of this article is depicted, wherein the processing area includes an air circulation device; Figure 4 A close-up side view of a first cooling station according to various aspects of this document is depicted, wherein the first cooling station includes one or more air inlets connected to an air circulation device; Figure 5 A close-up side view of a second cooling station, which includes a movable chamber, is depicted according to various aspects of this article; Figure 6Depicting various aspects based on this article Figure 1 A schematic top view of a thermoforming system, which specifically shows the article moving mechanism and heating station, first, second and third cooling stations and a schematic representation of the loading / unloading station; Figure 7A A side view of the upper of a footwear product according to various aspects of this article is depicted; Figure 7B A side perspective view of the shoe last, based on various aspects of this article, is depicted; Figure 7C Top and side perspective views of the last-made upper, based on various aspects of this article, are depicted. Figure 7A The upper is positioned at Figure 7B On the shoe last; Figure 8A Top and side perspective views of the compressed material are depicted according to various aspects of this article; Figure 8B Describing the location at Figure 8A The internal compression material Figure 7C Side perspective view of the components of the last-made shoe upper; Figure 9A The positioning of the article on the mating members of the compression assembly is described according to various aspects of this paper. Figure 8B Top and side perspective views of the components; Figure 9B The docking members that connect to the article compression assembly are described according to various aspects of this article. Figure 8B Top and side perspective views of the components; Figure 9C The positioning of the docking components according to various aspects of this paper is described. Figure 8B Top and side perspective views of the components; Figure 9D Depicting along the various aspects of this article Figure 9C The cross-section of the docking member and component depicted by the cutting line 9D; Figure 9E The positioning of the docking components according to various aspects of this paper is described. Figure 8B Top and side perspective views of the components; Figure 10A A side view of the upper and heel stabilizer is depicted according to various aspects of this article; Figure 10B It describes the positioning based on various aspects of this article. Figure 10A The inside of the shoe upper Figure 10A Side view of the heel stabilizer; Figure 11 Depicting various aspects based on this article Figure 10B Side and partial sectional views of the heel stabilizer and upper; Figure 12Depicting various aspects based on this article Figure 10B Side and partial sectional views of the heel stabilizer and upper, wherein the upper is positioned on the last, and wherein compression material is positioned on the last upper; Figure 13 A flowchart is provided illustrating a method for thermoforming articles based on various aspects of this document; Figure 14 A flowchart is provided illustrating a method for thermoforming articles based on various aspects of this document; Figure 15 A flowchart is provided illustrating a method for thermoforming articles based on various aspects of this document; Figure 16 A flowchart of a method for thermoforming articles according to various aspects of this paper is described; and Figure 17 A flowchart is provided illustrating a method for thermoforming articles based on various aspects of this document. Detailed Implementation

[0006] This document describes in detail the subject matter of various aspects of the invention to satisfy legal requirements. However, this description itself is not intended to limit the scope of this patent. Rather, the inventors have considered that the claimed subject matter may be embodied in other ways, in conjunction with other prior or future technologies, to include different steps or combinations of steps similar to those described in this document.

[0007] The aspects described herein relate to methods and systems for thermoforming articles. Some thermoforming systems may include heating the article and then cooling it while shaping it into the desired form. Existing thermoforming systems may be inefficient in at least one respect due to the varying number of processing steps required for different processes. Furthermore, some existing thermoforming systems are resource-intensive in terms of the space required to accommodate a large number of thermoformed parts.

[0008] The systems and methods disclosed herein can mitigate one or more of the aforementioned problems. For example, a thermoforming system is disclosed that may include a compact design capable of efficiently handling production volumes. As described below, in some aspects, the systems disclosed herein may include a heating station, a first cooling station, a second cooling station, and a third cooling station having more than one heating zone. In one aspect, these stations may be circumferentially positioned, wherein a product moving mechanism is positioned to transfer products from one station (or from one processing area) to the next station. Furthermore, as described below, in some aspects, the product moving mechanism may simultaneously transfer multiple products from one processing area or station to the next processing area or station. In these aspects, the systems and methods described herein have been designed to allow the same or similar number of processing times at each station or processing area in order to maximize efficiency and effectively utilize the circular layout in one aspect. In some aspects, as further discussed below, this results in the product moving mechanism transferring products to more than one processing area within the same heating station, because the products may need to be exposed to heat for a longer period of time than the time required for the products in another processing station, such as the first cooling station.

[0009] Furthermore, in some respects, the system described herein is suitable for cooling heated articles to a temperature at which the adhesive can effectively bond at least two parts of the articles together when the articles are exposed to compressive forces that can be supplied by pressures above atmospheric pressure.

[0010] Therefore, in one aspect, a method for thermoforming an article is provided. The method may include receiving the article and exposing it to a first heating zone. In this aspect, the first heating zone may include one or more heating elements and one or more first air circulation devices. Furthermore, in this aspect, the first heating zone may be adapted to expose the article to a temperature ranging from about 70°C to about 250°C. In this aspect, the method may further include exposing the article to a second heating zone. In this aspect, the second heating zone may include one or more second air circulation devices. Furthermore, in this aspect, the second heating zone may be adapted to expose the article to a temperature ranging from about 70°C to about 250°C. In this aspect, the method may further include, after exposing the article to the second heating zone, exposing the article to a first cooling station. In this aspect, the first cooling station may include one or more third air circulation devices. Furthermore, in this aspect, the first cooling station is adapted to reduce the temperature of at least a portion of the article to a range of about 40°C to about 90°C. In this aspect, the method further includes, after exposing the article to the first cooling station, exposing the article to a pressure greater than atmospheric pressure.

[0011] In another aspect, a system for thermoformed articles is provided. The system may include at least a partially enclosed heating station. In this aspect, the heating station may include a first heating zone and a second heating zone, the second heating zone being in fluid communication with the first heating zone. Furthermore, in this aspect, the first heating zone may include one or more thermal elements and one or more first air circulation devices. In this aspect, the second heating zone may include one or more second air circulation devices. In this aspect, at least the first heating zone is adapted to expose at least one article to a temperature ranging from about 70°C to about 250°C. Furthermore, in this aspect, the system also includes a first cooling station, which includes one or more third air circulation devices, wherein the first cooling station is exposed to atmospheric pressure. In this aspect, the system also includes a second cooling station, which includes a chamber adapted to expose at least one article to a pressure above atmospheric pressure. Furthermore, in this aspect, the system includes an article moving mechanism adapted to transfer at least one article from the heating station to the first cooling station, and also adapted to transfer at least one article from the first cooling station to the second cooling station.

[0012] Now turn to the attached diagram. Figure 1 A system 100 for thermoforming one or more articles is described. Figure 1 Article 130 is described as at least a part of a footwear article, such as an upper. It should be understood that the systems and methods disclosed herein can be used for many different types of articles or parts thereof, and article 130 described herein is merely one example contemplated for use in the systems and methods disclosed herein.

[0013] In various aspects, Figure 1 The system 100 includes a heating station 200, a first cooling station 300, a second cooling station 400, a third cooling station 500, a loading / unloading station 110, and a product moving mechanism 120. For example... Figure 1 Some aspects of the system 100 depicted may include a housing 140.

[0014] exist Figure 1 As depicted, heating station 200, first cooling station 300, second cooling station 400, third cooling station 500, and loading / unloading station 110 are circumferentially positioned relative to the center 121 of the article moving mechanism 120. In some respects, this circumferential positioning of the various stations of system 100 can provide system 100 with an effectively minimized area.

[0015] In various aspects, the article moving mechanism 120 is adapted to move one or more articles from one station or processing area to another. In these aspects, the article moving mechanism 120 may include a plurality of radially extending members 122, each of which moves or rotates one or more articles between the respective stations or processing areas of the system 100. For example, radially extending member 122a may move article 130 from loading / unloading station 110 to processing area 202 of heating station 200. In various aspects, the article moving mechanism 120 may move one or more articles when each article is respectively coupled to article compression assembly 600. The article compression assembly 600 is discussed in further detail below.

[0016] In some respects, the article moving mechanism 120 can move one or more articles from one station to another in a consistent manner. For example, in some respects, the radially extending member 122 can be fixedly coupled to the central portion 121, such that rotation of the article moving mechanism 120 causes each member and the article coupled thereto to move simultaneously to the adjacent station or processing area. In one respect, the system 100 is adapted to efficiently process or thermoformed articles in discrete, similarly timed steps. The timing of the various processes occurring at each station or processing area of ​​the system is discussed in further detail below.

[0017] In some respects, system use may begin at loading / unloading station 110, where articles, such as article 130, enter system 100. In some respects, door 112 may be present at loading / unloading station 110 to allow entry and / or removal of articles. In the same or alternative respects, control panel 114 may be coupled to housing 140 for operating various system processes.

[0018] Turn now Figures 2 to 4 The heating station 200 is described in further detail. From Figure 2 As can be best seen from the image, heating station 200 may include heating station housing 210. In some respects, heating station housing 210 may provide a at least partially enclosed environment that may help maintain the elevated temperature within heating station housing 210. Furthermore, as described below, since heating station 200 may include one or more air circulation devices in various aspects, heating station housing 210 may provide an enclosed environment for one or more air circulation devices to distribute heat throughout heating station 200 or its processing area.

[0019] It should be understood that the various processing areas and the heating station casing 210 are schematically represented to highlight them. Figure 2 The heating station 200 is depicted in the image. At this point, the components that can be positioned within the heating station 200 have been... Figure 2 The diagram provided is removed. In various aspects, the following is relative to Figure 3 and... Figure 4 The specific components that can be found within the heating station 200 are discussed in detail.

[0020] In one or more aspects, Figure 2 The heating station 200 depicted may include two heating zones, such as heating zone 201 and heating zone 205. In some aspects, the two heating zones 201 and 205 may be in fluid communication with each other. In one aspect, the heating station 200 may be described as a tunnel furnace or a heating tunnel. As discussed further below, the two heating zones 201 and 205 may include different elements or features. For example, in one aspect, heating zone 201 may include one or more heating elements and one or more air circulation devices, which in some aspects may facilitate an effective rise in processing temperature. Furthermore, in this example, heating zone 205 may include one or more air circulation devices in the absence of heating elements, which in some aspects may provide a constant or relatively constant temperature distribution for the effective processing of articles.

[0021] In some respects, the two-part organization of the heating station 200, such as heating zones 201 and 205 with different functional components, can facilitate efficient handling of the articles. For example, in some respects, heating zone 201, having one or more heating elements, can expose the articles to temperatures at which at least a portion of the article material will melt or deform for a short period of time, for example, less than 150 seconds. Furthermore, in these respects, heating zone 205, which may have one or more air circulation devices in the absence of heating elements, can help conduct heat energy to the internal parts of the heated articles to allow one or more of these internal parts to melt or deform as needed, while not exposing the external parts of the articles or other parts of the articles to the potentially elevated temperatures of heating zone 201 for extended periods. The specific processing timing of the heating station 200 and the system 100 as a whole is further discussed below.

[0022] from Figure 2 As can be seen from the depicted aspects, heating station 200 includes four distinct processing zones: 202, 204, 206, and 208, with each heating zone having two processing zones. For example, heating zone 201 may include processing zones 202 and 204, while heating zone 205 may include processing zones 206 and 208. In operation, articles, such as article 131, may enter heating station 200 from loading / unloading station 110 and be transferred to processing zone 202 within a specified time period, and then, within each zone, be transferred sequentially, for example, to processing zones 204, 206, and 208 within a specified time period.

[0023] Figure 3AThe processing area 202 of the heating zone 201 is depicted. Although the processing area 202 has been described, it should be understood that the foregoing description can also be applied to the processing area 204 of the heating zone 201. From Figure 3A As can be seen, product 131 is positioned on product compression assembly 600, which will be discussed in more detail below.

[0024] In some respects, the processing area 202 may include multiple thermal elements 220. From Figure 3A As can be seen from the description, multiple heating elements 220 can be positioned on more than one side of the article 131, which can promote effective and uniform heating of more than one side of the article 131. For example, heating elements 221 and 222 can be positioned adjacent to the heel region 131a of the article 131, heating elements 223, 224, 225 and 226 can be positioned adjacent to the ground-facing region 131b of the article 131, and heating elements 227, 228 and 229 can be positioned adjacent to the forefoot region 131c of the article 131. It should be understood that... Figure 3A The number of thermal elements depicted is merely an example, and other arrangements or numbers of thermal elements can be considered for use in system 100. Furthermore, Figure 3A The multiple thermal elements 220 are depicted as infrared (IR) lamps. It should be understood that other types of thermal elements are also considered for use in system 100.

[0025] In various aspects, as described above, heating zone 201 may be adapted to expose articles, such as article 131, to temperatures at which at least a portion of the article material will melt or deform. In some aspects, heating zone 201 and / or heating station 200 are adapted to expose articles, such as article 131, to temperatures ranging from about 70°C to about 250°C. In some aspects, heating zone 201 and / or heating station 200 are adapted to expose articles, such as article 131, to temperatures ranging from about 90°C to about 220°C. In one or more aspects, heating zone 201 and / or heating station 200 are adapted to expose articles, such as article 131, to temperatures ranging from about 110°C to about 180°C. In various aspects, heating zone 201 is adapted to increase the temperature of at least a portion of the article to the temperature range discussed in this paragraph. In some aspects, Figure 3A The heating zone 201 is adapted to increase the temperature within the heating zone 201 and / or heating station 200 from about 25°C to about 200°C in less than or equal to 10 seconds.

[0026] Figure 3A The processing area 202 of the heating zone 201 depicted may also include an air circulation device 232, which circulates air to distribute heat energy, such as the heat generated by the multiple heating elements 220, more evenly. Figure 3AAs can be seen from the description, the air circulation device 232 is positioned at or near the top 212 of the heating station housing 210. It should be understood that it can be positioned with... Figure 3A The air circulation device 232 depicted is positioned differently, for example, on the side wall 214 of the heating station housing 210. In various aspects, the air circulation device 232 can be any type of mechanical ventilation device, such as a fan.

[0027] As described above, in some aspects, the heating zone 201 may include two processing zones 202 and 204. In such an aspect, an article, such as article 131, may be exposed to, for example... Figure 3A The processing zone 202 depicted in the image is used for a specific time period, and then the image is moved to a processing zone 204, which may also include heating elements and air circulation devices, for example... Figure 3A Those depicted in processing area 202.

[0028] Turn now Figure 3B The text describes a processing area 206 within the heating zone 205. In some aspects, as described above, an article, such as article 131, can be transferred from the heating zone 201 to the processing area 206 of the heating zone 205, for example, by an article moving mechanism 120. As described above, the heating zone 205 may include one or more air circulation devices, such as air circulation device 234. Figure 3B As can be seen from the description, the air circulation device 234 is positioned at or near the top 212 of the heating station housing 210. It should be understood that it can be positioned in conjunction with... Figure 3B The air circulation device 234 depicted is positioned differently, for example, on the side wall 214 of the heating station housing 210. In various aspects, the air circulation device 234 can be any type of mechanical ventilation device, such as a fan.

[0029] As described above, in various aspects, heating zone 205, and processing zones 206 and 208, may not include heating elements, such as the IR lamps discussed above relative to heating zone 201. In various aspects, processing zone 206 may provide external heated air for circulation within heating zone 205, which is different from the heated air originating from the heating elements associated with heating zone 201. In some aspects, such heated air may be supplied to processing zone 206 via air circulation device 234 or via an inlet not depicted in the figures.

[0030] In various aspects, processing zone 206 may expose the article to temperatures ranging from about 70°C to about 250°C, from about 90°C to about 220°C, or from about 110°C to about 180°C. In various aspects, heating zone 205 is adapted to increase or maintain the temperature of at least a portion of the article, such as article 131, to the temperature range discussed herein. In various aspects, processing zone 206 may expose the article to temperatures lower than those of heating zone 201, but such temperatures may still be higher than the melting temperature, Vicat softening temperature, heat distortion temperature, or combinations thereof of the article material. In the same or alternative aspects, processing zone 206 may maintain the temperature of the article obtained from exposure to heating zone 201. In various aspects, processing zone 206 is adapted to increase the temperature of processing zone 206 from about 25°C to about 250°C within about 30 minutes or less.

[0031] 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 speed A. The heat distortion temperature can be determined according to the test method detailed in ASTM D648-16 using an applied stress of 0.455 MPa.

[0032] It should be understood that although the processing area 206 of the heating zone 205 has been discussed above, the same or similar features of the processing area 206 may exist in the processing area 208 of the heating zone 205.

[0033] Turn now Figure 4 The diagram depicts a first cooling station 300 of system 100. The first cooling station 300 may include one or more air circulation devices. For example, the cooling station 300 depicted in Figure 3 may include one or more inlets 302, 304, and 306 for circulating air at an ambient temperature, for example, from about 20°C to about 28°C, into the first cooling station 300. In such an aspect, from Figure 1 As best seen, the air circulation device 308 can be coupled to the housing 140 of the system 100 to supply ambient temperature air to the cooling station 300. In one aspect, the first cooling station 300 can circulate cooling air, such as air below room temperature, to aid in cooling the articles. It should be understood that the first cooling station 300 is merely one example of a cooling station, and other types of cooling stations or air circulation devices are also contemplated for use in the systems and methods described herein.

[0034] In all respects, the first cooling station 300 is adapted to reduce the temperature of the article to a temperature in the range of about 40°C to about 90°C, or about 50°C to about 80°C, or about 55°C to about 75°C, or about 120°C or lower. In one respect, the first cooling station 300 can reduce the temperature of the article to a temperature in the range of about 40°C to about 90°C, or about 50°C to about 80°C, or about 55°C to about 75°C in less than about 120 seconds, less than about 100 seconds, or less than about 75 seconds.

[0035] In some respects, as further discussed below, system 100 may include a third cooling station 500. In these respects, the third cooling station 500 may include reference... Figure 4 The discussion covers any or all components and related characteristics of the first cooling station 300.

[0036] Figure 5 A second cooling station 400 is depicted. In some respects, during operation, articles such as article 131 can be transferred from the first cooling station 300 to the second cooling station 400, for example, via an article moving mechanism 120.

[0037] Figure 5 The second cooling station 400 depicted herein may be adapted to expose articles, such as article 131, to pressures above atmospheric pressure. In some aspects, the second cooling station 400 may expose article 131 to pressures of about 100 kPa to about 500 kPa, about 110 kPa to about 400 kPa, or about 120 kPa to about 300 kPa. In some aspects, the increased pressure may provide additional compressive forces on article 131 to facilitate the formation of article 131 around the forming material, and / or to facilitate effective adhesion of one component of article 131 to another component.

[0038] In example Figure 5 In the aspects depicted, the second cooling station 400 may include a movable chamber 410 for sealing the article 131 in the inner portion 412. The movable chamber 410 may be, for example, Figure 5The open position depicted in the figure is moved to a sealed position not depicted in the figure. The movable chamber 410 can be moved vertically toward and away from the article positioned at the second cooling station 400. The movable chamber 410 can be moved vertically using any conventional mechanical movement mechanism known to those skilled in the art. In various aspects, in the open position, the movable chamber 410 is positioned above and away from the article 131, such that the article 131 is not positioned in the inner portion 412. In some aspects, in the sealed position, the sealing portion 414 located at the bottom of the movable chamber 410 contacts the surface 610a of the coupling platform 610 of the article compression assembly 600. The compression assembly 600 and the coupling platform 610 are discussed in detail below. The sealing portion 414 of the movable chamber 410 can comprise any type of material, such as an elastomeric material, adapted to form a temporary seal to allow for an increase in pressure in the inner portion 412 of the movable chamber 410.

[0039] In various aspects, in order to increase the pressure in the internal portion 412 of the movable chamber 410 to above atmospheric pressure, a gas, such as air, can be pumped into the internal portion 412, for example, via one or more lines 416 and 418. In one aspect, the gas or air pumped into the movable chamber 410 can be cooling air, for example, air in a temperature range of about 0°C to about 25°C, about 5°C to about 20°C, or about 15°C. In one aspect, cooling air can be generated using a conventional air cooling mechanism and pumped into the internal portion 412 of the movable chamber 410.

[0040] In various aspects, the second cooling station 400 is adapted to maintain the temperature of the article 131 within the range of about 40°C to about 90°C, about 50°C to about 80°C, or about 55°C to about 75°C. In one or more aspects, the specific temperature range may be determined based on the activation of the adhesive used to form at least a portion of the article 131. In such an aspect, by maintaining the article 131 or a portion thereof at a temperature within the activation temperature range of the adhesive, the additional compressive force provided by the increased pressure on the article 131 can promote more effective and efficient bonding of certain components of the article 131 together.

[0041] In various respects, by maintaining the article 131 or a portion thereof at a temperature within the aforementioned range while exposing the article to increased pressure, portions of the article 131 that have melted or deformed during the process described herein can be better shaped into the form of the material, as further discussed below. For example, in one respect, when the article 131 is an upper on a shoe last, increased pressure can facilitate the upper's formation into the shape of the shoe last before the material in the upper or a portion thereof cools below a temperature at which it will no longer deform or melt.

[0042] In some respects, after exposing article 131 to the second cooling station 400, article 131 may optionally be transferred to a third cooling station 500. In some respects, the third cooling station 500 may be similar to the one described above relative to the second cooling station 400. Figure 4 The first cooling station 300 described above functions. For example, as mentioned above, the third cooling station 500 may include the components described above relative to the first cooling station 300. Figure 4 The first cooling station 400 may contain any or all of the features described herein. In one aspect, to reduce the temperature of article 131, article 131 may be exposed to one or more sources of moving air. In these aspects, similar to the first cooling station 400, the third cooling station 500 may include an air inlet to circulate ambient air at, for example, about 20°C to about 28°C into the third cooling station 500. In some aspects, the third cooling station 500 may be adapted to cool article 131 to a temperature lower than that maintained in the second cooling station 400. For example, in one or more aspects, the third cooling station 500 may reduce the temperature of the shoe upper to a temperature less than about 90°C, less than about 80°C, or less than about 70°C. In some aspects, the third cooling station 500 may reduce the temperature of the shoe upper to a temperature in the range of about 15°C to about 90°C, about 20°C to about 65°C, or about 20°C to about 60°C.

[0043] In all respects, once an article, such as article 131, is exposed to a third cooling station 500 (or a second cooling station 400 in the absence of a third cooling station 500), article 131 may be transferred to loading / unloading station 110 for removal from system 100 or for transfer to another processing system.

[0044] As described above, in some respects, system 100 can provide a minimal area while also providing an efficient thermoforming process. In one aspect, the circumferential positioning of the stations or components of system 100 and / or the design of the article movement mechanism 120 can provide an efficient thermoforming process within a minimized area. For example, in one aspect, the article movement mechanism 120 can facilitate the transfer of one or more articles from one station to another in a consistent manner, such that rotation of the article movement mechanism 120 causes simultaneous movement of articles attached to each of the plurality of radially extending members 122. Figure 6 A top-view schematic diagram of system 100 is shown, which best illustrates these concepts.

[0045] from Figure 6 As can be seen, the article moving mechanism 120 can function as a rotary table, wherein the article moving mechanism 120 may include a plurality of radially extending members 122 (eight in total in this example), wherein each radially extending member 122 is coupled to a portion of a different article compression assembly. For example, Figure 6The component 122a of the article moving mechanism 120 is depicted as associated with or connected to the coupling platform 610a of the article compression assembly 600a. Figure 6 In one aspect, the article movement mechanism 120 can simultaneously rotate eight articles to different stations or processing areas. In another aspect, the article movement mechanism 120 can transfer each article to an adjacent station. For example, an article connected to the connection platform 610a can be transferred from the loading / unloading station 110 to the processing area 202 of the heating station 200, while an article connected to the connection platform 610b can be transferred from processing area 202 to processing area 204. In yet another aspect, the system 100 and its process can be adapted to allow appropriate levels of processing (e.g., hot or cold exposure) at specific time intervals, which can be applied to each of the seven processing locations (the eighth being the loading and unloading of articles).

[0046] In some respects, the article may spend substantially similar (or the same) time periods at each of the seven processing locations. In one respect, the article may be exposed to a particular processing location for a period of approximately 20 seconds to approximately 75 seconds, approximately 30 seconds to approximately 60 seconds, or approximately 45 seconds to approximately 55 seconds. For example, an article coupled to the coupling platform 610a may be transferred to processing area 202 of heating zone 201 for a period of approximately 20 seconds to approximately 75 seconds, and then it may be transferred to processing area 204 of heating zone 201 for a period of approximately 20 seconds to approximately 75 seconds. Furthermore, in this example, the article may be transferred to processing area 206 of heating zone 205 for a period of approximately 20 seconds to approximately 75 seconds, and then transferred to processing area 208 of heating zone 205 for the same or similar time periods. Furthermore, still in this example, the article may then be transferred to the first cooling station 300 for a period of approximately 20 seconds to approximately 75 seconds, and then transferred to the second cooling station 400 for the same or similar time periods. Furthermore, in this example, the article may be transferred to the third cooling station 500 for a period of approximately 20 seconds to approximately 75 seconds before being transferred to loading / unloading station 110. It should be understood that the time periods described herein are merely one example set of time periods that can be utilized, and this disclosure also considers other time periods that may be necessary for different processing needs. In addition, although the foregoing example design of system 100 and its seven processing stations (of which the eighth is loading / unloading station 110) has been described, other numbers of processing locations are considered and are within the scope of this specification.

[0047] In some aspects, the period of time during which the article is exposed to each specific processing location for approximately 20 seconds to approximately 75 seconds can be translated into the article being present in heating station 200 for approximately 80 seconds to approximately 300 seconds. Furthermore, in one aspect, where the period of time during which the article is exposed to each specific processing location for approximately 20 seconds to approximately 75 seconds can be translated into the period of time during which the article is present in each of heating zones 201 and 205 for approximately 40 seconds to approximately 150 seconds.

[0048] As described above, articles such as articles 130 or 131 exposed to system 100 for thermoforming can be combined with forming surfaces to allow the article or a portion of the article to at least partially form the shape of the forming surface by exposure to system 100 as described herein. As just one example, article 131 can be placed on a foot last such that article 131 can be formed into the shape of the last by exposure to system 100 and / or process as described herein, and article 131 may be part of an upper for footwear articles.

[0049] Figure 7A An example is depicted in which the article may be an upper 700 for footwear articles. In some examples, the upper may include one or more materials for processing in the system 100 described herein. In other words, the upper 700 may include one or more thermoplastic materials that are desired to be thermoformed using the processes and system 100 described herein. In all respects, the term thermoplastic material may also refer to a thermoplastic polymer composition.

[0050] In one aspect, the upper 700 may include one or more yarns or fibers, the yarns or fibers comprising a yarn or fiber composition comprising a thermoplastic material or a thermoplastic polymer composition. In these aspects, the thermoplastic material, the thermoplastic polymer composition, and / or the yarn or fiber composition may exhibit a melting temperature T of about 80°C to about 135°C or about 90°C to about 120°C. m (or melting point), Vicat softening temperature, heat distortion temperature, or any combination thereof. In one aspect, the thermoplastic material and / or yarn or fiber composition may exhibit a melting temperature of about 135°C or lower, about 125°C or lower, or about 120°C or lower. mVicat softening temperature, heat distortion temperature, or any combination thereof. In the same or alternative aspects, the upper may include one or more materials that do not melt or deform under the processing conditions disclosed herein. In the case of such thermoplastic materials or thermoplastic polymer compositions, this material may exhibit a melting temperature, Vicat softening temperature, heat distortion temperature, or any combination thereof greater than about 135°C, greater than about 140°C, or greater than about 150°C. Furthermore, in these aspects, another material that may be present in the article, such as a material other than a thermoplastic material or thermoplastic polymer composition, may not degrade at temperatures below about 150°C, about 140°C, or about 135°C.

[0051] Figure 7B An example of a surface formed therein is a shoe last 720. In various respects, the shoe last 720 may include a conventional foot-shaped shoe last, provided that such shoe last can withstand the temperature and pressure of the process and system 100 described herein without deforming, melting, degrading or cracking.

[0052] Figure 7C Depicting placed on shoe last 720 Figure 7A The shoe upper is 700. From Figure 7C As can be seen, the example upper 700 is boot-shaped because it includes a heel portion 702, a forefoot portion 704, a collar portion 706, and a ground-facing portion 708. In various aspects, thermoplastic material may be present in any or all of the aforementioned portions of the thermoformed upper 700 in the process and system 100 described herein. For example, in one aspect, thermoplastic material may be present in the ground-facing portion 708, which may form part of the ground-facing sole (midsole and / or outsole) of the finished footwear article.

[0053] In some respects, in order to help form the upper 700 as the forming surface of the last 720, a compressive force can be applied to the upper 700 using a compressive material, thereby pressing the upper 700 upward against the rigid last 720 to help form the upper 700 during the process and system 100 described herein. Figure 8A An example compression material 620 is depicted. The compression material 620 may be part of an article compression assembly 600, as discussed in more detail below.

[0054] from Figure 8AAs can be seen from the aspects depicted, the compression material 620 is boot-shaped because its shape is at least partially similar to that of the last 720 and / or the upper 700. In this respect, utilizing the compression material 620, whose shape is similar to that of the forming material such as the last 720, can reduce any defects or creases that may result in the final thermoformed article. In other words, compared to using a compression material 620 whose shape is dissimilar to that of the upper 700 and / or the last 720, the compression of the compression material 620 on the upper 700 can minimize any creases or wrinkles that may ultimately appear in the thermoformed upper 700, because the shapes of the compression material 620 and the upper 700 are substantially similar.

[0055] In some respects, the compression material 620 may be formed from any elastomeric material, provided that the elastomeric material exhibits a melting or degradation temperature at least 10°C higher, or at least 20°C higher, or even higher than the processing temperature described above for the reference heating station 200. In one respect, the compression material 620 may comprise a polysiloxane.

[0056] In some aspects, the compression material 620 is suitable for providing thermoformed articles with desired optical properties such as clarity, transparency, and / or haze. In some aspects, these desired optical properties described herein can provide a thermoformed surface that can transmit incident light with minimal scattering and minimal absorption. In one aspect, the inner surface of the compression material 620, i.e., the surface of the compression material 620 that contacts the article when the article is placed within the compression material 620, can exhibit a certain surface roughness so as not to adversely affect one or more of these optical properties of the thermoformed article. For example, in one aspect, when measured using an optical surface photometer and calculated according to JIS B 0601-2001, the inner surface of the compression material 620 can exhibit an average surface roughness Ra of less than 50 nm, less than 30 nm, less than 1 nm, or less than 100 μm.

[0057] In some respects, the use of the compression material 620 disclosed herein can impart the desired clarity to at least a portion of the surface of a thermoformed article. For example, in some respects, as measured according to ASTM D1746-15, the conventional transmittance or clarity of at least a portion of the thermoformed article may be at least about 70%, at least about 80%, at least about 85%, at least about 90%, or at least about 95%. In the same or alternative respects, as measured according to ASTM D1003-13, the thermoformed article or at least a portion thereof may exhibit a haze value of less than about 30%, less than about 25%, less than about 20%, less than about 15%, less than about 10%, or less than about 5%.

[0058] In one or more aspects, the compression material 620 disclosed herein may provide patterns or markings on the outer surface of a thermoformed article. For example, the inner surface of the compression material 620, i.e., the surface of the article that contacts the article when the article is placed within the compression material 620, may include raised and / or recessed markings or patterns that can be embossed onto at least a portion of the outer surface of the article by a thermoforming process. In one aspect, the raised or recessed markings and / or patterns may include the surface roughness characteristics discussed above, such that the embossed or stamped pattern obtained on the shoe upper can exhibit one or more of the clarity and haze characteristics discussed above.

[0059] Figure 8B An assembly 730 is depicted having compressed material 620 placed on the upper 700 and the last 720. From Figure 8B As can be seen from the aspects described, the compression material 620 is formed only around the upper 700 present on the shoe last 720. For example, due to the stretching configuration of the compression material 620 when covering the upper 700 present on the shoe last 720, the elastic properties of the compression material 620 can provide at least a first level of compressive force on the upper 700 present on the shoe last 720.

[0060] In some respects, for example by exposing the area between the inner surface 621 of the compression material 620 and the outer surface 710 of the upper 700 to negative pressure, the article compression assembly 600, discussed further below, can provide an increased level of compressive force on the upper 700 present on the last 720. Figure 9A and Figure 9B An example of a docking member 630 of an article compression assembly 600 is depicted. When coupled to an assembly 730 of compression material 620 placed on the upper 700 and the last 720, the docking member 630 can provide negative pressure to facilitate this increased level of compressive force on the upper 700. In various aspects, the docking member 630 is coupled to a coupling platform 610, which, as described above, is coupled to one of a plurality of radially extending members 122 of the article moving mechanism 120.

[0061] from Figure 9AAs best seen, the protrusion 722 extending from the last 720 can be inserted into the recess 632 of the collar 634 of the mating member 630 for connecting the assembly 730 of the compression material 620 on the upper 700 and the last 720 to the mating member 630. An example of the last protrusion could be a last extension extending from the last 720, which is separate but connected to the last 720. Alternatively, such a last extension can be integral with the last 720. In some aspects, the sealing portion 622 of the compression material 620 extends outward from and away from the upper 700 and the last 720 and terminates at the flange 624. In various aspects, the sealing portion 622 can cover the collar 634 of the mating member 630 when the flange 624 can contact the surface 637a of the bottom mating plate 637. Furthermore, from Figure 9A As can be seen from the image, the upper docking plate 636 includes two movable parts 631a and 631b, which can be closed onto the bottom docking plate 637, thereby fixing the flange 624 between the bottom docking plate 637 and the top docking plate 636.

[0062] Figure 9B The assembly 730, consisting of compressed material 620 connected to the shoe upper 700 and shoe last 720, is best depicted. From Figure 9B As can be seen, movable parts 631a and 631b are closed onto the bottom mating member 637 and can be secured in place using temporary fasteners 641, 642, 643, and 644. In such an aspect, one or more ports 638 can provide negative pressure to facilitate the compression of the compression material 620 onto the outer surface of the upper 700. It should be understood that the positioning of port 638 is merely one example of the location of ports that can provide negative pressure, and other positioning of ports or other specific amounts of ports are considered for use in the system disclosed herein.

[0063] Despite Figure 9A and Figure 9B As not shown, but as described above, the coupling platform 610 of the article compression assembly 600 can be coupled to one of the plurality of radially extending members 122 of the article moving mechanism 120, and through this connection, the port 638 can be in fluid communication with the negative pressure generating system. Figure 6 A negative pressure generating system 150 is depicted coupled to the article moving mechanism 120. The negative pressure generating system 150 can be coupled to the article moving mechanism 120 in any conventional manner, for example, one or more conduits can be coupled to each of the plurality of radially extending members 122 of the article moving mechanism 120, wherein these conduits can be in fluid communication with a port 638 associated with an article compression assembly 600.

[0064] exist Figure 9AIn the aspects depicted, the mating member 630 is angled relative to the horizontal plane 610a of the coupling platform 610 of the article compression assembly 600. In these respects, this can cause a portion of the article, such as the ground-facing portion 708 (or the plane 708a of the ground-facing portion 708), to also be angled relative to the horizontal plane 610a of the coupling platform 610. In these respects, this angular orientation of the shoe upper or other article can, for example, by making the forefoot region 704 more exposed to, for example... Figure 3A One or more heating elements are depicted to provide more efficient heating. In one aspect, the angle between plane 708a and plane 610a may be in the range of about 10º to about 60º, about 15º to about 50º, or about 20º to about 40º, or it may be about 30º.

[0065] Figure 9C Another example of a mating member is depicted, mating member 640, which, when connected to component 730a of compression material 620a placed on the upper 700 and the last 720, can provide negative pressure to help increase the level of compressive force on the upper 700. Component 730a is Figure 8B The alternative form of component 730 depicted is because the compressible material 620a in component 730a is derived from... Figure 8B The component 730 is modified from the compressed material 620. For example, in Figure 9C In the aspects described herein, the compressible material 620a does not include materials present in... Figure 8B The flange 624 on the compression material 620 may include other characteristics and parameters of the compression material 620. In some aspects, as further discussed below, the compression material 620a may include... Figure 8B Additional features not found in aspects of the compressed material 620. In all aspects, with Figure 9A and Figure 9B Similar to the docking member 630, the docking member 640 is connected to the connecting platform 610, as described above, which is connected to... Figure 1 One of the plurality of radially extending members 122 of the article moving mechanism 120.

[0066] At a higher level, Figure 9C The mating member 640 depicts an example of how the compression material 620a of component 730a can secure component 730a to the mating member 640 and promote a seal between the compression material 620a and the mating member 640, thereby allowing a negative pressure to be applied to promote compression of the compression material 620a onto the outer surface of the upper 700. Figure 9CAs can be seen, the mating member 640 may include a mating plate 642 having a recess 654 with a protrusion 722 sized to accommodate the shoe last 720, and one or more ports 646 that can provide such negative pressure to facilitate the compression of the compression material 620a onto the outer surface of the upper 700. It should be understood that the location of the port 646 is merely one example of the location of ports that can provide negative pressure, and other locations of ports or other specific numbers of ports are considered for use in the system disclosed herein.

[0067] In addition, from Figure 9C As can be seen, the mating member 640 includes a single mating plate 642, which, when a negative pressure is applied through the port 646, is adapted to seal the compressed material 620a around the port 646 together with the sealing portion 622a of the compressed material 620a. In such an aspect, from Figure 9C and Figure 9D As can be seen, the sealing portion 622a of the compression material 620a may include an O-ring 623, which is at least partially complementary in shape to the recess 641 in the mating plate 642. Furthermore, in Figure 9C and Figure 9D In the aspect depicted herein, the recess 641 in the mating plate 642 can form a periphery surrounding the recess 654 of the protrusion 722 for the shoe last 700 and surrounding the port 646. In such an aspect, this allows a seal, at least partially formed by the O-ring 623 and the recess 641 in the mating plate 642, to promote the compression of the compression material 620a onto the outer surface of the upper 700 when a negative pressure is applied via the port 646. It should be understood that the O-ring 623 and the recess 641 in the mating plate 642 are merely one example of how such a seal can be formed between the mating plate 642 and the compression material 620a, and other complementary structures present on the mating plate 642 and the compression material 620a are also considered for use in the systems and methods described herein.

[0068] Figure 9C The image depicts a component 730 that is not fully engaged with the mating member 640, such as a protrusion 722 of the last 720 not inserted into a recess 654 of the mating plate 642. It should be understood that in operation, when the O-ring 623 engages with the recess 641, the protrusion 722 of the last 720 can be inserted into the recess 654 of the mating plate 642. In such an aspect, the sealing portion 622a of the compression material 620a may include additional material, such as a portion of the sealing portion 622a positioned between the protrusion 722 and the mating plate 642, such as... Figure 9CAs depicted in the text. However, in such an aspect, when the last 720 and / or the upper 700 are exposed to negative pressure and when the last and the mating member 640 are fully engaged, additional material can also be compressed onto the last 720 and / or the upper 700, and this additional material will not adversely affect the thermoforming process of the upper 700 or cause deformation of the upper 700 during the thermoforming process.

[0069] Figure 9E Another example of a mating member is depicted, such as mating member 650, which, when connected to component 730b of compression material 620b placed on the upper 700 and the last 720, can provide negative pressure to help increase the level of compressive force on the upper 700. Component 730b is... Figure 8B The alternative form of component 730 depicted is because the compressible material 620b in component 730b is derived from... Figure 8B The component 730 is modified from the compression material 620, but may include other properties and parameters of the compression material 620. For example, in Figure 9E In the aspects described herein, the compressible material 620b does not include materials present in... Figure 8B The flange 624 on the compression material 620. In some aspects, as further discussed below, the compression material 620b may include... Figure 8B Additional features not found in aspects of the compressed material 620. In all aspects, with Figure 9A and Figure 9B Similar to docking member 630, docking member 640 is connected to docking platform 610, which, as described above, is connected to one of the plurality of radially extending members 122 of article moving mechanism 120.

[0070] from Figure 9E As can be seen from the aspects depicted, the mating member 650, the collar 652 extending outward from the mating member 650, and the compression material 620b of the assembly 730b are adapted to cooperatively provide a seal of the compression material 620b around the port 656 to apply negative pressure for compressing the compression material 620b onto the upper 700. In such an aspect, the sealing portion 622b of the compression material 620b may include two O-rings 662, which respectively engage a complementary-shaped recess 663 in the collar 652 and a complementary-shaped recess 665 in the mating plate 660 of the mating member 650. Although not depicted as a cross-section in the figures, the O-rings 662 and 664 may be positioned in a manner similar to... Figure 9D The corresponding recesses 663 and 665 are joined in the manner depicted in the cross-section. Although Figure 9EThe aspects depicted show the O-rings used, but it should be understood that any type of structure or shape that is integral with or separate from the compression material 620b can be used with corresponding complementary shapes or recesses in the collar 652 and the mating plate 660.

[0071] It should be understood that, despite Figure 9E The aspect depicted shows two O-rings 662 and 664 for forming a seal on the collar 652 and the mating plate 660 together with the compression material 620b; however, it should be understood that more or fewer O-rings or sealing structures are considered for use in this disclosure. For example, in an alternative aspect, Figure 9E The compression material 620b may include an O-ring 662 to engage the collar 652, but does not include an O-ring 664 to engage the mating plate 660. Alternatively, the compression material 620b may include more than one O-ring adapted to engage the collar 652. Yet another aspect, the compression material 620b may not include one or more O-rings or other sealing structures and may be manually or otherwise held in place around the port 656, for example by sealing around a portion of the collar 652 and / or the mating plate 660, while providing negative pressure such that a seal is still generated that can provide compressive force to the upper 700.

[0072] Although the above is Figures 9A to 9E Various examples of mating members are depicted, but it should be understood that any combination of features from the various mating members described above can be combined. For example, besides Figure 9A and Figure 9B In addition to the features described herein, an O-ring or other sealing structure may be present on the compression material 620 to engage the collar 634 to ensure a tighter or better seal.

[0073] In various aspects, the uppers disclosed herein may include additional materials to provide additional comfort and / or support for the wearer of footwear articles formed using the processes and systems described herein. Example additional materials may include a frame and heel stabilizer that can be positioned on the footbed of the footwear article. Figure 10A and Figure 10B The heel stabilizer 800 and the upper 700 are depicted. In one respect, the heel stabilizer 800 can be formed of any type of material, as long as the material does not melt or deform during the aforementioned processing. Although the heel stabilizer 800 is specifically depicted in the figure, it should be understood that other components, such as the aforementioned underframe, can also be combined with the upper 700 for processing.

[0074] Figure 10BA heel stabilizer 800 is depicted positioned in the inner portion 712 of the upper 700. In some aspects, to secure the heel stabilizer 800 to the inner portion 712 of the upper 700, an adhesive may be used to secure the heel stabilizer 800 or other components to the upper 700. Any conventional adhesive, such as a hot-melt adhesive, is considered for use in the processes and systems described herein. In one aspect, the adhesive is capable of withstanding the processing temperatures provided in the heating station 200 and the first cooling station 300, and can effectively bond under the conditions described above relative to the second cooling station 400, for example, under conditions where the article is cooled or maintained in a temperature range of about 40°C to about 90°C.

[0075] Figure 11 A depiction of an upper 700 with a heel stabilizer 800 positioned therein is shown, wherein a portion of the upper 700 is removed to show a cross-section of the upper 700 and a portion of the heel stabilizer 800. Figure 11 In the aspect described, adhesive 820 is positioned between the inner surface 714 of the upper 700 and the outer surface 802 of the heel stabilizer 800.

[0076] Figure 12 The image depicts a heel stabilizer 800 inside the upper 700, where the upper 700 is positioned on the last 720, and a compression material 620 is positioned on the upper 700. As described above, in some aspects, the compression material 620 can apply compressive force to the upper 700 and compress the upper 700 onto the last 720 via the elastic properties of the compression material 620, the application of pressure above atmospheric pressure, or both. Furthermore, as described above, in one aspect, the system 100 can be adapted to provide increased pressure to the upper 700 at a temperature within the effective bonding temperature range of the adhesive, such as adhesive 820, such that the increased pressure and accompanying increased compressive force on the upper 700 adjacent to the heel stabilizer 800 and the last 720 can more effectively bond the heel stabilizer 800 and the upper 700 together. It should be understood that, although in Figure 12 It is described Figure 8B The compression material is 620, but other compression materials can also be used, such as... Figure 9C and Figure 9E The compression materials 620a and 620b.

[0077] In one aspect not depicted in the figures, one or more components, such as a heel stabilizer or frame, may comprise one or more materials adapted to be at least partially melted or deformed by the processes discussed herein, and can be cooled and hardened, and fixed or bonded to at least a portion of the upper. In such an aspect, the material of the heel stabilizer or frame (or other component) may not be fully cured so as to further shape the last or other forming material when exposed to the increased pressure of the aforementioned second cooling station 400.

[0078] It should be understood that examples of additional components, such as heel stabilizers and frames, have already been discussed above, and other components may be added before or after the processes described herein. In one example, insoles, plates, toe caps, and / or side-mounted structures may also be added to the upper, with or without a frame and heel stabilizer.

[0079] Figure 13 A flowchart depicts a method 900 for thermoforming an article. Method 900 may include a step 910 of receiving the article. In various aspects, the article can be any type of article, such as any of the articles described above. In one aspect, the article can be a shoe upper, such as the one referenced above. Figures 7A to 12 The shoe upper is described as 700.

[0080] In some aspects, method 900 may include step 920 of exposing the article to a first heating zone. In various aspects, the heating zone may include one or more heating elements and one or more air circulation devices, such as those referenced above. Figure 2 and Figure 3A The heating zone 201 describes the heating element and air circulation device. In various aspects, the article in the first heating zone can be exposed to temperatures ranging from about 70°C to about 250°C. In one aspect, the first heating zone may include the above-referenced... Figure 2 , Figure 3A and Figure 6 The discussion covers any or all features, characteristics, and parameters of the heating zone 201.

[0081] Step 930 of method 900 includes exposing the article to a second heating zone. In various aspects, the heating zone may include one or more air circulation devices, such as those referenced above. Figure 2 and Figure 3B The air circulation device described in heating zone 205. In various aspects, the article in the second heating zone can be exposed to a temperature ranging from about 70°C to about 250°C. In one aspect, the second heating zone can increase the temperature of at least a portion of the article at a reduced rate compared to the rate of temperature increase when the article is exposed to the first heating zone. In one aspect, the second heating zone may include the above-described air circulation device relative to the first heating zone. Figure 2 , Figure 3B and Figure 6 The heating zone 205 describes any or all of its features, characteristics, and parameters.

[0082] Step 940 of method 900 includes exposing the article to a first cooling station. In various aspects, the article may be exposed to the first cooling station after being exposed to a second heating zone. In various aspects, the first cooling station may be adapted to cool at least a portion of the article to a temperature in the range of about 40°C to about 90°C. In one aspect, the first cooling station may include one or more air circulation devices, such as those referenced above. Figure 1 and Figure 4 The first cooling station 300 describes an air circulation device. In various aspects, the first cooling station can exist under ambient temperature and pressure. In various aspects, the first cooling station may include the above-mentioned references. Figure 1 , Figure 4 and Figure 6 The discussion concerns any of the features, characteristics, and parameters of the first cooling station 300.

[0083] Step 950 of method 900 includes exposing the article to a pressure greater than atmospheric pressure. In one aspect, after the article has been exposed to a first cooling station, the article may be exposed to a pressure greater than atmospheric pressure. In another aspect, the above reference may be used. Figure 1 and Figure 5 The second cooling station 400 described above exposes the article to pressure greater than atmospheric pressure. In one aspect, the increased pressure can apply compressive force (with or without the aforementioned compressive material) to the outer surface of the article to help shape the article into the form of the forming material, for example, shaping a shoe upper into the shape of a shoe last. In the same or alternative aspect, the increased pressure can apply compressive force (with or without the aforementioned compressive material) to promote adhesion between one part of the article and another part of the article. In such an aspect, an adhesive, as described above, can be used. Figure 5 , Figure 6 , Figure 11 and Figure 12 The discussion focuses on its effectiveness within a 400°C temperature range for the second cooling station. The above references can be used in various aspects. Figure 5 , Figure 6 , Figure 11 and Figure 12 The discussion includes any or all features, characteristics, and parameters of the second cooling station 400 to help perform the functions and features of step 950.

[0084] Figure 14A flowchart depicts a method 1000 for thermoforming an article. Method 1000 may include a step 1010 of receiving the article. In various aspects, the article may be of any type, such as any of the articles described above. In some aspects, the article may include the thermoplastic polymer composition or thermoplastic material described above. In one aspect, the article may be a shoe upper, such as the one referenced above. Figures 7A to 12 The shoe upper is described as 700.

[0085] In some aspects, method 1000 may include step 1020 of exposing the article to one or more heating zones. In such an aspect, exposing the article to one or more heating zones may increase the temperature of at least a portion of the article to above the melting temperature of the thermoplastic polymer composition. In various aspects, the one or more heating zones may include those referenced above. Figure 2 , Figure 3A , Figure 3B and Figure 6 Any or all features, characteristics, and parameters of the heating zones 201 and / or 205 discussed.

[0086] In various aspects, method 1000 may include step 1030 of exposing the article to a first cooling station. In one aspect, the article may be exposed to the first cooling station to reduce the temperature of at least a portion of the article to a temperature that is: 1) below the melting temperature of the thermoplastic polymer composition; and 2) above the heat distortion temperature, Vicat softening temperature, or both of the thermoplastic polymer composition. In various aspects, step 1030 of exposing the article to the first cooling station may be performed after step 1020 of exposing the article to one or more heating zones. In various aspects, the first cooling station may be adapted to cool at least a portion of the article to a temperature in the range of about 40°C to about 90°C. In one aspect, the first cooling station may include one or more air circulation devices, such as those referenced above. Figure 1 and Figure 4 The first cooling station 300 describes an air circulation device. In various aspects, the first cooling station can exist under ambient temperature and pressure. In various aspects, the first cooling station may include the above-mentioned references. Figure 1 , Figure 4 and Figure 6 The discussion concerns any of the features, characteristics, and parameters of the first cooling station 300.

[0087] In various aspects, method 1000 may include step 1040 of exposing the article to a pressure greater than atmospheric pressure. In one aspect, step 1040 may be performed after step 1030 of exposing the article to a first cooling station. In one aspect, the above reference may be used. Figure 1 and Figure 5The second cooling station 400 described above exposes the article to pressure greater than atmospheric pressure. In one aspect, the increased pressure can apply compressive force (with or without the aforementioned compressive material) to the outer surface of the article to help shape the article into the form of the forming material, for example, shaping a shoe upper into the shape of a shoe last. In the same or alternative aspect, the increased pressure can apply compressive force (with or without the aforementioned compressive material) to promote adhesion between one part of the article and another part of the article. In such an aspect, an adhesive, as described above, can be used. Figure 5 , Figure 6 , Figure 11 and Figure 12 The discussion focuses on its effectiveness within a 400°C temperature range for the second cooling station. The above references can be used in various aspects. Figure 5 , Figure 6 , Figure 11 and Figure 12 The discussion includes any or all features, characteristics, and parameters of the second cooling station 400 to help perform the functions and features of step 1040.

[0088] Figure 15 A flowchart depicts a method 1100 for thermoforming an article. Method 1100 may include step 1110 of receiving an upper for a footwear article. In one aspect, the article may be an upper, such as the one referenced above. Figures 7A to 12 The shoe upper 700 is described. In some aspects, the shoe upper may include the aforementioned thermoplastic polymer composition or thermoplastic material. In various aspects, the shoe upper may be positioned on a last or other forming material. In various aspects, the last may include the above-mentioned reference material. Figures 7B to 12 The description of any or all features, characteristics and parameters of the shoe last 720.

[0089] In various aspects, method 1100 may include step 1120 of compressing material onto the outer surface of the shoe upper to form a compressed shoe upper. In various aspects, the material used for compressing onto the shoe upper may include the material referenced above. Figure 8A , Figure 8B , Figure 9C and Figure 9E The discussion concerns one or more of the compression materials 620, 620a, or 620b. In each aspect, [the following methods can be utilized]. Figure 9A , Figure 9C and Figure 9E The mating components 630, 640 and 650, along with the aforementioned associated processes, facilitate the compression of material onto the outer surface of the shoe upper.

[0090] In various aspects, method 1100 may include step 1130 of exposing the compressed upper to one or more heating elements. In these aspects, exposing the compressed upper to one or more heating elements may increase the temperature of at least a portion of the upper to above the melting temperature of the thermoplastic polymer composition. In one or more aspects, exposing the compressed upper to one or more heating elements may include exposing the compressed upper to the above-referenced... Figure 2 and Figure 3A The discussion focuses on the heating station 200.

[0091] In some aspects, method 1100 may include step 1140 of reducing the temperature of at least a portion of the upper. In these aspects, the temperature of at least a portion of the upper may be reduced to a temperature that is: 1) below the melting temperature of the thermoplastic polymer composition; and 2) above the heat distortion temperature, Vicat softening temperature, or both of the thermoplastic polymer composition. In one or more aspects, reducing the temperature of at least a portion of the upper may include exposing the compressed upper to one or more cooling stations, such as those referenced above. Figure 4 The first cooling station 300 is described. In various aspects, step 1140, which reduces the temperature of at least a portion of the upper, may be performed after step 1130, which exposes the compressed upper to one or more heating elements.

[0092] In various aspects, method 1100 may include step 1150 of exposing the compressed upper to a pressure greater than atmospheric pressure. In one aspect, step 1150 may be performed after step 1140 of reducing the temperature of at least a portion of the upper. In one aspect, the above reference may be used. Figure 1 and Figure 5 The second cooling station 400 described herein exposes the compressed upper to pressure greater than atmospheric pressure. In one aspect, the increased pressure can apply compressive force to the outer surface of the upper to help form at least a portion of the last. In the same or alternative aspect, the increased pressure can apply compressive force to promote adhesion between one component of the upper and another component of the upper. In such an aspect, an adhesive, as described above, can be used. Figure 5 , Figure 6 , Figure 11 and Figure 12 The discussion focuses on its effectiveness within a 400°C temperature range for the second cooling station. The above references can be used in various aspects. Figure 5 , Figure 6 , Figure 11 and Figure 12 The discussion includes any or all features, characteristics, and parameters of the second cooling station 400 to help perform the functions and features of step 1150.

[0093] Figure 16A flowchart depicts a method 1200 for thermoforming an article. Method 1200 may include a step 1210 of receiving the article. In various aspects, the article may be of any type, such as any of the articles described above. In some aspects, the article may include the thermoplastic polymer composition or thermoplastic material described above. In one aspect, the article may be a shoe upper, such as the one referenced above. Figures 7A to 12 The shoe upper is described as 700.

[0094] In various aspects, method 1200 may further include step 1220 of exposing the article to a first heating zone. In one aspect, the first heating zone may include one or more heating elements and one or more first air circulation devices. In various aspects, the first heating zone may be adapted to increase the temperature of the first heating zone from about 25°C to about 200°C in less than or equal to 50 seconds. In one aspect, the first heating zone may include the above-referenced... Figure 2 , Figure 3A and Figure 6 The discussion covers any or all features, characteristics, and parameters of the heating zone 201.

[0095] In some aspects, method 1200 may include step 1230 of exposing the article to a second heating zone. In such an aspect, the second heating zone may include one or more second air circulation devices, such as those described above relative to... Figure 3B The air circulation device described in heating zone 205. In various aspects, the second heating zone may be adapted to maintain the temperature reached by the article in the first heating zone. In various aspects, such a temperature may be at or above the melting temperature, heat distortion temperature, Vicat softening temperature, or a combination thereof of the thermoplastic material of the article. In various aspects, the second heating zone may include the above-mentioned reference. Figure 2 , Figure 3B and Figure 6 The discussion covers any or all features, characteristics, and parameters of the heating zone 205.

[0096] In various aspects, method 1200 may include step 1240 of reducing the temperature of at least a portion of the article to about 120°C or lower. In one aspect, step 1240 of reducing the temperature of at least a portion of the article may be performed after step 1230 of exposing the article to a second heating zone. In various aspects, step 1240 may be performed at a cooling station, for example... Figure 1 , Figure 4 and Figure 6 The cooling station 300 described herein is executed and may include any or all of the features, characteristics and parameters of the cooling station 300.

[0097] Figure 17A flowchart depicts a method 1300 for thermoforming an article. Method 1300 may include step 1310 of receiving an upper for a footwear article. In one aspect, the article may be an upper, such as the one referenced above. Figures 7A to 12 The discussion concerns the upper 700. In various aspects, the upper can be positioned on a last or other forming material. In various aspects, the last may include the above-mentioned reference. Figures 7B to 12 The description of any or all features, characteristics and parameters of the shoe last 720.

[0098] In various aspects, method 1300 may include step 1320 of compressing material onto the outer surface of the shoe upper to form a compressed shoe upper. In various aspects, the material used for compressing onto the shoe upper may include the material referenced above. Figure 8A , Figure 8B Figure 9c and Figure 9E The discussion concerns one or more of the compression materials 620, 620a, or 620b. In each aspect, [the following methods can be utilized]. Figure 9A , Figure 9C and Figure 9E The mating components 630, 640 and 650, along with the aforementioned associated processes, facilitate the compression of material onto the outer surface of the shoe upper.

[0099] In various aspects, method 1300 may further include step 1330 of exposing the compressed upper to a first heating zone. In one aspect, the first heating zone may include one or more heating elements and one or more first air circulation devices. In various aspects, the first heating zone may be adapted to increase the temperature of the first heating zone from about 25°C to about 200°C in less than or equal to 50 seconds. In one aspect, the first heating zone may include the above-referenced... Figure 2 , Figure 3A and Figure 6 The discussion covers any or all features, characteristics, and parameters of the heating zone 201.

[0100] In some aspects, method 1300 may include step 1340 of exposing the compressed upper to a second heating zone. In such an aspect, the second heating zone may include one or more second air circulation devices, such as those described above relative to... Figure 3B The air circulation device described in heating zone 205. In various aspects, the second heating zone may be adapted to maintain the temperature of the compressed upper achieved in the first heating zone. In various aspects, such a temperature may be at or above the melting temperature, heat distortion temperature, Vicat softening temperature, or a combination thereof of the thermoplastic material of the upper. In various aspects, the second heating zone may include the above-mentioned reference... Figure 2 , Figure 3B and Figure 6 The discussion covers any or all features, characteristics, and parameters of the heating zone 205.

[0101] In various aspects, method 1300 may include step 1350 of reducing the temperature of at least a portion of the shoe upper to about 120°C or lower. In one aspect, step 1350 of reducing the temperature of at least a portion of the article may be performed after step 1340 of exposing the compressed shoe upper to a second heating zone. In various aspects, step 1240 may be performed at a cooling station, for example... Figure 1 , Figure 4 and Figure 6 The cooling station 300 described herein is executed and may include any or all of the features, characteristics and parameters of the cooling station 300.

[0102] Despite Figures 13 to 17 The document references one or more steps, but it is important to note that one or more additional or alternative steps may be implemented in order to achieve the various aspects provided herein. Therefore, boxes may be added or omitted while still remaining within the scope of this document.

[0103] The following clauses are the aspects considered in this article.

[0104] Clause 1. A method for thermoforming an article, the method comprising: receiving the article; exposing the article to a first heating zone including one or more heating elements and one or more first air circulation devices, wherein the first heating zone is adapted to expose the article to a temperature in the range of about 70°C to about 250°C; exposing the article to a second heating zone including one or more second air circulation devices, wherein the second heating zone is adapted to expose the article to a temperature in the range of about 70°C to about 250°C; after exposing the article to the second heating zone, exposing the article to a first cooling station including one or more third air circulation devices, wherein the first cooling station is adapted to reduce the temperature of at least a portion of the article to a range of about 40°C to about 90°C; and after exposing the article to the first cooling station, exposing the article to a pressure greater than atmospheric pressure.

[0105] Clause 2. The method according to Clause 1, wherein the first heating zone and the second heating zone are at least partially enclosed.

[0106] Clause 3. The method according to Clause 2, wherein the first heating zone and the second heating zone are in fluid communication with each other.

[0107] Clause 4. The method according to any one of Clauses 1 to 3, wherein exposing the article to the first heating zone includes moving the article to a first position within the first heating zone and subsequently moving the article from the first position to a second position within the first heating zone.

[0108] Clause 5. The method according to Clause 4, wherein the article is located at the first position in the first heating zone for a period of about 40 seconds to about 70 seconds.

[0109] Clause 6. The method according to any one of Clauses 1 to 5, wherein the article is exposed to the first heating zone for a first time period and to the second heating zone for a second time period, and wherein each of the first time period and the second time period is from about 80 seconds to about 140 seconds.

[0110] Clause 7. The method described in Clause 6, wherein the first time period and the second time period are substantially the same.

[0111] Clause 8. The method according to any one of Clauses 1 to 7, wherein when the article is exposed to the second heating zone, the second heating zone is adapted to increase the temperature of the at least portion of the article at a reduced rate compared to the rate of temperature increase of at least a portion of the article when the article is exposed to the first heating zone.

[0112] Clause 9. The method according to any one of Clauses 1 to 8, wherein the exposure of the article to pressure greater than atmospheric pressure occurs at a second cooling station, wherein the second cooling station is spaced apart from the first cooling station, and wherein the second cooling station includes a chamber adapted to temporarily seal and isolate the article from ambient temperature and pressure.

[0113] Clause 10. The method according to any one of Clauses 1 to 9, wherein the article comprises at least a first component and a second component, wherein when the article is exposed to a pressure greater than atmospheric pressure, the article exhibits a temperature in the range of about 50°C to about 80°C.

[0114] Clause 11. The method according to Clause 10, wherein the adhesive is present at the joint between at least a portion of the first component and at least a portion of the second component.

[0115] Clause 12. The method according to any one of Clauses 1 to 11 further includes compressing the material on the outer surface of the article.

[0116] Clause 13. The method according to Clause 12, wherein the material is an elastomeric material, wherein the elastomeric material exhibits a melting temperature greater than about 135°C.

[0117] Clause 14. The method according to any one of Clauses 1 to 13, wherein the article comprises at least a portion of footwear articles.

[0118] Clause 15. A system for thermoformed articles, the system comprising: a heating station at least partially enclosed, the heating station including a first heating zone and a second heating zone, the second heating zone being in fluid communication with the first heating zone, wherein the first heating zone includes one or more thermal elements and one or more first air circulation devices, wherein the second heating zone includes one or more second air circulation devices, wherein at least the first heating zone is adapted to expose at least one article to a temperature in the range of about 70°C to about 250°C; a first cooling station including one or more third air circulation devices, the first cooling station being exposed to atmospheric pressure; a second cooling station including a chamber adapted to expose the at least one article to a pressure above atmospheric pressure; and an article moving mechanism adapted to transfer the at least one article from the heating station to the first cooling station, and also adapted to transfer the at least one article from the first cooling station to the second cooling station.

[0119] Clause 16. The system according to Clause 15, wherein the first cooling station is adapted to reduce the temperature of at least a portion of the at least one article of the product to a range of about 50°C to about 70°C.

[0120] Clause 17. The system according to Clause 15 or 16 further includes an article compression assembly adapted to compress an elastomeric material on the outer surface of the at least one article when the at least one article is exposed to one or more of the heating station, the first cooling station, or the second cooling station.

[0121] Clause 18. The system according to Clause 17, wherein the article compression assembly is coupled to a negative pressure generating system, wherein the article compression assembly is adapted to compress the elastomeric material on the outer surface of the at least one article by exposing the outer surface of the at least one article and the inner surface of the elastomeric material to a pressure less than atmospheric pressure.

[0122] Clause 19. The system according to Clause 17, wherein the article compression assembly is adapted to be coupled to the shoe last.

[0123] Clause 20. The system according to Clause 19, wherein the article comprises at least a portion of footwear articles.

[0124] Clause 21. A method for thermoforming an article, the method comprising: receiving an article comprising a thermoplastic polymer composition; exposing the article to one or more heating zones to increase the temperature of at least a portion of the article to above the melting temperature of the thermoplastic polymer composition; after exposing the article to the one or more heating zones, exposing the article to a first cooling station to reduce the temperature of the at least a portion of the article to a temperature that is: 1) below the melting temperature of the thermoplastic polymer composition; and 2) above: the heat distortion temperature, the Vicat softening temperature, or both of the thermoplastic polymer composition; and after exposing the article to the first cooling station, exposing the article to a pressure greater than atmospheric pressure.

[0125] Clause 22. The method according to Clause 21 further comprises: compressing material on the outer surface of the article before exposing the article to the one or more heating zones.

[0126] Clause 23. The method according to Clause 22, wherein the material is an elastomeric material, and wherein the elastomeric material exhibits a melting temperature greater than about 135°C.

[0127] Clause 24. The method according to Clause 22, wherein compressing the material on the outer surface of the article comprises: exposing a region between the inner surface of the material and the outer surface of the article to a pressure less than atmospheric pressure to compress the material onto the outer surface of the article.

[0128] Clause 25. The method according to Clause 22, wherein the article of article is positioned on the forming material.

[0129] Clause 26. The method according to any one of Clauses 21 to 25, wherein the article comprises at least a portion of footwear articles.

[0130] Clause 27. The method according to Clause 26, wherein the at least portion of the footwear article is positioned on the last.

[0131] Clause 28. The method according to any one of Clauses 21 to 27, wherein the one or more heating zones include a first heating zone and a second heating zone, wherein the first heating zone includes one or more heating elements and one or more first air circulation devices, and wherein the second heating zone includes one or more second air circulation devices.

[0132] Clause 29. The method according to Clause 28, wherein exposing the article to the one or more heating zones includes exposing the article to the first heating zone and subsequently exposing the article to the second heating zone.

[0133] Clause 30. The method according to Clause 29, wherein when the article is exposed to the second heating zone, the second heating zone is adapted to increase the temperature of the at least portion of the article at a reduced rate compared to the rate of temperature increase of the at least portion of the article when the article is exposed to the first heating zone.

[0134] Clause 31. The method according to any one of Clauses 21 to 30, wherein when the article is exposed to a pressure greater than atmospheric pressure, the article exhibits a temperature in the range of about 50°C to about 80°C.

[0135] Clause 32. The method according to Clause 31, wherein the article comprises at least a first component and a second component, and wherein an adhesive is present at the joint between at least a portion of the first component and at least a portion of the second component.

[0136] Clause 33. The method according to any one of Clauses 21 to 32 further comprises: after exposing the article to a pressure greater than atmospheric pressure, exposing the article to a second cooling station to reduce the temperature of the at least portion of the article to below the temperature of the heat distortion temperature of the thermoplastic polymer composition, the Vicat softening temperature, or both.

[0137] Clause 34. A method for thermoforming articles, the method comprising: Receiving an upper for footwear articles, the upper positioned on a shoe last, wherein the upper comprises a thermoplastic polymer composition; compressing material onto the outer surface of the upper to form a compressed upper; exposing the compressed upper to one or more heating elements to increase the temperature of at least a portion of the compressed upper to above the melting temperature of the thermoplastic polymer composition; after exposing the compressed upper to the one or more heating elements, reducing the temperature of the at least a portion of the compressed upper to a temperature that is: 1) below the melting temperature of the thermoplastic polymer composition; and 2) above: the heat distortion temperature, Vicat softening temperature, or both of the thermoplastic polymer composition; and after reducing the temperature, exposing the compressed upper to a pressure greater than atmospheric pressure.

[0138] Clause 35. The method according to Clause 34 further comprises: after exposing the compressed upper to a pressure greater than atmospheric pressure, reducing the temperature of at least a portion of the compressed upper to below the following temperature: the heat distortion temperature of the thermoplastic polymer composition, the Vicat softening temperature, or both.

[0139] Clause 36. The method according to Clause 34 or 35, wherein the material is an elastomeric material, wherein the elastomeric material exhibits a melting temperature greater than about 135°C.

[0140] Clause 37. The method according to Clause 36, wherein compressing the material onto the outer surface of the upper comprises: exposing a region between an inner surface of the material and the outer surface of the upper to a pressure less than atmospheric pressure to compress the material onto the outer surface of the upper.

[0141] Clause 38. The method according to any one of Clauses 34 to 37, wherein when the compressed upper is exposed to a pressure greater than atmospheric pressure, the at least portion of the compressed upper exhibits a temperature in the range of about 50°C to about 80°C.

[0142] Clause 39. The method according to Clause 38, wherein the upper comprises at least a first component and a second component, and wherein an adhesive is present at the joint between at least a portion of the first component and at least a portion of the second component.

[0143] Clause 40. The method according to any one of Clauses 34 to 39, wherein the one or more thermal elements are present in a heating station, wherein the heating station further includes an air circulation device.

[0144] Clause 41. A method for thermoforming an article, the method comprising: receiving the article; exposing the article to a first heating zone including one or more heating elements and one or more first air circulation devices, wherein the first heating zone is adapted to increase the temperature of the first heating zone from about 25°C to about 200°C in less than or equal to 50 seconds; exposing the article to a second heating zone including one or more second air circulation devices, wherein the second heating zone is adapted to maintain the temperature reached by the article in the first heating zone; and after exposing the article to the second heating zone, reducing the temperature of at least a portion of the article to about 120°C or lower.

[0145] Clause 42. The method according to Clause 41 further comprises: compressing material onto the outer surface of the article before exposing the article to the first heating zone.

[0146] Clause 43. The method according to Clause 42, wherein the material is an elastomeric material, and wherein the elastomeric material exhibits a melting temperature greater than about 135°C.

[0147] Clause 44. The method according to Clause 42 or 43, wherein compressing the material onto the outer surface of the article comprises: exposing a region between the inner surface of the material and the outer surface of the article to a pressure less than atmospheric pressure to compress the material onto the outer surface of the article.

[0148] Clause 45. The method according to any one of Clauses 42 to 44, wherein the article comprises at least a portion of footwear articles.

[0149] Clause 46. The method according to Clause 45, wherein the at least portion of the footwear article is positioned on the last.

[0150] Clause 47. The method according to any one of Clauses 41 to 46, wherein the first heating zone and the second heating zone are at least partially enclosed.

[0151] Clause 48. The method according to Clause 47, wherein the first heating zone and the second heating zone are in fluid communication with each other.

[0152] Clause 49. The method according to any one of Clauses 41 to 46, wherein reducing the temperature of at least a portion of the article to about 120°C or lower comprises: reducing the temperature of at least a portion of the article to a temperature of about 70°C to about 120°C.

[0153] Clause 50. The method according to Clause 49 further comprises: after reducing the temperature of at least a portion of the article to a temperature of about 70°C to about 120°C, exposing the article to a pressure greater than atmospheric pressure.

[0154] Clause 51. The method according to Clause 50, wherein when the article is exposed to a pressure greater than atmospheric pressure, the at least portion of the article exhibits a temperature in the range of about 50°C to about 80°C.

[0155] Clause 52. The method according to Clause 51, wherein the article comprises at least a first component and a second component, wherein an adhesive is present at the joint between at least a portion of the first component and at least a portion of the second component.

[0156] Clause 53. The method according to any one of Clauses 41 to 53, wherein exposing the article to the first heating zone comprises exposing the article to the first heating zone for about 80 seconds to about 140 seconds.

[0157] Clause 54. The method according to Clause 53, wherein exposing the article to the second heating zone comprises exposing the article to the second heating zone for about 80 seconds to about 140 seconds.

[0158] Clause 55. The method according to Clause 50, wherein the temperature reduction of at least a portion of the article to a temperature of about 70°C to about 120°C occurs in a first cooling zone, and wherein the article is exposed to a pressure greater than atmospheric pressure occurs in a second cooling zone, wherein the second cooling zone is spaced apart from the first cooling zone, and wherein the second cooling zone includes a chamber adapted to temporarily seal and isolate the article from ambient temperature and pressure.

[0159] Clause 56. A method for thermoforming an article, the method comprising: receiving an upper for a footwear article, the upper positioned on a shoe last; compressing material onto an outer surface of the upper to form a compressed upper; exposing the compressed upper to a first heating zone, the first heating zone including one or more heating elements and one or more first air circulation devices, wherein the first heating zone is adapted to increase the temperature of the first heating zone from about 25°C to about 200°C in less than or equal to 50 seconds; exposing the compressed upper to a second heating zone, the second heating zone including one or more second air circulation devices, wherein the second heating zone is adapted to maintain the temperature reached by the compressed upper in the first heating zone; and after exposing the compressed upper to the second heating zone, reducing the temperature of at least a portion of the compressed upper to about 120°C or lower.

[0160] Clause 57. The method according to Clause 56, wherein the material is an elastomeric material, and wherein the elastomeric material exhibits a melting temperature greater than about 135°C.

[0161] Clause 58. The method according to Clause 56 or 57, wherein compressing the material onto the outer surface of the upper comprises: exposing a region between the inner surface of the material and the outer surface of the upper to a pressure less than atmospheric pressure to compress the material onto the outer surface of the upper.

[0162] Clause 59. The method according to any one of Clauses 56 to 58, wherein reducing the temperature of at least a portion of the compressed upper to about 120°C or lower comprises: reducing the temperature of at least a portion of the compressed upper to a temperature of about 70°C to about 120°C, and wherein the method further comprises: after reducing the temperature of at least a portion of the compressed upper to a temperature of about 70°C to about 120°C, exposing the compressed upper to a pressure greater than atmospheric pressure.

[0163] Clause 60. The method according to Clause 59, wherein when the compressed upper is exposed to a pressure greater than atmospheric pressure, the at least portion of the compressed upper exhibits a temperature in the range of about 50°C to about 80°C.

[0164] Clause 61. An article compression assembly comprising: a first mating plate; a second mating plate; the second mating plate being coupled to the first mating plate, wherein the second mating plate includes one or more movable portions adapted to move the second mating plate from an open position located away from the one or more movable portions of the first mating plate to a closed position located adjacent to the one or more movable portions of the first mating plate; and a vacuum port.

[0165] Clause 62. The article compression assembly according to Clause 61, wherein the one or more movable portions include a first movable portion and a second movable portion.

[0166] Clause 63. The article compression assembly according to Clause 62, wherein the first movable portion is pivotally connected to a first side of the first mating plate, and the second movable portion is pivotally connected to a second side of the first mating plate.

[0167] Clause 64. The article compression assembly according to Clause 63, wherein the first side of the first mating plate is opposite to the second side of the first mating plate.

[0168] Clause 65. The article compression assembly according to any one of Clauses 61 to 64 further includes a sealing member coupled to the first mating plate, the sealing member extending toward the second mating plate and away from the first mating plate.

[0169] Clause 66. The article compression assembly according to Clause 65, wherein the vacuum port extends through at least a portion of the sealing member.

[0170] Clause 67. The article compression assembly according to Clause 65, wherein the sealing member includes a recess adapted to receive a portion of the forming material.

[0171] Clause 68. The article compression assembly according to Clause 65, wherein the one or more movable portions include a first movable portion and a second movable portion, and wherein the sealing member includes an edge having a first portion and a second portion, wherein one side of the first movable portion is complementary in shape to the first portion of the edge of the sealing member, and wherein one side of the second movable portion is complementary in shape to the second portion of the edge of the sealing member.

[0172] Clause 69. An article compression assembly according to any one of Clauses 61 to 68, wherein one or more temporary fasteners are connected to the one or more movable portions and adapted to temporarily fasten the first mating plate and the second mating plate together.

[0173] Clause 70. The article compression assembly according to any one of Clauses 61 to 69 further includes a compression material comprising a forming portion and a sealing portion, wherein at least a portion of the forming portion is complementary in shape to at least a portion of the shoe last.

[0174] Clause 71. The article compression assembly according to Clause 70, wherein the sealing portion includes a flange adapted to be positioned between the first and second mating plates when the one or more movable portions of the second mating plate are in the closed position, and wherein when the flange is positioned between the first and second mating plates, the vacuum port is in fluid communication with an internal portion of the compressed material.

[0175] Clause 72. An article compression assembly comprising: one or more mating members; a vacuum port; and a compression material including a forming portion and a sealing portion, wherein, when exposed to a pressure less than atmospheric pressure, the sealing portion is adapted to form a seal around the vacuum port such that at least an internal volume of the forming portion of the compression material is exposed to the pressure less than atmospheric pressure, and wherein at least a portion of the forming portion is shaped to complement at least a portion of a shoe last.

[0176] Clause 73. The article compression assembly according to Clause 72, wherein the one or more mating members include a recess for receiving a protrusion on the shoe last.

[0177] Clause 74. The article compression assembly according to Clause 73, wherein when the protrusion on the last is positioned in the recess, and when the last is positioned in the internal volume of the forming portion, the sealing portion is adapted to form the seal around the vacuum port such that at least the internal volume of the forming portion of the compressed material is exposed to a pressure less than atmospheric pressure.

[0178] Clause 75. The article compression assembly according to any one of Clauses 72 to 74 further includes a sealing member extending outward and away from the one or more mating members, wherein the sealing member includes a recess for receiving a protrusion on the shoe last.

[0179] Clause 76. The article compression assembly according to Clause 75, wherein the sealing member is a separate element coupled to the one or more mating members.

[0180] Clause 77. The article compression assembly according to Clause 75, wherein the vacuum port extends through at least a portion of the sealing member, and wherein the sealing portion of the compressed material is adapted to form a seal around the vacuum port by at least partially contacting the sealing member.

[0181] Clause 78. The article compression assembly according to Clause 77, wherein the sealing portion of the compressed material includes a first forming structure, and wherein at least a portion of the sealing member includes a second forming structure that is complementary in shape to the first forming structure, and wherein the first forming structure is adapted to contact the second forming structure and form the seal around the vacuum port.

[0182] Clause 79. The article compression assembly according to Clause 78, wherein the first forming structure includes an O-ring.

[0183] Clause 80. The article compression assembly according to Clause 78, wherein the first forming structure is integral with the sealing portion of the compression material.

[0184] Clause 81. An article compression assembly according to any one of Clauses 72 to 80, wherein the sealing portion of said compression material includes a first forming structure, and wherein at least a portion of said one or more mating members includes a second forming structure that is complementary in shape to the first forming structure, and wherein said first forming structure is adapted to contact the second forming structure and form the seal around said vacuum port.

[0185] Clause 82. The article compression assembly according to Clause 81, wherein the first forming structure includes an O-ring.

[0186] Clause 83. The article compression assembly according to Clause 81, wherein the first forming structure is integral with the sealing portion of the compression material.

[0187] Clause 84. The article compression assembly according to Clause 81, wherein the second forming structure includes a recess in one of the one or more mating members.

[0188] Clause 85. The article compression assembly according to Clause 81, wherein the one or more mating members include a recess for receiving a protrusion on the shoe last.

[0189] Clause 86. The article compression assembly according to Clause 85, wherein the second forming structure is positioned around the recess for receiving the protrusion on the shoe last.

[0190] As can be seen from the foregoing, the present invention is well suited to achieve all the above-described objects and objectives, as well as other obvious and inherent advantages of the structure.

[0191] It should be understood that certain features and sub-combinations are useful and can be used without reference to other features and sub-combinations. This is to be considered by the claims and falls within the scope of the claims.

[0192] Although specific elements and steps are discussed in conjunction with each other, it should be understood that any element and / or step provided herein is to be considered as being compatible with any other element and / or step, regardless of their explicit provision, while still remaining within the scope provided herein. Since many possible embodiments of this disclosure can be made without departing from the scope of the invention, it should be understood that everything set forth herein or shown in the accompanying drawings should be interpreted as illustrative and not limiting.

Claims

1. A product compression assembly, comprising: First docking plate; Second docking plate; The second docking plate is connected to the first docking plate, wherein the second docking plate includes one or more movable portions, the one or more movable portions being adapted to move the second docking plate from an open position located away from the first docking plate to a closed position located adjacent to the first docking plate. And vacuum ports.

2. The article compression assembly according to claim 1, wherein the one or more movable parts include a first movable part and a second movable part.

3. The article compression assembly according to claim 2, wherein the first movable portion is pivotally connected to a first side of the first docking plate, and the second movable portion is pivotally connected to a second side of the first docking plate.

4. The article compression assembly according to claim 3, wherein the first side of the first mating plate is opposite to the second side of the first mating plate.

5. The article compression assembly according to claim 1, further comprising a sealing member connected to the first mating plate, the sealing member extending toward the second mating plate and away from the first mating plate.

6. The article compression assembly of claim 5, wherein the vacuum port extends through at least a portion of the sealing member.

7. The article compression assembly of claim 5, wherein the sealing member includes a recess adapted to receive a portion of the forming material.

8. The article compression assembly of claim 5, wherein the one or more movable portions include a first movable portion and a second movable portion, and wherein the sealing member includes an edge having a first portion and a second portion, wherein one side of the first movable portion is complementary in shape to the first portion of the edge of the sealing member, and wherein one side of the second movable portion is complementary in shape to the second portion of the edge of the sealing member.

9. The article compression assembly of claim 1, wherein one or more temporary fasteners are connected to the one or more movable portions and are adapted to temporarily fasten the first mating plate and the second mating plate together.

10. The article compression assembly of claim 1, further comprising a compression material, the compression material comprising a forming portion and a sealing portion, wherein at least a portion of the forming portion is complementary in shape to at least a portion of the shoe last.

11. The article compression assembly of claim 10, wherein the sealing portion includes a flange adapted to be positioned between the first and second mating plates when the one or more movable portions of the second mating plate are in the closed position, and wherein when the flange is positioned between the first and second mating plates, the vacuum port is in fluid communication with an internal portion of the compressed material.

12. A product compression assembly, comprising: One or more docking components; Vacuum port; And a compression material comprising a forming portion and a sealing portion, wherein, when exposed to a pressure less than atmospheric pressure, the sealing portion is adapted to form a seal around the vacuum port such that at least the internal volume of the forming portion of the compression material is exposed to the pressure less than atmospheric pressure, and wherein at least a portion of the forming portion is shaped to complement at least a portion of the shoe last.

13. The article compression assembly of claim 12, wherein the one or more mating members include a recess for receiving a protrusion on the shoe last.

14. The article compression assembly of claim 13, wherein when the protrusion on the last is positioned in the recess, and when the last is positioned in the internal volume of the forming portion, the sealing portion is adapted to form the seal around the vacuum port such that at least the internal volume of the forming portion of the compressed material is exposed to a pressure less than atmospheric pressure.

15. The article compression assembly of claim 12, further comprising a sealing member extending away from and away from the one or more mating members, wherein the sealing member includes a recess for receiving a protrusion on the shoe last.

16. The article compression assembly of claim 15, wherein the sealing member is a separate element coupled to the one or more mating members.

17. The article compression assembly of claim 15, wherein the vacuum port extends through at least a portion of the sealing member, and wherein the sealing portion of the compressed material is adapted to form a seal around the vacuum port by at least partially contacting the sealing member.

18. The article compression assembly of claim 17, wherein the sealing portion of the compressed material includes a first forming structure, and wherein at least a portion of the sealing member includes a second forming structure that is complementary in shape to the first forming structure, and wherein the first forming structure is adapted to contact the second forming structure and form the seal around the vacuum port.

19. The article compression assembly of claim 18, wherein the first forming structure includes an O-ring.

20. The article compression assembly of claim 18, wherein the first forming structure is integral with the sealing portion of the compression material.

21. The article compression assembly of claim 12, wherein the sealing portion of the compressed material includes a first forming structure, and wherein at least a portion of one or more mating members includes a second forming structure that is complementary in shape to the first forming structure, and wherein the first forming structure is adapted to contact the second forming structure and form the seal around the vacuum port.

22. The article compression assembly of claim 21, wherein the first forming structure includes an O-ring.

23. The article compression assembly of claim 21, wherein the first forming structure is integral with the sealing portion of the compression material.

24. The article compression assembly of claim 21, wherein the second forming structure includes a recess in one of the one or more mating members.

25. The article compression assembly of claim 21, wherein the one or more mating members include a recess for receiving a protrusion on the shoe last.

26. The article compression assembly of claim 25, wherein the second forming structure is positioned around the recess for receiving the protrusion on the shoe last.

Images