Granular foam article and method of manufacture

Abstract

Methods for manufacturing articles, particularly granular foam articles for sportswear, articles manufactured by this method, such as midsoles or parts of shoes, and shoes having such midsoles, are described. According to one aspect of the invention, a method for manufacturing articles, particularly cushioning articles for sportswear, is provided, the method comprising: placing one or more elements between a first and a second portion of a mold; closing a fixing member of the mold, wherein the fixing member, the mold portion, and / or the elements define a cavity; loading granules into the cavity on one or more sides of the elements; moving the first and second portions of the mold to a closed position; and fusing the granules.

Description

References merged

[0001] All documents cited in prior applications, during their examination (“Documents Referenced in the Application”), and in the “Documents Referenced in the Application”, and all documents cited or referenced herein (“Documents Referenced herein”), together with any manufacturer’s descriptions, specifications, and product instructions for any product mentioned herein or incorporated herein by reference in any document, are hereby incorporated by reference and may be used in the practice of this invention. More specifically, all cited documents are incorporated by reference to the same extent as each individual document is specifically and individually designated as incorporated by reference. Technical Field

[0002] This invention relates to granular foam articles and methods for manufacturing granular foam articles. In particular, elements can be selectively placed in the foam article. Elements positioned within an article may include one or more of the following: support structures, including rods, torsion bars, plates, retainers, frames, and / or caps; textiles; films; foils; strands; filaments; external object connectors—objects that can be coupled to the article such that a portion of the object extends beyond the outer surface of the article, such as studs (e.g., running studs and / or decorative studs), clips (e.g., bicycle clips), straps, friction components, pads, springs, ports, decorative items, such as ornaments, buckles, etc.; electronic components, such as transmitters, electrodes, sensors (e.g., optical sensors, pressure sensors, gyroscopes, accelerometers, etc.), displays, control panels, lights, LEDs, batteries, etc.; conductive elements, such as wires, strips, sheets, etc.; shielding elements, such as elements that protect another element or a portion of the midsole from adverse environmental conditions (e.g., heat, moisture, and / or pressure during the forming process); cushioning elements, such as spring elements, pads, bladders, etc.; tags, such as near-field communication tags, chips, etc.; and / or combinations thereof. For example, a shoe midsole may include one or more elements positioned therein. This method includes using a double-sided or multi-sided gap process to ensure that the foam on each side of the portion of the element positioned within the article of manufacture is properly compressed and / or fused. Background Technology

[0003] Any reference or identification of any document in this application should not be construed as an admission that the document is prior art to this invention.

[0004] Shoes are endowed with properties, and the effectiveness of these properties may vary depending on the specific type of shoe. Parts of the shoe, such as the midsole, can have protective functions. The midsole can provide stability. Additionally, the midsole can have a cushioning effect, for example, to absorb the force generated from the contact between the shoe and the ground.

[0005] Traditional manufacturing methods for foam products (such as midsoles) involve using foam particles or pellets in conjunction with a granular foam consolidation process to form the product from the granular foam. Historically, the granular foam consolidation process used steam box molding. Current methods involve filling a cavity with pellets and compressing a portion of the cavity to generate compressive forces on the particles.

[0006] Figure 1 A typical process 10 for molding shoe midsoles is depicted. Conventional steam molding includes: loading material into a hopper container 12; providing a mold 14 including mold portions 16, 18 of a cavity 20 defining the desired article shape; closing the mold 14 including mold surfaces 22, 24 and filling the cavity 20 with the material to be molded (e.g., particulate foam) 26 through inlets 28, 28'; steam treating the material within the mold 14; cooling and stabilizing the steam-treated material; and demolding, such that the molded article 30 separates from the mold surfaces 22, 24.

[0007] Figure 2 Stages 32, 34, 36, 38, and 40 of the conventional process are depicted. Loading 32 involves adding particles 42 to a mold 44 under atmospheric pressure. Pressurization 34 involves applying pressure to the particles 42 such that the particles are pressurized within the mold by reducing the volume in the mold using a movable part 46. Additional loading 36 of particles 42 is performed under pressure. Depressurization 38 allows the particles 42 to expand. Fusion 40 of the particles 42 occurs when steam is applied. As shown, the surface portions of the particles 42 are melted, causing the particles to bind together to form a granular but closed foam structure.

[0008] Adding components to granular foam articles makes the formation of granular foam articles more complex. Incorporating components into articles formed from granular foam may include placing the components on the outer surface of the foam article, partially embedding them within the foam article, or fully embedding them within the foam article.

[0009] One drawback of existing functional elements and midsole constructions is that the midsole and any components added to it typically must be manufactured separately and bonded, for example, by gluing. For instance, using additional components in a foam product may require additional materials such as adhesives, glues, etc. In this case, the materials are chosen based on their ability to bond with each other. This significantly limits the choice of materials and, consequently, the design possibilities for the midsole and the shoe. In this context, to place the component within the foam product, the product is typically formed as two or more pieces, with the component coupled to the product.

[0010] Figure 3 -4 illustrates a traditional example of adding elements to a granular foam midsole. Specifically, Figure 3A sole 48 with a reinforcing element 50 is shown, which is glued to the sole material 52. This construction has disadvantages. On the one hand, these constructions are limited to materials that can be connected to each other, particularly glued together. The necessity of connecting materials increases the amount of manufacturing work and the amount of materials required (e.g., adhesives). Another example of a conventional shoe is shown... Figures 4A-4C As shown, a traditional shoe 54 includes an upper 56, a midsole 58, and an outsole 60. (As...) Figure 3 -4 As shown in both cases, the elements added to the midsole are located on the outside of the midsole.

[0011] To reduce and / or eliminate processing steps during in-process fabrication, granular foam can be molded together with components positioned within a mold. For example, components can be positioned in a mold, such as... Figures 5A-5B As shown, these figures depict the traditional method of forming midsoles from granular foam. (As...) Figure 5A As shown, a conventional mold 65 has a fixed mold portion 62 and a movable mold portion 64. An inlet 66 for loading granular foam material is shown, which communicates with the mold cavity 68. Figure 5B It is depicted that granular foam material 70 is loaded into mold cavity 68 using inlet 66.

[0012] As previously mentioned, adding components to foam articles, such as midsoles, typically occurs on the outer surface of the foam article. Adding components to foam articles during the molding process is complex. While these components can improve the mechanical properties of the article, positioning them within a portion of the article complicates the delivery of the granular foam, the application of energy, and / or the fusion of the granules. For example, adding components such as sheets, rods, or textiles may inhibit granule movement within the mold cavity and / or cause uneven compression during molding.

[0013] In traditional processes, components can be positioned between separately formed granular foam products and secured using post-processing methods. For example, adhesives, films, etc., can be used to fix the components.

[0014] In contrast, bonding elements during the forming process may inhibit particle delivery to various parts of the mold cavity. Furthermore, particle delivery and / or movement of the mold sections may affect the positioning of the elements during the forming process.

[0015] This disclosure addresses these issues. Summary of the Invention

[0016] The terms “invention,” “the stated invention,” “this invention,” and “of this invention” as used in this patent are intended to broadly refer to all subject matter of this patent and the following claims. Statements containing these terms should not be construed as limiting the subject matter described herein or limiting the meaning or scope of the following claims. Embodiments of the invention covered by this patent are defined by the following claims, not by this summary. This summary is a general overview of various aspects of the invention and introduces some concepts further described in the detailed description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to determine the scope of the claimed subject matter. The claimed subject matter should be understood by referring to appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0017] The articles described herein can be formed from particles of an expanded material. Foam articles may include granular foam segments with different values ​​of a property of interest. For example, a first segment of the granular foam may have a first value for a predetermined property, while a second segment of the granular foam may have a second value for a predetermined property. Predetermined properties may include density, strength, stiffness (e.g., flexural or compressive stiffness), energy feedback, cushioning, rigidity, bonding properties, abrasion resistance, weight, and / or deformation characteristics. In some cases, an element may be at least partially located between the granular foam segments. For example, an element may be at least partially located between a first granular foam segment and a second granular foam segment. The granular foam segments may be coupled to each other by fused particles. In some cases, the granular foam segments may be coupled to the element by fused particles. Optionally, the element may be independent of the foam segments. For example, one embodiment may include an element not coupled to a foam segment. Furthermore, in some embodiments, portions of the element may not be coupled to the foam segment.

[0018] The granular foam products described herein may have a predetermined degree of fusion. In granular foam products, the desired degree of fusion can be determined by considering the desired characteristics of the granular foam product, its intended use, the characteristics of the user, material properties, and / or process parameters. Measuring the degree of fusion in granular foam materials may involve measuring properties such as tear strength, delamination tear, and energy feedback, and / or examining the granular foam material using a microscope.

[0019] The midsole may include granular foam with a predetermined degree of fusion. In some embodiments, the midsole may include granular foam segments with a predetermined degree of fusion. The degree of fusion in the finished midsole and / or its segments can be measured by analyzing specific properties of the midsole, such as tear strength, delamination tear test, energy return, and / or by examining the granular foam material using a microscope.

[0020] Specifically, athletic shoes may include a midsole formed from particles of expanded material, and one or more elements positioned on, near, or within the midsole. In some cases, the midsole may include one or more particle foam segments with different predetermined properties. For example, the midsole may include particle foam segments with a first value of predetermined properties and particle foam segments with a second value of predetermined properties. Predetermined properties may include density, stiffness (e.g., flexural stiffness or compressive stiffness), energy return, rigidity, connectivity, cushioning, abrasion resistance, weight, color, transparency, and / or deformation characteristics.

[0021] The component may be located near at least one granular foam segment. In some cases, a portion of the component may be located within at least one granular foam segment. The component or a portion thereof may be located at the interface between granular foam segments. Elements positioned within the midsole may include one or more of the following: support structures, including rods, torsion bars, plates, retainers, frames, and / or caps; textiles; films; foils; strands; filaments; external object connectors—objects that can be coupled to the article such that a portion of the object extends beyond the outer surface of the article, such as nails, clips (e.g., bicycle clips), straps, friction components, pads, springs, or other devices; electronic components, such as transmitters, electrodes, sensors (e.g., optical sensors, pressure sensors, gyroscopes, accelerometers, etc.), displays, control panels, LEDs, batteries, etc.; conductive elements, such as wires, strips, sheets, etc.; shielding elements, such as elements that protect another element or a portion of the midsole from adverse environmental conditions (e.g., heat, moisture, and / or pressure during the forming process); cushioning elements, such as spring elements, pads, bladders, etc.; tags, such as near-field communication tags, chips, etc.; and / or combinations thereof. For example, textiles may be combined with plates in the midsole.

[0022] In some cases, the midsole may include multiple elements. For example, the midsole may include one or more plates positioned at the mold interface of different granular foam segments. Furthermore, in some embodiments, various combinations of elements may be used, including plates and sensors.

[0023] Articles formed from foam particles may include multiple elements in various configurations. In some embodiments, elements and shielding elements may be used in a portion of the article. For example, in some embodiments, the article may include one or more elements sensitive to heat, water, pressure, and / or electromagnetic fields. In these cases, it is desirable to use shielding elements to reduce the chance of the sensitive element coming into contact with at least one of heat, water, pressure, and / or electromagnetic fields and / or to inhibit such contact. For example, in a midsole, a first element (i.e., the sensitive element) may be positioned adjacent to a shielding element within the midsole, such that the shielding element reduces and / or prevents the first element from being exposed to heat, water, pressure, and / or electromagnetic fields.

[0024] Some embodiments may include a granular foam article having voids at predetermined locations within the article. For example, a midsole may have one or more voids in the granular foam. The location and geometry of the voids can provide a way to create predetermined characteristic regions within the article. In some cases, the voids can provide access to components within the article.

[0025] Articles manufactured from foam particles may include placing elements—including joining structures—between mold portions in a mold. Fixing components may be positioned within the mold adjacent to the element to hold the element in place. By fixing the element, movement of the element or components can be reduced and / or inhibited. For example, fixing components may be used to secure a plate during manufacturing.

[0026] During loading, the space between the mold section and the component can be used to load particles into the mold cavity. In some cases, there are spaces on each side of the component where particles can be loaded. For example, the "space" can be located on either side of the plate, between the plate and the molding section.

[0027] After the pellets are loaded, the die section can be moved to a closed position. Once the die section has been moved to a position that allows the pellets to be compressed as desired, energy can be supplied to the die so that at least a portion of the pellets is fused together.

[0028] The mold parts can move independently of each other. Furthermore, the mold parts can move independently of fixed components and elements. For example, the mold parts can move independently of the plate positioned between them.

[0029] The mold portion may include components for engaging elements. For example, the mold portion may have recesses, flanges, or pins that engage with sections of the plate. Components on the mold portion may engage engagement structures located on the element. For example, engagement structures may be positioned on outer and / or inner sections of the element. In particular, the plate for the midsole may include engagement structures, such as tabs and / or openings on both outer and / or inner sections of at least one of the outer or inner portions of the element.

[0030] In some embodiments, components can be used to influence the geometry of the article during the forming process. For example, a component may include a geometry that creates a void with a predetermined size, shape, and / or location to impart specific characteristics to the article. In particular, a pin may have a geometry that creates a void in the midsole corresponding to a specific geometry that imparts specific properties to a midsole region. Specifically, a void in the form of a column can be used to control the cushioning properties of the midsole region.

[0031] The fixing component may be formed from one or more parts. Materials used for the fixing component may include, but are not limited to, metals, such as steel, aluminum, etc. In particular, metal fixing components may be used in applications that utilize steam as the energy source for molding and / or fusion. In alternative embodiments where the energy source is electromagnetic radiation, it is desirable to use materials suitable for the application. For example, if electromagnetic radiation, such as microwave or radio frequency heating, is used, it is desirable to utilize fixing components formed of polytetrafluoroethylene (“PTFE”).

[0032] In certain cases, the securing component may take the form of a rim or clamp. Some examples of securing components may include multiple rims. As used herein, a rim may refer to a circular element formed of a metallic material. The rim may include features for engaging elements used in articles or insoles. For example, the rim may be configured to couple to an engagement structure on a plate used in the insole. In some cases, one or more rims may be used to secure textile, foil, or film elements.

[0033] In some cases, the mold portion may include pins for positioning elements. For example, pins in the mold portion may be used to position the plate via an engagement structure of the engaging plate. In particular, the pins may engage holes in the plate, which are positioned such that the pins align the plate in a desired position between the mold portions. While the plate is held in place by both the fixing member and the pins in the mold portion, the mold portion can move independently of the plate.

[0034] The mold section can be moved to the closed position before energy is applied to the mold. In some cases, a primer is applied to the mold section before moving it. In some cases, a primer is applied to the mold section before loading the foam particles.

[0035] After the mold section is moved to the desired position, energy can be supplied to the mold section using at least one of heated steam or electromagnetic radiation.

[0036] In some cases, the surfaces of one or more mold sections can be porous. For example, each mold section can have a porous surface through which steam can enter the mold cavity. Porous surfaces can allow for more consistent application of steam to the particles within the mold.

[0037] In some cases, a vacuum can be used to hold components in place within a mold section. For example, negative pressure can be applied to a porous mold section, allowing components such as textiles to be positioned near the mold section. In this way, vacuum pressure can be used to hold components in place within the mold.

[0038] In some embodiments, one or more elements may be positioned between mold portions for use in the article of manufacture. The method of claim 10 further includes placing a second element into the mold.

[0039] In some cases, different particles can be supplied to different mold portions. Specifically, in the first "gap" (i.e., the region between the first side of the element and the first mold portion), particles with a first set of characteristics can be loaded to fill the first cavity portion, and particles of a second type with a second set of characteristics can be loaded into the second "gap" (i.e., the region between the second side of the element and the second mold portion) to enter the second cavity portion.

[0040] For example, according to a first aspect, a method for forming an element from granular foam, particularly for forming a midsole. The method includes: placing a plate between a first portion and a second portion of a mold; closing a fixing member of the mold, the fixing member forming a cavity; loading granules into the cavity on both a first side and a second side of the plate; moving the first and second portions of the mold to a closed position; and fusing the granules.

[0041] Compression of the cavity increases the contact surface area and interparticle pressure, both of which are important for good fusion between the pellets and for the quality and performance of the product.

[0042] Since the particles are loaded into the cavity on both the first and second sides of the plate, the particles can be compressed on both sides of the plate. This ensures that the desired volume of spheres is loaded and the desired compression is achieved on both the first and second sides of the plate, and ensures that the plate does not move during compression.

[0043] According to some embodiments, the first part and the second part of the mold move independently of each other. In some embodiments, the first part and the second part of the mold may also move independently of the mold's fixed components and / or plates.

[0044] In some embodiments, the plate may have tabs located on the outer and / or inner portions of the plate, and the tabs may have openings. A portion of the mold may have corresponding recesses and / or pins to engage the tabs.

[0045] In some embodiments, a positioning member may be coupled to an element to position the element at a predetermined location within a mold portion. The positioning member may engage one or more of the element and a retaining member, mold portion, or pin. For example, a pin within the mold portion may be used to engage a section of the positioning member so that the element is properly aligned during forming.

[0046] In a further embodiment, the particles loaded into the first portion of the cavity may have a first set of characteristics, and the particles loaded into the second portion of the cavity may have a second set of characteristics. In some embodiments, the first portion of the cavity may be on a first side of a plate, and the second portion of the cavity may be on a second side of a plate.

[0047] According to some embodiments, a primer may be applied before moving the top and second portions of the mold to the closed position.

[0048] In some embodiments, a portion of the mold may be porous.

[0049] In some embodiments, the textile can be placed between a first part and a second part of the mold. Vacuum pressure applied to opposite sides of the mold can be used to hold the textile in place within the mold. For example, when using a porous mold, a vacuum can be applied to the mold portion opposite the mold cavity to hold the textile in place.

[0050] In some embodiments, electromagnetic radiation can be used to fuse the surface of the particles. In one embodiment, heated steam can be used to fuse the particles.

[0051] In some embodiments, the plate may be placed at points unequally distanced from the first and second portions of the mold. In a further embodiment, a second plate may be placed within the mold. Additionally, in some embodiments, additional elements may be placed within the mold.

[0052] Furthermore, according to some embodiments, the midsole may have a monolithic structure. A plate may be disposed within this monolithic structure. Mold lines on the monolithic structure may separate areas of different materials. In some embodiments, the plate in the monolithic structure may be positioned such that the contour of the plate follows the mold lines. The monolithic structure may be made of fused particles. The particles may be uniformly fused on a first side and a second side of the monolithic structure. In some embodiments, the midsole may have a first characteristic (e.g., a first density) at a first portion of the monolithic structure and a second characteristic (e.g., a second density) at a second portion of the monolithic structure. Specifically, the first portion of the monolithic structure may be on a first side of the plate, and the second portion of the monolithic structure may be on a second side of the plate.

[0053] In some embodiments, the midsole may include a second element. For example, the midsole may include a plate and textile. Alternatively, embodiments of the midsole may include multiple elements. For example, the midsole may include two or more plates disposed at the mold line.

[0054] These and other embodiments are disclosed or obvious from the following detailed description and are covered by the following detailed description. Attached Figure Description

[0055] In the following detailed description, embodiments of the invention are described by way of non-limiting examples, which are illustrated in the following drawings.

[0056] Figure 1A prior art process for steam molding articles made of granules is described.

[0057] Figure 2 A schematic diagram of the mold portion is depicted during a prior art process of steam molding an article made of granules.

[0058] Figure 3 A bottom view of a shoe with existing technology is depicted.

[0059] Figure 4A A side view of a shoe with existing technology is depicted.

[0060] Figure 4B A top view schematic diagram of an embodiment of the outsole is depicted.

[0061] Figure 4C A top view schematic diagram of the midsole embodiment is depicted.

[0062] Figure 5A A schematic diagram depicts a prior art construction for articles formed from granules.

[0063] Figure 5B A schematic diagram depicts a prior art construction for articles formed from granules.

[0064] Figure 6A A schematic diagram depicts a structure for articles formed from granules, wherein elements are positioned within foam granules.

[0065] Figure 6B A schematic diagram depicts a structure for articles formed from granules, wherein elements are positioned within foam granules.

[0066] Figure 7 This is a side view of a midsole with elements set in the midsole.

[0067] Figure 8A A side perspective view of the component is depicted.

[0068] Figure 8B A side perspective view depicting a midsole with embedded elements is shown.

[0069] Figure 9A A schematic diagram depicts a structure for articles formed from granules, wherein elements are positioned within foam granules.

[0070] Figure 9B A schematic diagram depicts a structure for articles formed from granules, wherein elements are positioned within foam granules.

[0071] Figure 10 A flowchart outlining a method for forming a midsole in which elements are disposed is depicted.

[0072] Figure 11 A top perspective view depicting a mold section with pins of a predetermined structure.

[0073] Figure 12 A top perspective view depicting a mold portion having elements positioned on a flange of the mold portion.

[0074] Figure 13 An enlarged view depicts the recesses on the mold section and the tabs of the elements positioned therein.

[0075] Figure 14 A side perspective view depicting an embodiment of a pin positioned in a mold section.

[0076] Figure 15 A side perspective view depicting an embodiment of a pin positioned in a mold section.

[0077] Figure 16 A side perspective view depicting an embodiment of a column positioned within a mold section.

[0078] Figure 17 A side perspective view depicting an embodiment of a pin positioned in a mold section.

[0079] Figure 18 A side perspective view depicting an embodiment of an element (specifically a board).

[0080] Figure 19 A side perspective view depicting an embodiment of an element (specifically a board).

[0081] Figure 20 A side perspective view depicting an embodiment of an element (specifically a board).

[0082] Figure 21 A side perspective view depicting an embodiment of a plate positioned within a mold section.

[0083] Figure 22 A side perspective view depicting an embodiment of the element is shown.

[0084] Figure 23 A side perspective view depicting an embodiment of multiple elements positioned within a mold section.

[0085] Figure 24 A side perspective view depicting an embodiment of multiple elements positioned within a mold section.

[0086] Figure 25 A side perspective view depicting an embodiment of an element embedded in a foam article.

[0087] Figure 26 A top view depicting an embodiment of the engagement of pins and recesses in the plate and mold section.

[0088] Figure 27 A top view depicting an embodiment of the fixing component in the mold section.

[0089] Figure 28 A top view depicting an embodiment in which a fixed component engages with an element in a mold section.

[0090] Figure 29 An enlarged top view depicting an embodiment in which a fixed component engages with an element in a mold section.

[0091] Figure 30 A top view depicting an embodiment of a porous mold cavity surface positioned within a mold section.

[0092] Figure 31 A perspective view depicting an embodiment of a midsole coupled to an element and positioned within a mold section.

[0093] Figure 32 A rear view of an embodiment of the midsole is depicted.

[0094] Figure 33 A side view depicts an embodiment of a shoe including a midsole as described herein.

[0095] Figure 34 A side view depicts an embodiment of a midsole comprising granular foam regions with different properties and elements coupled to each other.

[0096] Figure 35 A bottom view depicting an embodiment including fused particle regions and elements placed between them is shown.

[0097] Figure 36 A side view depicting an embodiment of a midsole in which elements are placed.

[0098] Figure 37 A perspective view depicting an embodiment of a midsole including elements embedded in the midsole.

[0099] Figure 38 A top view depicting an embodiment of a midsole including elements in which tabs are positioned.

[0100] Figure 39 A side view depicts an embodiment of a positioning component that can be positioned within a mold and removed from a finished product.

[0101] Figure 40 A side view depicts an embodiment of a positioning component that can be positioned within a mold and removed from a finished product.

[0102] Figure 41 A perspective view depicting an embodiment of a positioning component that can be positioned within a mold and removed from a finished product.

[0103] Figure 42 A perspective view depicting an embodiment of a positioning component that can be positioned within a mold and removed from a finished product.

[0104] Figure 43 A cross-sectional view depicting an embodiment of a positioning component embedded in a finished article is shown.

[0105] Figure 44 A top cross-sectional view depicting an embodiment of a positioning component embedded in a finished article is shown.

[0106] Figure 45 An unfolded perspective view depicting a portion of an embodiment of the article after the removable tabs have been removed from it.

[0107] Figure 46 A perspective view depicting an embodiment of a removable tab embedded in a finished midsole.

[0108] Figure 47 A perspective view depicting an embodiment of a midsole including elements embedded in the midsole.

[0109] Figure 48 A side view depicting a portion of the midsole, including elements embedded within it.

[0110] Figure 49 A cross-sectional view depicting an embodiment of a positioning component coupled to a portion of the mold and an element when positioned within the midsole.

[0111] Figure 50 A perspective view depicting an embodiment of the surface of a mold portion including multiple pins and movable sub-components.

[0112] Figure 51 A perspective view depicting an embodiment of the surface of a mold portion including pins and movable sub-components.

[0113] Figure 52 A perspective view depicting an embodiment of the surface of a mold portion including a column and sub-components.

[0114] Figure 53 A schematic diagram depicts an embodiment of a mold used in a dual-gap molding process.

[0115] Figure 54 A schematic diagram depicts an embodiment of a mold used in a double-sided gap molding process.

[0116] Figure 55 A schematic diagram depicts an embodiment of a mold portion used in a double-gap and double-sided gap molding process. Detailed Implementation

[0117] Specific details have been used in describing the subject matter of embodiments of the present invention to satisfy legal requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements and / or processes, and may be used in combination with other existing or future technologies. Unless the order of the steps or the arrangement of the elements is explicitly described, this description should not be construed as implying any particular order or arrangement between the steps or elements.

[0118] The description of preferred embodiments is intended to be read in conjunction with the accompanying drawings, which are considered an integral part of the entire written description of these disclosures. While this disclosure is susceptible to various modifications and alternatives, embodiments are illustrated by way of example in the drawings and will be described in detail herein. The patterns depicted in the drawings are representative and not drawn to scale. The purposes and advantages of the claimed subject matter will become more apparent from the following detailed description of these embodiments in conjunction with the accompanying drawings.

[0119] In the following description, embodiments and variations of the invention are detailed with reference to the midsoles of shoes (particularly athletic shoes). However, the invention is not limited to these embodiments. For example, the invention can also be used in safety shoes, casual shoes, hiking shoes, golf shoes, winter shoes, boots, ice skates, or other types of footwear known in the art. Furthermore, this disclosure is not limited to use in shoes, but can also be used in other applications, such as any articles manufactured in compression molding.

[0120] As used in this article, “crack” refers to excessive opening of the mold. Specifically, it refers to the distance between opposing mold surface sections—in the “open” state for particle filling and in the “closed” state when the particles are fused together. The “closed” state determines the dimensions and shape of the final part, aside from minor tolerances for material expansion.

[0121] As used herein, "gap height" refers to the distance that the surface of a mold portion may travel when moving from an open position to a closed position. For example, in some embodiments, the surface movement of the mold portions may involve approximately 20 mm for a first mold portion and approximately 10 mm for a second mold portion. When the movement of the mold portions occurs in the same plane, the gap height of the mold is 30 mm. In particular, the gap height can be the distance that the particles can be compressed during molding.

[0122] As used herein, "double gap" refers to a process in which a mold surface has two regions with different gap heights. For example, in some cases, this may include a fixed mold portion and a movable mold portion having two regions that move independently of each other. In one particular embodiment, a double gap method can be used to manufacture articles having two regions of different densities.

[0123] As used herein, "multi-gap" refers to a process in which multiple areas of a mold surface have sub-components with different gap heights. For example, in some cases, this may include a fixed mold portion and a movable mold portion having two areas defined by sub-components that move independently of each other.

[0124] As used herein, “two-sided gap” refers to a molding process in which parts of a mold move independently of each other. For example, a mold may have a top mold portion and a bottom mold portion, both of which move independently of each other and whose surfaces define a cavity. The cavity may be further defined by the surface of a retaining member that positions and / or secures reinforcing elements within the cavity.

[0125] The formation of an article (particularly a midsole) may require numerous choices regarding materials and methods. In particular, material selection includes, for example, the choice of the particles used, including particle characteristics such as particle foam type, size, and density; the materials used in the elements; the placement of the elements within the mold; the loading configuration of the particles within the mold portion; the amount of compression of the mold portion; and the amount and / or distribution of heat supplied to the mold. In some embodiments, the fusion of the particles may be generated by heat provided by electromagnetic radiation and / or steam. These and other techniques will be explained below, and embodiments of midsoles formed using these techniques will be described.

[0126] Articles formed by fusing granular foam particles can have a continuous surface, wherein the particles are fused together. In most embodiments, the surface formed by the fused foam particles can retain the particle shape. Therefore, articles described herein, such as midsoles, while continuous, can include surfaces with varying surface textures.

[0127] Gap molds are used to produce articles from granular foam. Typically, a gap mold can comprise two molding sections. To fill the mold with foam granules, the molding sections are arranged such that they are spaced apart. In the open position, the mold sections are spaced apart by a predetermined distance. In the closed position, the mold sections are designed to press the foam granules together before welding.

[0128] As described herein, the total distance traveled by the molded surface of the molded portion from the open position to the closed position is defined as the gap height. The desired gap height can be selected based on the geometry of the mold portion and / or the article to be formed, as well as material properties (e.g., shrinkage characteristics). The gap height can range from about 1 mm to about 100 mm. In some embodiments, a gap height in the range of about 20 mm to about 70 mm may be desired. A specific example may include a gap height of about 30 mm to about 60 mm.

[0129] The clearance height for double-sided or multi-sided molding (i.e., the total clearance height of the mold at specific corresponding locations along the surface of a mold portion) can range from about 1 mm to about 100 mm. Specifically, the clearance height can be distributed between two mold portions. For example, during the fusion process, the surface of a sub-part of the first mold portion can move about 30 mm, while the surface of the second portion can move about 40 mm; therefore, for a double-sided process, the total clearance height of the mold is about 70 mm. In some embodiments, the surface of the first mold portion can move about 20 mm, while a portion of the second mold portion moves about 50 mm. Therefore, in this embodiment, the clearance height of the mold is about 70 mm.

[0130] In one particular embodiment, for any location in a double-sided or multi-sided molding process, the clearance height on one side of the mold portion can range from about 1 mm to about 40 mm. For example, the clearance height at a location on one side of a double-sided molding process can be less than about 30 mm.

[0131] In some embodiments, a distance may still exist between the mold portions when they are in the closed position. For example, the surfaces of the mold portions defining the mold cavity may be spaced apart. Furthermore, surfaces not belonging to the mold cavity may be spaced apart. As described herein, two mold portions can move independently of each other. This can allow for different levels of compression if, for example, elements exist between the mold portions.

[0132] Furthermore, the gap height can vary along the mold surface of the mold portion. In some embodiments, the mold surface defining the mold cavity can have segments with different geometries than the surrounding surface of the mold portion. For example, the mold surface of the mold portion for the midsole can have multiple segments. In particular, the midsole mold portion can have a border segment, a forefoot segment, and a heel segment. Each segment can be positioned at a predetermined starting height specific to that segment before the forming process. Furthermore, each segment can move to different predetermined ending positions at different rates and / or at different distances during the forming process.

[0133] Forming foam articles using gap molding can include injecting foam particles into a mold cavity formed between two mold portions. The mold portions can be positioned such that they are spaced apart from each other. This spaced-apart configuration facilitates loading particles within and / or around an element placed within the mold portion and the cavity. Once the mold portions are in place, the cavity can be filled with particles. After filling, the mold portions can move toward each other, causing the particles to be compressed. This compression can be controlled to achieve a predetermined amount of compression. After compression, steam can be distributed using vents in the mold to fuse the foam particles together.

[0134] The formation of granular foam articles becomes more complex when components are added, such as support structures including rods, torsion bars, plates, retainers, frames, and / or caps; textiles; films; foils; strands; filaments; external object connectors—objects that can be coupled to the article such that a portion of the object extends beyond the outer surface of the article, such as nails (e.g., running nails and / or decorative nails), clips (e.g., bicycle clips), straps, friction components, pads, springs, ports; decorative items such as ornaments, buckles, etc.; electronic components such as transmitters, electrodes, sensors (e.g., optical sensors, pressure sensors, gyroscopes, accelerometers, etc.), displays, control panels, lights, LEDs, batteries, etc.; conductive elements such as wires, strips, sheets, etc.; shielding elements, such as elements that protect another element or a portion of the midsole from adverse environmental conditions (e.g., heat, moisture, and / or pressure during the formation process); cushioning elements such as spring elements, pads, bladders, etc.; tags such as near-field communication tags, chips, etc.; and / or combinations thereof. While these components can improve the mechanical properties of the article, positioning them within a portion of the article complicates the delivery of the granular foam, the application of energy, and / or the fusion of the granules. For example, adding components such as sheets, rods, or textiles may inhibit granule movement within the mold cavity and / or cause uneven compression during molding. Furthermore, components positioned within the mold may affect the application of energy during the fusion process. For instance, components may affect the distribution of vapor and / or heat within the mold section.

[0135] Positioning components so that they are molded into the article during the molding process may be desirable. By incorporating components during article formation, the amount of material required can be reduced and / or eliminated. For example, positioning components within the article can reduce the number of steps and / or materials required for manufacturing and / or assembly. In particular, positioning components within a granular foam article during “in-mold assembly” of a part can be more complex, depending on the process used.

[0136] like Figure 6A As shown, in the open position, within the mold cavity 76, element 72 is positioned adjacent to the fixed mold portion 74. Specifically, as shown, element 72 is a plate positioned near the fixed mold portion 74. Figure 6A In the example shown, the movable mold portion 78 is positioned at a specific distance from the element 72, which defines a space 80.

[0137] When expanded foam particles are added to the mold cavity, the element may inhibit particle movement, resulting in an uneven particle distribution (not shown). For example, the element may at least partially block particles from entering a portion of mold cavity 82. This may lead to overfilling of the particle foam in some areas, which could result in inconsistent compression and / or fusion. For example, mold cavity portion 84 may be more open and more accessible for filling particles. Depending on the geometry of the element, particles may be inhibited and unable to move freely through the element. If the particles are not distributed as intended, sections of the mold cavity may experience force imbalances. For example, the element may experience force differentials that could cause the plate to bend and / or move.

[0138] Furthermore, during the loading of foam particles and / or the movement of the mold section, components positioned within the mold cavity may shift. Figure 6B This illustrates another problem with positioning components in the mold. If the component shifts during molding, this can lead to overfilling of some granular foam in certain areas, which may result in inconsistent compression and / or fusion.

[0139] exist Figure 6B During the depicted molding process, element 72 is displaced. For example, element 72 shifts as the cavity is filled with pellets and closed by the movable die portion 78. The distance the movable die portion 78 moves during compression is represented by distance 86. For example, distance 86 can depict the range of motion of the movable die portion. Displacement in element position may potentially inhibit pellet movement. Figure 6B The diagram depicts a molding process in which element 72 interferes with the loading of particulate foam by moving within mold cavity 76. For example, the movement of element 72 alters the configuration of mold cavity portions 82 and 84. Consequently, the foam particles may be unevenly distributed within a portion of the article. This can lead to uneven and inconsistent compression and / or fusion in the final article.

[0140] Specifically, when forming a granular foam insole, displacement of the component position during molding can alter the properties of the granular foam and the insole. Component movement may be due to the forces exerted on the granular foam beads and / or the compression of the beads when the movable mold portion moves. Another issue is that, if not secured in some way during loading, compression, energy application, and / or fusion, the component may move at some point in the process or throughout the entire process.

[0141] In particular, the formation process (where the elements interfere with the loading of the foam particles) may cause uneven distribution of the foam particles in part and / or the entire midsole. This may result in uneven and inconsistent compression and / or fusion in the final midsole.

[0142] Figure 7An example of a midsole formed using a single-gap process is depicted, which includes two mold sections (one fixed and one movable). As depicted, during the formation of the midsole, element 88 has been displaced. This shift in position results in displacement of element 88. This displacement alters the properties of the midsole. Furthermore, as... Figure 7 As shown, the movement of element 88 results in areas of uneven loading and / or compression, which creates areas of uneven fusion in region 90. For example, as Figure 7 As shown, component 88 is on board 92. From Figure 7 It can be seen that the fusion characteristics differ in the upper region 90 and the lower region 95 of the plate. Furthermore, plate 92 is not held near the die line 96. Therefore, the plate may cause uneven compression in the foam midsole by reducing and / or inhibiting the movement of particles and / or the plate. The movement of the plate may be caused by the force of particles entering the die, the movement of the die portion, and / or compressive forces. Region 90 depicts uneven fusion, while region 95 depicts normal fusion.

[0143] The foam particles in areas 90 and 95 are represented by circles. Figure 7 In this image, the foam particles are not depicted to scale. Furthermore, the fused foam particles will be continuous and will essentially retain their particle shape.

[0144] The fusion in areas of an article (e.g., a midsole) may be affected by: the elements positioned therein, the movement of the elements positioned therein, and / or, the particles during formation, the amount of steam, electromagnetic energy, heat and / or pressure applied, and the duration of the application of steam, electromagnetic energy, heat and / or pressure.

[0145] The degree of fusion within an article can affect the properties of the finished product. For example, tear strength and / or energy feedback can each indicate the degree of fusion within the article. Standards can be used to evaluate the properties of the finished product. In particular, tear strength can be evaluated using standards such as ASTM D3574 F or other test methods known in the art.

[0146] In some embodiments, if the tear strength of the fused granular foam is below a predetermined value, it may indicate that at least some granules in the article are not sufficiently fused. For example, in one particular embodiment, a peel test can be used to evaluate peel strength values, which measures the average force required to separate bonded material per millimeter width. Specifically, for the articles described herein, when using a peel test, a peel test value equal to or greater than about 3 N / mm width may be expected. In one particular embodiment, a midsole with a peel strength value greater than 3 N / mm width may have sufficient fusion to meet the requirements of the midsole. However, for granular foam articles, a peel strength value less than 3 N / mm width may indicate that there is at least one area in the article where the fusion is insufficient to achieve the desired properties of the article.

[0147] Furthermore, a decrease in energy return may indicate over-fusion between particles. Over-fusion of particles may indicate that the particles may have melted and fused together—in a way that reduces the properties of the formed article. For example, over-fusion of particles can lead to a loss of particle integrity, energy return, and / or cushioning properties. The physical manifestations of over-fusion may include changes in particle properties, such as changes in color, hardness, and / or size. In a particular example, changes in the color, hardness, and / or size of the particles, as well as changes in the energy return value in the midsole, may indicate over-fusion of particles in the midsole.

[0148] Figure 8A Element 98 is depicted, specifically a stabilizing element for use in the midsole of a shoe. Element 98 includes a tab 100 and an opening 102. The tab and opening can be used during manufacturing to position and / or hold the element within the midsole. Figure 8B As shown, most of element 98 is embedded in the midsole material 104.

[0149] Tabs and / or openings in a component may be positioned to allow the component to be secured in place and / or to retain its position before, during, and / or after molding. Any visible portion of the tabs and / or openings may be removed after molding is complete.

[0150] To mitigate problems associated with the movement of components during particle loading and / or molding, dual or multi-gap processes can be used. Gap heights can range from about 1 mm to about 100 mm. In some embodiments, a gap height ranging from about 10 mm to about 70 mm may be desired. A particular example may include a gap height of about 30 mm to about 40 mm separated between two mold sections. Having multiple gaps within the mold can allow for enhanced customization by increasing the number of delivery points for introducing foam particles into the mold cavity during article formation, changing the amount of particles delivered, and / or changing the conditions (e.g., compression) experienced by the particles. By increasing the number of delivery points for foam particles, better foam particle distribution can be achieved. For example, each gap can facilitate the use of multiple inlets and / or supply lines to various locations, allowing specific material to be delivered to areas within the mold cavity. Furthermore, the mold sections may include a filling gate. Particles can be filled into the mold using conventional techniques known in the art, such as pressure filling via a filling gate. Thus, specific particles can be introduced into predetermined areas of the article, allowing the article to be tuned for a specific purpose. For example, particles that could result in a more rigid foam could be introduced into areas of the midsole that require increased rigidity, while cushioning areas could be the result of introducing tuned particles to provide more cushioning.

[0151] Two-sided or multi-sided clearance methods may involve using multiple clearances—formed between the element and / or movable mold portions. In some embodiments, the clearance may be an opening between a portion of the mold and the element. Furthermore, multiple mold portions and / or mold sub-components may be used to form the clearances during the molding process. Typically, a fixed component, along with the mold portions, sub-components, and / or elements, defines the mold cavity. Utilizing clearances on both sides of the element is referred to as "two-sided clearance." In particular, using clearances on a first side of the element and on a second side of the element is referred to as "two-sided clearance" molding. Multi-sided clearance methods may involve using additional mold portions, such as sliders. In some embodiments, the slider may enter at various angles.

[0152] In addition, some embodiments may include an additional mold portion—specifically designed for the article (e.g., the midsole). The additional mold portion and / or sub-components may be held in place by fixing components, allowing multiple gaps to be achieved during the forming process.

[0153] Figure 9AA schematic diagram depicting the article formation process is shown. Mold 98 is open. Gaps 110 and 112 are formed between the surface of element 114 (located within mold 98) and mold portions 116 and 118. As shown, mold portions 116 and 118 are in the open position. Element 114 is secured in the pre-molded position using retaining members (not shown), spaced apart from the surfaces of mold portions 116 and 118 that partially define mold cavity 120. Mold cavity 120 may include cavity segments 122 and 124. Lines 126 and 128 indicate the initial positions of the mold portions in the open position.

[0154] Gap can be used to load particles into the mold cavity at different locations. For example, foam particles can be loaded into the mold cavity at a gap. Furthermore, particle loading can occur at one or more locations within one or more gaps. In this way, particles with predetermined properties can be used to create zones in foam particles and / or fused articles.

[0155] Some embodiments may include loading particles into a mold cavity via a mold section. For example, particles may be delivered into the mold cavity through one or more gates located in the mold section. Furthermore, the gates may be located throughout the mold section, allowing different particles to be loaded into different parts of the mold cavity. In this way, particles with predetermined properties can be used to create zones in foam particles and / or fused articles.

[0156] In one embodiment, the particles can be loaded into the mold cavity via a gap and / or through a mold section. For example, the particles can be delivered into the mold cavity via one or more gates positioned in the mold section and through a gap. This allows for more consistent loading of particles around the component. Furthermore, different particles can be loaded in different portions of the gap around the component to create zones in the foam particles and / or fused articles.

[0157] During the molding process, mold sections 116 and 118 move to compress the particles. Figure 9B The figure shows plate 114 in mold 98 in the closed position, the mold comprising portions 116 and 118. As shown, the movement of the mold portions differs. The amount of movement may vary based on molding conditions and / or desired characteristics of the final product. Lines 126 and 128 indicate the initial position of mold opening, and distances 130 and 132 show the differences between the movement of mold portion 116 and mold portion 118, respectively.

[0158] After the foam article is formed, visible portions of the elements, such as tabs and / or excess material, can be trimmed if necessary. In some embodiments where the elements are textiles, foils, and / or films, portions of the elements extending beyond the midsole can be used to wrap areas of the midsole, outsole, and / or upper in the finished shoe.

[0159] When used to form a midsole, the double-gap technology described herein allows for areas of the midsole with different properties, while also allowing the midsole to be manufactured in a single operation. The characteristics of interest can be based on desired functions and / or properties of the midsole areas. For example, characteristics of interest may include cushioning, elasticity, energy return, weight, thickness, stiffness, and / or density. Various techniques are used to achieve such characteristics and / or functions, which will be described below.

[0160] Figure 10 A flowchart is depicted illustrating a method 140 according to one aspect of this disclosure. In this particular example, the method involves: using a mold having multiple portions; positioning an element in one of the mold portions 142; positioning a retaining member near the element in the mold 144; positioning the mold portions such that the element is located between first and second mold portions 146; loading expanded foam particles into a mold cavity on either side of the element 148; moving the mold portions such that the mold portions close 150 after the granular foam filling is complete; providing energy to the mold portions 152; and fusing the particles 154. In some embodiments, during the phase in which the particles fuse together, an element (e.g., a plate or reinforcing element) may also be fused to the particles.

[0161] Closing a mold may involve moving mold sections toward the final molding position. In particular, mold sections can be moved so that they are positioned to provide the correct spacing for the final part.

[0162] In some embodiments, it can be used Figure 10 The method described herein forms the midsole. During the formation of the midsole in this manner, the outsole can be attached to the granular foam while the foam is being fused. Specifically, portions of the outsole can be inserted into a mold. For example, outsole foil and plates can be inserted before fusion.

[0163] When an element is positioned within a cavity formed by a mold section, a retaining member can be used to hold it in place. In some cases, the retaining member can hold the element in place during movement of the mold section. The retaining member can be positioned within the mold section such that it defines at least a portion of the cavity during compression and fusion.

[0164] The movement of the mold portion can be controlled throughout the molding process. For example, the mold portion can be moved using various known mechanical structures, including springs or actuators such as gears, pneumatic or electromagnetic actuators. The mold portion can be moved such that a gap (i.e., separation) is created between the component and the mold portion.

[0165] In one embodiment, after the positioning element and the mold section, particles or "foam particles" of the expanded material are loaded into a first and a second section of the mold. The particles loaded into the first section may have the same properties as the particles loaded into the second section of the mold, or the particles may have different characteristics based on the intended use of the product, the requirements of the developer and / or the requirements and / or characteristics of the product user.

[0166] In some embodiments, the pellets are loaded through an opening created between the bottom portion of the mold and an element positioned within the mold. In some embodiments, a retaining member can hold the element in place so that the pellets can be loaded through the opening between the mold portions. The retaining member may partially define the mold cavity, particularly the sidewalls of the mold cavity, wherein the sidewalls of the mold cavity will correspond to the sidewalls of the finished article (e.g., a midsole).

[0167] Mold portions and / or sub-components may be positioned on different sides of the element, such that a gap exists between the mold portion and the element. For example, a double gap may refer to a situation where one gap is on a first side of the element (e.g., a plate) and a second gap is on a second side of the element (e.g., a plate). In some embodiments, where two or more elements are used in the article of manufacture, three or more gaps may exist through which particles are conveyed into the mold cavity.

[0168] Particles can be added to the mold cavity through two or more inlets, gates, and / or supply lines. For example, a first supply line can deliver particles to a first gap, and a second supply line can deliver particles to a second gap. In some embodiments, multiple supply lines and / or gates can be used to deliver particles to predetermined areas of the mold cavity. In particular, in embodiments using multiple elements and / or elements with complex geometries, using multiple supply lines, gates, and / or inlets can allow for more efficient delivery of particles to the mold cavity. Additionally or alternatively, particle loading of the mold can be performed via a supply line communicating with the cavity of the mold using openings, fill gates, inlets, or combinations thereof. In some embodiments, loading is performed via multiple supply lines, gates, and / or inlets. For example, particles can be filled into the mold using pressure filling through multiple fill gates.

[0169] In one particular embodiment, the mold portion may include front and rear feet with different clearance heights. In this case, the gate may be located in both the front and rear foot regions of the mold portion.

[0170] Some embodiments utilizing a two-sided clearance process may include gates positioned on two or more mold sections. Between the two or more mold sections, elements, such as reinforcing elements, may be positioned. For example, both the top and bottom insole mold sections may be movable toward a closed position. In the closed position, the reinforcing element may be positioned between the mold sections. In such embodiments, a filling gate may be positioned on both the top and bottom mold sections.

[0171] A primer can be added to mold portions, components, and / or granules to enhance the bonding properties of the foam granules. In some embodiments, the primer can be added directly to the mold portion. Alternatively, the primer can be added to the granules and introduced into one or more mold portions during granule transport. In some cases, the introduction of the primer can be controlled such that it is introduced into specific areas of the mold, thereby giving the resulting article of interest areas with predetermined properties of interest.

[0172] When in the open position, the gaps between mold sections can affect the available loading volume of the mold. This available loading volume, in turn, can affect the amount of material loaded and thus molded and / or fused into an article or part thereof. For example, the available loading volume can affect the characteristics of the cushioning element, and thus its mechanical properties. For instance, the loading volume can affect the density, stiffness, and / or elasticity of the insole or a portion thereof.

[0173] Assuming, for example, that the available loading volume is fully utilized and the die closure position is the same regardless of the gap height, a larger distance between the first and second die portions in a double-gap notch location (i.e., a larger gap height) will allow more particles to fill the die compared to a smaller gap height, thus allowing these particles to be compressed more strongly when the die closes. However, in some cases, details of the filling height and / or die closure position can also affect compression.

[0174] In one specific example of the embodiment, the first portion and the bottom portion of the mold can move toward each other from an open position toward a closed position, thereby compressing the granules into a desired final shape. In some embodiments, the first portion and the bottom portion of the mold can move independently of each other. For example, portions of the mold can move different distances to accommodate desired characteristics of the area where the article to be formed.

[0175] In some embodiments, components of the first portion and the bottom portion of the mold can move independently of the fixed components of the mold.

[0176] Furthermore, the components of the first and bottom portions of the mold can move independently of elements (such as plates) positioned between the mold portions. The movement of the components of the first and bottom portions of the mold can differ. For example, the first and bottom portions can move different distances between an open position and a closed position.

[0177] Furthermore, in some embodiments, during the molding process, the movement of the first or bottom portion can be controlled such that one portion moves faster than the other. In some embodiments, the first and bottom portions of the mold can move to compress the particles and generate balanced pressure on the top and bottom sides of the plate. In some embodiments, the first and bottom portions of the mold can move different distances to generate different pressures on the first and second sides of the plate. The first and bottom portions of the mold can move toward each other using various known mechanical structures, including springs or actuators such as gears, pneumatic or electromagnetic actuators.

[0178] In some embodiments, the first mold portion and the second mold portion may include several individual sub-components, and the gap height between the sub-components on the first portion and the corresponding sub-components on the second portion can be individually controlled. In this way, the gap height of the sub-components can be varied. In some embodiments, only one mold portion includes such individual sub-components, while the other mold portion does not, which allows for a simpler mold construction. By including individually controllable sub-components in at least one mold portion (e.g., the top or bottom portion), the gap height, and therefore the loading of the mold and the compression of the first particulate material, can be locally controlled. Therefore, the first particulate material, particularly the granules, can be compressed with different forces in different areas of the mold. Thus, in some embodiments, different densities can be obtained in different areas of the finished article of manufacture. In some embodiments, density variations caused by different thicknesses within the mold cavity can be balanced or compensated.

[0179] For example, if a midsole for footwear is produced in a mold, the resulting granular foam component is typically much thinner in the forefoot section than in the rear section. In cross-section, such a sole has a generally wedge-shaped shape. For example, one or more mold sections can pivot about a pivot axis to create a crack-gap location, said axis being transverse to the longitudinal axis of the mold at the thinner end of the mold (in other words, eccentrically arranged), and then, when pivoting back to the closed position of the mold, to obtain an approximately constant density of the foam particles contained therein. Therefore, this option can be advantageously applied to the manufacture of products with a wedge-shaped cross-section. For example, during mold closure, one or more mold sections can pivot, for example, about an eccentrically arranged pivot axis.

[0180] Furthermore, individually controllable sub-components of the mold section or one or more eccentrically arranged pivot axes can also be used to compress mold cavity regions of varying thicknesses as uniformly as possible to achieve the most uniform heating and fusion quality throughout the granular foam component. However, this may be suitable if certain areas will be heated more intensely using electromagnetic radiation. In some cases, electromagnetic radiation can be used to ensure proper fusion of the granules. In some embodiments, it may be desirable to establish predetermined, non-constant temperature profiles during the production of the granular foam component.

[0181] The particles can be fused together by supplying energy to the mold. In some embodiments, more energy is supplied to the particles in the first part of the mold than to the particles in the second part of the mold.

[0182] In some embodiments, steam and / or heat can be used to supply energy. For example, when steam is used, portions of the mold may include one or more vents to allow steam to pass through. In some embodiments, a porous structure may be used, which allows steam to flow through the porous structure and allows for more uniform heating than through vents. The steam can be controlled such that portions of the particle surface are melted, allowing the particles to bond together. The amount of steam and / or the location of steam entry can be controlled to allow the particles to bond together while remaining intact. For example, the particles can bond together to form a granular but closed plastic foam structure.

[0183] In some cases, the properties of granular foam products can be affected by the parameters of the added steam. Specifically, the temperature of the added steam can affect the strength of the melting on the particle surface. Higher steam temperatures can create stronger bonds between the particles. Furthermore, the bond strength can be controlled by the duration of the steam treatment process.

[0184] In some embodiments, the amount and duration of steam supplied may vary. For simple articles using only a few different materials and / or components, the steam treatment time may be relatively short. More complex article constructions involving multiple materials and / or components may require longer steam treatment times and / or more steam quantities.

[0185] In some embodiments, the mold portion may be pressurized during a portion of the method. Higher initial pressure used to compress the particles can result in a higher density of the expanded particles. The density of the expanded particles can vary from about 0.030 g / cm³ to about 0.3 g / cm³. In some embodiments, the density of the expanded particles in the finished article of manufacture can range from about 0.070 g / cm³ to about 0.250 g / cm³.

[0186] After the article is formed, slow cooling of the particles can stabilize the structure of the article. This can allow the article to have higher long-term stability. In some embodiments, the article can be cured after it is formed. When curing the article, the curing temperature and curing duration can be selected to achieve specific properties in the finished article, such as desired structural stability.

[0187] In some embodiments, energy can be supplied using electromagnetic radiation, and in some embodiments, it is supplied in the form of electromagnetic radiation in the range of about 10 MHz to about 300 GHz. Specifically, electromagnetic radiation in the range of about 20 MHz to about 450 MHz can be used. For example, electromagnetic radiation in the range of about 20 MHz to about 50 MHz can be provided to fuse foam particles in the midsole. Alternatively, electromagnetic radiation in the range of about 400 MHz to about 450 MHz can be used.

[0188] In one embodiment, a portion of the mold may be made, for example, of epoxy resin, PTFE, PE, PEEK, or other materials that are structurally stable during the application of an electromagnetic field. The surface material of the mold can be selected to have a loss factor similar to that of the foam particles, which can result in substantially uniform heating of both the particles and the mold walls defining the cavity, thereby achieving better surface fusion of the parts. The surface of the mold can be modified, for example, by a coating process or by applying a suitable surface material in other ways known in the art.

[0189] Utilizing a double-gap notch in molding enhances control over molding conditions, thus providing a way to tune the characteristics of the molded element. For example, using a double-gap notch allows the element designer and / or developer to tune one or more areas of a granulated foam component to have specific, predetermined characteristics. In some cases, granulated foam components can be designed for specific applications. For instance, a granulated foam component for running shoes will have different preferred characteristics than a granulated foam component for shoes used for lateral movements.

[0190] In particular, the use of double-gap notches can be used to control the density of regions within a granular foam component. Using double-gap notches can help increase the density in specific areas of the granular foam component being manufactured. For example, in such areas, the mold can be opened to a greater extent, thus "overfilling" the granules. During compression, this overfilled area may require additional force to compress the granules when the mold closes. Therefore, in the finished granular foam component, this area can have an increased density.

[0191] In some embodiments, the expanded material particles of the midsole are subjected to a combination of heating, pressurization, and / or steam treatment after filling the mold. Following this combination of heating, pressurization, and / or steam treatment, the surface of the particles may at least partially melt, causing the particle surfaces to bond together upon cooling. In some cases, the combination of heating, pressurization, and / or steam may result in the formation of chemical bonds between the particles. Forming chemical bonds in this manner can reduce the need for binding materials (e.g., adhesives).

[0192] The mold portion may include engaging members that engage elements positioned within the mold. Specifically, engaging members may include various geometries, such as protrusions, flanges, overhangs, hooks, pillars, pins, recesses, etc. Members on the mold portion may be configured to engage elements inserted into the mold. The configuration of the members may be designed to engage specific elements and / or portions thereof. Some mold portions may include multiple types of members for engaging elements. Figure 11 A portion 200 of a mold for a shoe midsole is shown. Mold portion 200 includes a positioning notch 202, an engagement member 204, a filling gate 205, and a vent 206. A flange 208 in mold portion 200 is used to engage elements and / or retaining members (not shown). In some embodiments, the mold portion may include a positioning notch that engages with an element to properly position the element within the mold portion before securing it with the retaining member.

[0193] like Figure 12 As shown, element 210 is partially positioned on flange 212 in die section 214. Element 210 includes an opening 211. During compression, the flange of the die section and the element positioned thereon can maintain their position while other sections of the die section move. In particular, die surface 216 moves during die compression. For example, the flange and element can remain positioned while the die surface moves to compress material within the die section. Figure 12 As shown, tab 218 and opening 220 engage with engagement member 222 to position element 210. A filler gate 215 in mold portion 214 is used to deliver particles into the mold. The filler gate may include a design applied to the surface of the fused particles during article formation. For example, in some embodiments, the gate may include a reversed image of a mark or design that will be imprinted onto a portion of the article (e.g., a midsole) during particle fusion.

[0194] Figure 13 An unfolded view of the tab 218 of element 210 with an opening 220 is depicted. The flange 224 of the mold portion 214 includes a cutout 226 corresponding to the tab 218.

[0195] Engaging components can be formed to engage part of an element. For example, engaging components may include pins positioned throughout the mold section. The configuration of the pins may vary based on the geometry of the element to be positioned in the midsole. The diameter, shape, profile, and / or height of the pins may vary depending on their position in the mold and / or the type and / or configuration of the element. Furthermore, in some cases, the diameter, shape, and / or profile of the pins may vary along the length of the pin. In some embodiments, the cross-section of the pin may be of any shape, including but not limited to regular and / or irregular shapes. For example, the cross-section of the pin may include a circle, ellipse, star, rectangle, etc.

[0196] Furthermore, the pin can have a diameter that varies along its length. For example, the pin can have a larger diameter at the mold surface closer to the mold portion. Figure 14-16 Pin 230, used in the mold section, is depicted. Specifically, Figure 14 A pin 230 is depicted, which has a smaller diameter section 232 at the top and a larger diameter section 234 at the bottom.

[0197] also, Figure 14-15 Pins 230 are depicted with small-diameter segments 232 and large-diameter segments 234 of varying lengths. The lengths of these segments depend on the configuration of the components to be positioned within the article of manufacture. This aids in positioning components, such as plates. The configuration of individual pins can vary based on the configuration of the components to be inserted into the article of manufacture. For example, as... Figure 14-16 As shown, the length of the pin and the length of the pin segments can vary. Furthermore, as... Figure 16 As shown, pin 236 includes slot 238 to engage a portion of the element. Figure 17 A pin 240 positioned in a mold portion 242 is depicted, having a slot 244 that is a portion of an engaging element 246. Further embodiments may include engaging components, such as pins including openings, slots, ridges, etc., to engage elements.

[0198] Components included in an article (e.g., a midsole) may have characteristics specific to a particular purpose and / or user expectations. For example, a component may be designed to have a unique set of properties. A component may have a set of properties optimal for a specific application, including but not limited to running on a track, cross-country running, jumping, throwing, weightlifting, wrestling, fencing, lateral movements (e.g., tennis, table tennis, basketball, pickle, football, rugby, baseball, or American football), skiing, snowboarding, cycling, etc. Furthermore, a component may have a set of properties optimal for the user, and may be based on factors including but not limited to the user's weight, height, anatomy, and / or stride length. Optionally, the shoe developer and / or designer may have a predetermined set of properties of interest for a particular shoe or purpose.

[0199] The characteristics of interest for an element may vary depending on the element, but may include, but are not limited to, density, material, thickness, deformation, reflectivity, tensile strength, thermal insulation, luminescence, stability, cushioning, conductivity, wicking capacity, elasticity, temperature resistance, stiffness, energy feedback, connectivity, abrasion resistance, cost, weight, melting temperature, tear resistance, and / or other characteristics known in the art.

[0200] For example, in some embodiments, the element may have a predetermined stiffness. In certain cases, the material used in the element may have a tensile stiffness modulus in the range of about 1 GPa to about 15 GPa. In some embodiments, the material used in the element may be fiber-reinforced. For example, the element may include long carbon fiber composites as reinforcing materials. In a particular embodiment, a portion of the element may have a tensile stiffness modulus in the range of about 1 GPa to about 15 GPa.

[0201] In a further embodiment, the profile or cross-section of the element can affect the stiffness of the article. For example, the midsole may have an element with a predetermined profile and / or cross-section, thereby imparting predetermined properties to the midsole.

[0202] The characteristics of a component, such as material, profile, thickness, geometry, and layup, can at least partially determine the configuration of positioning elements (e.g., protrusions, tabs, and / or openings) on the component. Positioning elements can be integrally formed with the component.

[0203] In some embodiments, the positioning members may be designed to removably engage portions of the element during forming. For example, positioning members may be placed on the element before and / or during positioning the element within the mold, such that they remain in place during article formation. After article formation is complete, the positioning member material can be removed from the article.

[0204] Elements positioned within the article may include one or more of the following: support structures, including rods, torsion bars, plates, cages, frames, and / or caps; textiles; films; foils; strands; filaments; external object connectors—objects that can be coupled to the article such that a portion of the object extends beyond the outer surface of the article, such as nails (e.g., running nails and / or decorative nails), clips (e.g., bicycle clips), straps, friction components, pads, springs, ports, decorative items, such as ornaments, buckles, etc.; electronic components, such as transmitters, electrodes, sensors (e.g., optical sensors, pressure sensors, gyroscopes, accelerometers, etc.), displays, control panels, lights, LEDs, batteries, etc.; conductive elements, such as wires, strips, sheets, etc.; shielding elements, such as elements that protect another element or a portion of the midsole from adverse environmental conditions (e.g., heat, moisture, and / or pressure during the forming process); cushioning elements, such as spring elements, pads, bladders, etc.; tags, such as near-field communication tags, chips, etc.; and / or combinations thereof.

[0205] For example, a granular foam article formed using the methods described herein and used on clothing articles may include a support structure and an external object connector. The external object connector may be embedded in the molded granular foam. In some cases, at least a portion of the external object connector may be in communication with the outer surface of the granular foam article, allowing an object to be coupled to the external object connector.

[0206] In a particular example, the midsole may include a threaded external object connector to which an external object can be coupled. In the midsole, the external object connector may have an annular opening communicating with the outer surface of the foam article, such that the threads of a racetrack stud can engage with the threads on a portion of the annular opening of the external object connector.

[0207] Components used in articles can be made of materials with desired properties, including but not limited to metals, fibers (e.g., carbon fiber, glass fiber, and natural fibers), composite materials, ceramics, textiles, strands, and plastics (including thermosetting plastics, thermoplastic plastics such as polypropylene, polyethylene, polycarbonate, thermoplastic polyurethane (TPU), or combinations thereof). Materials used for components can be selected to obtain desired properties such as stiffness, color, transparency, bonding characteristics, heat resistance, water resistance, strength, sensitivity to electromagnetic radiation, sensitivity to pressure, abrasion resistance, cost, weight, and / or energy feedback. It should be noted that components can take many forms and are not limited to any shape depicted in the embodiments herein.

[0208] The midsole can be designed such that the expanded material at least partially surrounds one or more elements of the midsole. For example, the elements can at least partially extend through the expanded material of the midsole. In this case, the elements and the expanded material can be coupled without adhesives. Such a design increases the design freedom of the midsole. Therefore, the properties of the midsole can be precisely influenced.

[0209] In some cases, the element can also bond to the midsole material, for example, to the expanded material of the midsole. This bonding can further increase the stability of the sole. The bonding between the midsole and the element can include adhesive bonding, fusion bonding, and / or bonding achieved by adding additives. In particular, additives of interest may include, but are not limited to, thermoplastic powders, thermosetting powders, and / or primers, such as cement primers, which can increase the bond strength between the element and the particulate foam material. For example, some embodiments may include the addition of urethane powder, which can enhance the bond formed between the element and the midsole material, particularly the expanded material.

[0210] Examples may include coated and / or pre-laminated elements for use in granular foam articles. For example, the elements may be at least partially coated with a film or foil to increase the adhesion of portions of the element to the granules upon fusion.

[0211] Various embodiments of elements that can be positioned within the midsole are provided by Figure 18-22 As shown. Components can be, but are not limited to, metals, fibers (e.g., carbon fiber, glass fiber, and natural fibers), composite materials, textiles, plastics (including thermosetting plastics, thermoplastic plastics such as polypropylene, polyethylene, polycarbonate, thermoplastic polyurethane (TPU)), or any other suitable materials to provide desired properties to the article. For example, it may be desired that the component provides a predetermined stiffness to a portion of the midsole. Optionally, the material and / or construction of the component can be selected such that the component provides a predetermined energy return to the midsole.

[0212] like Figure 18 As shown, element 250 is a plate with an internal tab 252 having an opening 254. Furthermore, in the heel region 256, the plate includes an external tab 258 with an opening 260.

[0213] Figure 19 An embodiment of element 270 for use in a midsole is shown, specifically plate 272. The plate can be designed to have a unique set of properties determined by the developer. In particular, the plate can be used to stiffen the midsole. For example, the plate can have a construction and / or material designed to provide a specified stiffness. Figure 19 As shown, plate 272 is a single piece. In some embodiments, the plate may include two or more pieces.

[0214] like Figure 19 As shown, plate 272 includes engagement structures 274, such as an inner tab 276 disposed on an inner portion of plate 272 and an outer tab 278 disposed on an outer portion of plate 272. The outer tab 278 and the inner tab 276 are protrusions extending from plate 272. The engagement structures can have various geometries and / or openings to allow engagement of the plate with a portion of a mold, another element (e.g., another plate or rod), or a fixing component. Figure 19 As shown, the outer tab 278 and / or the inner tab 276 include holes 280 projecting through them. Furthermore, the plate 272 includes holes 280 projecting through the body of the plate 272. The plate may be made of metal, composite material, carbon fiber, plastic, or a combination thereof to provide desired properties such as stiffness and resilience. It should be noted that the plate may have a form designed for a particular purpose and / or user, and is not limited to the shape depicted in the embodiments described herein.

[0215] Figure 20 The image shows an element, specifically a plate 290. Plate 290 has a plurality of tabs 292 and openings 294. The configuration of the tabs and / or openings can be specific to a particular element, such as a plate. The characteristics of the element, such as material, profile, thickness, geometry, stiffness, dimensions, surface area, and / or predetermined location within the article of manufacture, can at least partially determine the configuration of the tabs and / or openings on the element.

[0216] The plate construction can be varied according to the desired characteristics of the midsole. Figure 21 This is a bottom view of an example plate 300, which includes structural fingers 302 extending from the heel portion 304 to the forefoot portion 306. As shown, the plate 300 is positioned within a mold portion 308. Pins 310 of the mold portion 308 engage openings 312 in the plate 300.

[0217] Figure 22 Another configuration of element 320 for the midsole is shown, which extends from the heel portion 322 to the forefoot portion 324. Here, the finger-like element 326 has different shapes and profiles depending on the intended use of the shoe and the materials used.

[0218] Most of the examples above depict a single element used in articles such as midsoles. Some embodiments may include multiple elements combined to impart specific properties to the article. Figure 23-24 In this configuration, elements, particularly plate 330 and textile 332, are combined to form an element for use in the insole. In this configuration, pin 334 has a slot 336 to engage plate 330. For example, pin 334 extending from mold portion 338 includes a slot 336 to engage a portion of the plate. Figure 24 From and Figure 23 The opposite side shown depicts a view of plate 330 and textile 332.

[0219] Other combinations not shown in the accompanying drawings are also possible, such as combinations of plates, rods, cables, springs, tubes, and / or sheet elements, such as textiles, films, or foils. In some embodiments, portions of the various elements may extend beyond the article of manufacture. For example, in some embodiments, it may be desirable to use textiles that extend beyond the midsole during molding. This configuration may allow textiles to be used to wrap a portion of the midsole, upper, and / or outsole.

[0220] In some embodiments, a portion of the element 340 embedded in the particulate foam article 342 is exposed, such as Figure 25 As shown.

[0221] like Figure 26 As shown, plate 350 is placed within a portion of mold 352, such that at least some openings 354 engage with pins 356. Tabs 358 extend outside the mold cavity. Some tabs 360 extend into the mold cavity. Figure 26 As shown, some tabs 362 extending into the mold cavity engage with pins 356.

[0222] like Figure 26 As shown, the mold portion 352 has a surface 364 including a filling gate 365 and a positioning section 366. A plate 350 can be positioned within the mold portion 352 such that a section of the plate 350 rests on the positioning section 366. Figure 26 As shown, the outer tab 358 of plate 350 rests on positioning section 366. Figure 26 As shown, the positioning section 366 includes a flange 368 and a recess 370, so that the plate 350 is correctly positioned in the mold portion 352.

[0223] Figure 27 A mold portion 380 and a retaining member 382 are shown. The retaining members can be positioned such that they engage at least a portion of the element and a portion of the mold portion. The retaining member 382 includes members 384 and 386. The two members 384 and 386 meet at a joint 388 to further define a mold cavity 390 and retain the position of the element. In some embodiments, the molded portion may include a plurality of filling gates and a plurality of steam vents.

[0224] like Figure 28 As shown, the fixing component 400 engages with the external protrusion ( Figure 26 (as shown in the image) and location segment 366 ( Figure 26(As shown in the diagram). Specifically, the plate 402 positioned on the positioning member is secured by adding a fixing member 400, which is positioned near the positioning section (not shown). For example, the fixing member 400 is positioned on the flange such that an outer tab (not shown) is disposed between the fixing member 400 and the flange (not shown). The fixing member 400 thus holds the plate 402 in the proper position within the mold portion 404.

[0225] like Figure 28 As shown, the fixing member 400 and the mold portion 404 define a cavity 406 into which the granular foam is loaded. Thus, the fixing member can define the area where the foam granules will be placed, as well as the portion where an element (e.g., a plate) contacts the foam granules.

[0226] Figure 27-29 The diagram shows mold portions 380 and 404 in which fixing components 382 and 400 are positioned. The fixing component can be a single component 400. Figure 28 (as depicted in the text), or it can be composed of multiple components 384, 386 ( Figure 27 (As shown in the figure) is formed. As shown, the fixing component helps to define the mold cavity and rests on the mold part. Figure 27 A mold portion 380 is depicted, which has a pin 392, a vent 394 and a gate 396 positioned on a surface 390 of the mold portion 380.

[0227] A retaining member can be positioned to hold an element, such as a plate, in place during in-process forming (including loading, movement, and / or fusion). The retaining member engages portions of the element to reduce and / or inhibit movement of the element within the mold cavity. The retaining member engages a portion of the element and at least some mold portions. In some embodiments, a retaining member can be used to secure two or more elements.

[0228] The fixing component may include one or more sections. The form of the fixing component may be determined by the shape of the element being fixed. In some embodiments, the fixing component may include, but is not limited to, one or more frames, rings, clamps, screws, bolts, flanges, or combinations thereof.

[0229] exist Figure 28 In the example shown, the retaining member 400 is positioned to hold the element 418 in place. The retaining member can be closed against a positioning member (not shown) in the mold portion. The wall 401 of the retaining member 400 and the surface 408 of the mold define a portion of a cavity 406 in which the article is formed.

[0230] In some embodiments, the fixing member and / or positioning member may have complementary geometries. For example, the fixing member and positioning member may have recesses and / or protrusions that engage with each other during use. Furthermore, the fixing member and / or positioning member may have geometries such as recesses and / or protrusions corresponding to a portion of the plate. This allows the fixing member and the second positioning member to close on the plate, thereby holding the plate in place while forming a cavity.

[0231] like Figure 29 As shown, a pin 410 engages a hole 414 in an internal tab 416 of a plate 418 within a mold portion 412. The pin can be configured to align with and be inserted into a hole in the plate, such as the hole 414 within the internal tab 416. In some embodiments, the pin may engage a hole in the body of the plate. Furthermore, Figure 29 A mold cavity is depicted, defined by the surface 415 of the mold portion and the wall 405 of the fixing member 400. A plate 418 is positioned within the mold cavity.

[0232] In some cases, the pin may have a diameter that varies along its length. In some embodiments, the opening in the element may have a diameter larger than the diameter near the top of the pin and smaller than the diameter further below the pin. This can limit the movement of the element beyond a desired position during use. In some cases, the engaging component includes geometry for engaging the element, such as a cutout, slot, etc.

[0233] Figure 30 A porous structure 420 is shown, which can be included in the top and / or bottom portion of a mold. Compared to what can be achieved using one or more steam vents, the porous structure 420 allows steam to be distributed more evenly on the particles in the mold, thereby allowing for more consistent particle heating and fusion. This porous structure can be used on one or more surfaces of a mold portion for forming articles from granular foam.

[0234] like Figure 30 As shown, pin 422 has a slot 424 extending through a portion of its head 426, which engages one or more elements. For example, multiple elements may be engaged with the pin during a given article of manufacture. In some embodiments, combinations of different engaging components may be used to secure the elements.

[0235] Figure 31 A textile element 430 is shown positioned in mold portions 432, 434. The textile element 430 can be positioned on a particulate foam insole 436 within the mold. Figure 36Use the circles on the bottom of the granular foam. Although the granules are depicted as discontinuous circles, this is only intended to illustrate the location of the granular foam material. The fused granular foam material will be continuous, with the granules fused together. Before fusion, the granules will also come into contact due to overfilling the mold with granules to ensure proper fusion and compression.

[0236] In some cases, textile, film, and / or foil elements may be positioned between the top and bottom mold portions of the mold. The textile, film, and / or foil elements used in this process may have unique properties and can provide increased durability and strength, among other benefits. For example, textile, film, and / or foil elements may be placed into the mold portion during formation, fused to a portion of the midsole, and then a portion of the element may be used to wrap the midsole. These elements can be used to impart lateral stability, durability, and / or other properties of interest to the midsole. In one particular embodiment, one or more textile elements may be used to wrap a portion of the midsole.

[0237] In some embodiments, textile, film, and / or foil elements may be included in a mold portion as well as in another element (e.g., a plate). Optionally, multiple elements may be positioned in the article of manufacture in combination with textiles, films, and / or foils. In some embodiments, textile elements may be included in the mold portion without a plate.

[0238] In some embodiments, and as Figure 31 As shown, a vacuum pressure is used to hold the textile element 430 in place against a portion of the mold portions 432, 434. For example, a vacuum pressure can be applied such that suction is applied to the textile element through steam vents and / or the porous structure of the mold portions. By utilizing a vacuum or negative pressure, the textile element can be held in place within the mold portions. In some embodiments, a vacuum or negative pressure can be used to position and / or hold one or more elements—made of textiles, foils, films, strands, filaments, or other materials.

[0239] Figure 32 Midsole 450 is shown. Midsole 450 may include plate 454. As shown, midsole 450 includes foam regions 452 and 456. Foam regions may include particles of different shapes and / or sizes, as shown in the representative patterns in regions 452 and 456. Figure 32The patterns shown are intended to be representative and are not drawn to scale. In certain embodiments, the fused foam particles will be continuous and substantially retain their particle shape. During the fusion process, mold regions 452, 456 and plate 454 are coupled to each other. The insole 450 is coupled to the outsole 458. In some embodiments, each foam region may have different properties. For example, one foam region may have a higher density than another. In another example, the first foam region may have a higher cushioning value than the second foam region. In some cases, the mold regions may have the same properties.

[0240] Properties in a molded article (e.g., a midsole) can vary along the length, width, and / or height of the article. Furthermore, properties can vary from one region of the article to another. For example, the properties of a first midsole region can differ from those of a second midsole region. In a particular embodiment, the properties of the midsole region can vary along the length, width, and / or height of the midsole region.

[0241] As described in this article, the midsole can be a single or integral structure, meaning that the structure is a single component rather than multiple components glued together, for example, using a secondary bonding process.

[0242] Figure 33 A side view of the midsole of interest for use in a shoe is shown. The midsole 462 is coupled to the upper 460. The midsole portions, elements, and outsole can be coupled to each other during the fusion process. For example, to form such a midsole during manufacturing, particles with a first characteristic are loaded in a first region, and particles with a second characteristic are loaded in a second region. Two mold portions can be positioned close to each other, such that the elements are positioned between the first and second regions.

[0243] Therefore, after formation, the fused granular foam formed in the first region may have different properties than the fused properties in the second region. These differences in properties between the regions may be due to differences in materials and / or manufacturing methods, including but not limited to: the addition of additives—such as the addition of thermoplastic and / or thermosetting polymer powders, the amount of energy applied, the amount of pressure applied, the permeability of the mold portion to vapor, and / or the time frame for applying energy or pressure.

[0244] like Figure 34As shown, the midsole 470 includes elements 472 and 473 located in partial regions 476 and 480 formed within the midsole. These partial regions may have different properties from each other. Embodiments of the midsole may include partial regions having properties different from those found in the majority of the midsole. In some cases, partial regions may be tuned to specific regions within the midsole. For example, the values ​​for flexibility and / or cushioning in a partial region in the forefoot are likely to differ from those in a partial region in the heel. Furthermore, midsole regions 474 extending along the length of the midsole will also have different values. In particular, midsole regions may have properties different from those in the partial regions. The first and second regions may be compressed differently, i.e., under different pressures, temperatures, and / or may be precisely manufactured using different base materials in a manufacturing method.

[0245] During the formation of a midsole with partial areas using a two- or multi-gap method, the partial areas can be subjected to energy application. Using two or more gaps ensures that the partial areas are effectively filled and fused. Energy can be applied to the midsole or its portions via steam, heat, electromagnetic radiation, or a combination thereof. Specifically, steam can be supplied to both partial areas. In some embodiments, this can occur in a specific sequence across the midsole. For example, a first partial area can be fused first, followed by a second partial area. Furthermore, the remainder of the midsole can be fused subsequently. The fusion of granular material can occur in a mold comprising multiple mold sections and / or multiple elements. Alternatively, energy can be supplied across the midsole such that the partial areas fuse simultaneously.

[0246] As discussed herein, the midsole may include randomly arranged particles of expanded material. In some embodiments, the entire midsole comprises expanded material.

[0247] In a further embodiment, only one or a few portions of the midsole comprise the expanded material, while the remainder comprises the non-expanded material. By using suitable combinations of different expanded and / or non-expanded materials, midsoles with desired cushioning and stability properties can be manufactured. The particles of the expanded material may specifically comprise one or more of the following materials: expanded ethylene-vinyl acetate (eEVA), expanded thermoplastic polyurethane (eTPU), expanded polypropylene (ePP), expanded polyamide (ePA), expanded polyether block amide (ePEBA), expanded polyoxymethylene (ePOM), expanded polystyrene (PS), expanded polyethylene (ePE), expanded polyethylene oxide (ePOE), and expanded ethylene propylene diene monomer (eEPDM). Each of these materials includes specific typical properties that can be advantageously used in the manufacture of the sole, depending on the performance requirements of the sole. Therefore, eTPU, in particular, exhibits excellent cushioning performance that remains unchanged even at low or high temperatures. Furthermore, eTPU is highly elastic, and in the event of compression that may occur when the foot impacts the ground, eTPU almost completely returns the stored energy to the foot during the subsequent expansion process. This increases the efficiency of movement. In contrast, ePP offers greater stability and very low weight. In some embodiments, the midsole includes portions of eTPU in the forefoot region (partially below the toes) and heel region, while the remainder comprises ePP, eEVA, or another inflated or non-inflated material. Due to the excellent cushioning properties of eTPU and the low weight of ePP, a midsole that includes eTPU in the forefoot and heel regions and ePP in the remaining areas protects the wearer's foot and joints from injury, keeping the sole weight low. This combination can be advantageous, for example, for running shoe soles.

[0248] Depending on the performance requirements of the midsole, one or more materials may be used for its manufacture due to their characteristics. The particles used in the embodiments described herein may, for example, include at least one of the following materials: expanded thermoplastic polyurethane (eTPU), expanded polyamide (ePA), expanded polyether block amide (ePEBA), polylactic acid (PLA), polyether block amide (PEBA), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and thermoplastic polyester elastomer (TPEE).

[0249] In addition, some embodiments may include particles made of at least one of the following: polyamides, such as homopolymers, copolymers, polyether block copolymers, and polyphthalamides; polyesters; polyetherketones, such as polyetherketone (PEK), polyetheretherketone (PEEK), and polyetherketoneketone (PEKK); and polyolefins, such as polypropylene (PP), polyethylene (PE), olefin block copolymers (OBC), polyolefin elastomers (POE), polyethylene-vinyl acetate copolymers (EVA), polybutene (PB), and polyisobutylene (PIB).

[0250] The diameter of the particles used in this method can range from about 0.5 mm to about 10 mm. In some cases, the diameter used can range from about 1 mm to about 8 mm. In specific cases, the diameter of the particles used in this method can range from about 2 mm to about 7 mm.

[0251] In some embodiments, particles with a specific shape may be selected. For example, the particles may be spherical, oval, cylindrical, or a mixture thereof. In a particular embodiment, the particles used in foam articles manufactured according to the methods described herein are typically oval.

[0252] The size and / or shape of the particles within the article can vary. For example, some regions within the article may include particles of a specific size and shape, based on the desired characteristics of that region. In some embodiments, multiple regions in the article may have predetermined sizes and / or shapes for each particle to be used in each region.

[0253] The processes described herein and the particles used in the midsole can be selected based on the characteristics of the particles. In some cases, the molded element (e.g., the midsole) may include a single type of particle. However, in some embodiments, particles may also be selected for specific areas of the molded element. For example, particles may be arranged in the mold based on the properties of the material and / or desired characteristics in the molded part. In particular, particles may be aligned relative to each other and / or otherwise intentionally arranged within the mold. In some cases, particles may be randomly arranged within the mold.

[0254] In a specific example, components comprising particles from at least one of the aforementioned materials exhibit excellent cushioning properties, good elasticity and energy return, and they can also be very lightweight. Their properties can also be largely independent of temperature. Therefore, it may be advantageous to use a mixture (or region) of different expanded particles in a mold, which can then be formed into components using the methods described herein.

[0255] In some cases, particles can be selectively positioned in areas of the mold based on their diameter. This can impart desired properties to areas of the midsole.

[0256] The material loaded into the mold can include more than one base material. For example, in one particular embodiment, expanded PP and expanded TPU can be used in the first region of the midsole, while expanded TPU with different particle sizes can be used in the second region of the midsole. Furthermore, materials of different colors, shapes, and sizes can be used in individual regions of the midsole. Utilizing a double-gap or multi-gap forming process allows for increased design flexibility because material can be delivered to specific areas of the mold portion. In particular, the double-gap forming process can be used in conjunction with double-gap or multi-gap processes, for example, using sub-components within the mold portion.

[0257] Using particles of different sizes, shapes, and / or colors can increase the design and / or functional options of the finished product. Components can be fused together using steam energy, under pressure, and / or using the methods and processes described above to form a unique component.

[0258] Components can be positioned between portions of the mold. For example, an component can be positioned between a top portion and a bottom portion of the mold. In some embodiments, the component can be positioned such that it engages a coupling member, such as a pin, a portion of the mold, a retaining member, or a combination thereof.

[0259] In some embodiments, the midsole may have multiple regions with different characteristics from the lateral side (outer side of the foot) to the medial side (inner side of the foot). For example, the molding portion may include sub-components that move independently of each other on their surface. The sub-components can move independently of each other to allow each region to undergo different levels of compression. Such a midsole can be formed using multiple molding portions, sub-components, elements, and / or inlets to supply granular material to these regions. Elements may be positioned between different materials. Figure 35 As shown in the bottom view of the midsole 490, different expanded materials 496, 498, and 500 are used in different areas of the midsole separated by elements 492 and 494. As illustrated, in some embodiments, the elements may be positioned along the longitudinal axis of the midsole but perpendicular to the insole. In this way, the midsole can be divided into a near-center region, a central region, and a periphery region. The particles in the different regions may include materials with different particle sizes and / or shapes. Figure 35 This is an illustrative representation of granular foam materials with different sizes and / or shapes used in different regions. Although Figure 35 The illustration depicts granular foam with a regular pattern, but this is only intended to illustrate that each region has different particles. The fused granular foam in these regions will be continuous and have variable surfaces.

[0260] The midsole can be formed through a series of steps that allow the expanded foam to fuse to all components and / or external parts. For example, the method described herein can allow, for instance, Figure 33 The midsole and outsole assembly shown is such that the midsole segments, elements, and / or outsole are fused together without the use of additional adhesives. Using such a process allows for the formation of a monolithic midsole-outsole structure, meaning that the structure is a single component, rather than multiple components glued together, for example, using a secondary bonding process.

[0261] The midsole may include elements at the junction of two or more materials—where mold lines exist. For example, such as Figure 36 As shown, the midsole 550 may have a mold line 552. In some embodiments, a plate 554 is disposed in the midsole 550 adjacent to the mold line 552 as part of an integral structure. Figure 36 As shown, plate 554 is positioned near mold line 552. As also shown, the upper portion 556 of the midsole has a different profile than the lower portion 558. Specifically, as... Figure 36 As shown, the lower part 558 and the plate 554 extend beyond the upper part 556 at the heel area 560.

[0262] For example, in some embodiments, the upper and / or lower portions may be shaped such that they engage with the shoe upper, provide more cushioning to the area of ​​the foot, and / or accommodate design or technical elements.

[0263] Figure 37 Further embodiments are shown, depicting a midsole 600 formed of fused granular foam, the midsole having elements 602, 604 positioned in the midsole and extending beyond the surface of the midsole in the finished midsole. Figure 37 The foam particles in the midsole 600 shown are represented by circles; the foam particles are not depicted to scale. Furthermore, in such an embodiment, the fused foam particles will be continuous and substantially retain their particle shape. A portion of the element (not shown) is embedded into the midsole during the forming process using a double-gap process. In some embodiments, the die portion may be modified to accommodate portions of the element that will extend beyond the midsole. In some embodiments, a multi-gap system may be used to ensure that the particles are properly dispersed in the various areas surrounding the element.

[0264] Figure 38 A top view of a midsole 700 is depicted, which includes an element 706 having a plurality of positioning members 710 positioned within the midsole formed of fused foam particles. Although Figure 38The foam particles are depicted as circles, but this is merely a representation. In certain embodiments, the fused foam particles will be continuous and substantially retain their particle shape. As shown, a portion of the element extends beyond the midsole. Optionally, the element may be fully embedded in the midsole. A gate mark 708 is visible on the surface of the midsole. The gate mark reflects the location of the gate on the mold portion used for loading the particles during midsole formation. In some embodiments, the gate may include a cap designed to impart a shape to the midsole during formation. After the particles are loaded into the mold cavity, the cap may be positioned on the gate to inhibit and / or prevent particle movement.

[0265] As described herein, positioning features on a component (e.g., protrusions, tabs, openings, etc.) can be designed to removably engage portions of the component during formation. Figure 38 In the depicted example, positioning members 710 are placed at predetermined locations on an element (not shown). These locations may be determined based on the element's design (e.g., material, shape, etc.), mold portion, mold, foam material characteristics, midsole design and / or required characteristics, molding conditions, etc. After the positioning members are placed on the element, the element may be positioned near the mold portion. Optionally, some processes may include positioning at least some positioning members after at least a portion of the element is positioned in the mold portion and / or within the mold.

[0266] Some embodiments may include elements extending from one mold portion to one or more additional mold portions. Alternatively, multiple elements may be placed in a single mold portion and secured using locating members. The locating members may engage features of the elements, mold portions, molds, and / or fixing components. The engaging members of the mold portions, molds, and / or fixing components may include various geometries, such as protrusions, projections, flanges, overhangs, hooks, pins, pillars, recesses, openings, etc.

[0267] Positioning members can be placed on the component before and / or during positioning of the component within and in the mold portion. The positioning members can engage with fixing components, mold portions, and / or the mold, allowing the component to remain in place during article formation. In some cases, the positioning members can be removed from the article after formation is complete.

[0268] The positioning member can be positioned such that the element is completely embedded in the article. Furthermore, the position of the positioning member, the design and / or position of the element, and / or the loading of particles can be adjusted to ensure the element is completely embedded in the article. For example, during loading, particles can be loaded into the mold such that the entire element is covered by the particles. Optionally, the loading of the element, the positioning member, and / or the particles can be controlled so that the element and / or portions thereof are visible in parts of the finished article.

[0269] Examples of positioning components are in Figures 39-44 Described in the text. For example... Figures 39-40 A side view depicting an embodiment of the positioning member is shown. The positioning member can be partially formed of various materials, including but not limited to metals (e.g., aluminum) and alloys (e.g., steel), plastics (e.g., polyamides, particularly polyamide-11 and / or polyamide-12), rubber, composite materials, etc. For example, a metal positioning member may include rubber on portions of the engaging element and / or granular foam.

[0270] The selection of materials for mold parts, fixing parts, components, and / or positioning parts can be determined by the type of energy used during the method. Materials used may include, but are not limited to: metals, such as steel and aluminum; thermosetting materials, such as epoxy resins; and plastics, such as polytetrafluoroethylene (PTFE), polyamides (including, for example, polyamide-11 and / or polyamide-12), polyethylene (PE), polyetheretherketone (PEEK), and / or other materials that are structurally stable during the application of an electromagnetic field.

[0271] In embodiments where the energy source is electromagnetic radiation, it is desirable to use suitable materials. For example, if electromagnetic radiation, such as microwave or radio frequency heating, is used, it is desirable to utilize fixtures formed of PTFE.

[0272] Conversely, if steam is used, metal is preferred for parts that are likely to have the most contact with steam and / or heat (e.g., mold parts, fixing parts, and / or positioning parts).

[0273] Because positioning components are removable, they can be reused. Reusable positioning components can reduce the amount of material required to produce articles. Therefore, using reusable positioning components can increase the sustainability of products and / or methods.

[0274] In one particular embodiment, the positioning member may be formed of a material not bonded to the particulate foam material. For example, the positioning member or a portion thereof positioned near the particulate foam may be made of a material not bonded to the particulate foam. Specifically, plastic materials not bonded to the foam particles and / or elements, particularly polyamides such as polyamide-11 and / or polyamide-12, may be used to form portions of the positioning member. In particular, portions of the positioning member that contact the foam particles and / or elements may be formed of polyamide-11 and / or polyamide-12.

[0275] like Figure 39 As shown, the positioning member 710 includes a coupling structure 712 and a joining structure 714. The coupling structure can be designed to join a part of the member using friction mating joints, snap-fit ​​joints, friction form-fit joints, form-fit joints, surface finishes, friction elements, etc.

[0276] The coupling configuration can be designed to be coupled to a portion of an element using one or more of the following: a surface configuration having a predetermined coefficient of friction, a predetermined surface roughness (e.g., measured in surface roughness Ra (μm)), friction elements such as protrusions, hooks, knobs, bumps, recesses, undercuts, pawls, and / or openings. In some embodiments, portions of the coupling configuration may include deformable materials such as rubber to reduce and / or suppress damage to the element and / or particulate foam.

[0277] like Figure 39 The depicted coupling configuration 712 includes elongated segments 716 and 718. The length of the elongated segments can range from about 1 mm to about 15 mm. In some embodiments, the length of the elongated segments can range from about 5 mm to about 10 mm. For example, some embodiments may include elongated segments with a length ranging from about 6 mm to about 8 mm. In some embodiments, the preferred length of the elongated segments may depend on the design and / or location of the elements and / or positioning components during use.

[0278] Elongated segments can engage a portion of an element. In some embodiments, the elongated segments can be designed such that they apply force to a portion of the element positioned between the elongated segments during use. In such embodiments, the elongated segments can act as pliers and / or clamps. For example, the engagement configuration can form a joint with a portion of the element. In this case, a portion of the element can be designed such that it engages a portion of the coupling configuration.

[0279] Specifically, the elongated segments and / or portions of the coupling structure may include surfaces having a predetermined coefficient of friction, a predetermined surface roughness, friction elements, and / or rubber, such as protrusions, hooks, knobs, bumps, recesses, undercuts, pawls, and openings. In some embodiments, the elongated segments of the positioning member may include rubber to protect the element. For example, portions of the elongated segments may include continuous or discontinuous layers of rubber. In some embodiments, rubber dots may be positioned on the surface of the elongated segments that may contact the element.

[0280] The surface of the coupling structure can be designed such that it is coupled to the surface of the element in such a way that a predetermined force is required to separate the coupling structure from the element.

[0281] In some embodiments, the retaining member can apply force to the engagement structure by securing it against a portion of the mold. For example, the engagement structure can be positioned between a flange on the mold portion and a portion of the retaining member.

[0282] like Figures 39-40As shown, the positioning member 710 includes a segment 720 corresponding to an opening (not shown). The opening in the positioning member can be used to engage a pin, post, or other engaging member positioned in the mold portion. The length of the engaging configuration can be determined by the characteristics of the mold portion, the fixing member, and / or the mold to which the positioning member engages. For example, the length of the coupling configuration can be selected such that it does not extend beyond the fixing member when an element is engaged in a part of the mold.

[0283] Positioning components can have various geometries. For example, Figure 40 A side view of the positioning component is depicted, which has a slightly different configuration for the coupling structure 722. Portions 726 and 726' of the coupling structure 722 are formed from elongated segments 728 and 730. The forming of the elongated segments allows for easier removal of the positioning component from the finished article.

[0284] Figures 41-42 A perspective view depicting embodiments of positioning components 732 and 734 is shown. A slot 736 is designed as part of an engaging element. Engaging configuration 738 includes an opening 740. The opening in the engaging configuration can be used to couple the positioning component to one or more of a mold, mold portion, and / or fixing component using engaging members (e.g., protrusions, flanges, overhangs, hooks, pins, pillars, recesses, etc.). For example, Figure 42 A perspective view depicts a positioning component that can be positioned within a mold and removed from a finished article. In one particular embodiment, an opening in the engagement configuration connecting to the element can engage a pin positioned in the mold portion to position the attached element within the mold portion.

[0285] Figure 43 A cross-sectional view of a removable positioning member 744 coupled to article 746 is depicted. As shown, a coupling configuration 748 is positioned within article 746. A portion of element 750 is shown coupled to positioning member 744 such that segments 752, 754 engage element 750. In some embodiments, the positioning member is designed such that segments of the coupling configuration apply compressive forces to a portion of the element positioned between the segments.

[0286] The engagement structure 756 of the positioning member 744 is exposed from the surface 758 of the article 746. This portion of the engagement structure can be used in conjunction with a fixing member to secure the positioning member and / or element during the forming and / or fusion process of the article.

[0287] In some embodiments, elements such as plates may be embedded in the article, such as insoles. Figure 44A top view of a positioning member 760 is depicted, which is coupled to a portion of a plate 762 embedded in a midsole 764. As shown, a portion 766 of the midsole material is reduced near the positioning member 760. This reduction of the midsole material (e.g., foam material) allows for easier removal of the positioning member after forming and / or fusion. An opening 768 in the engagement structure 770 is used to position and / or secure the plate during the forming and / or fusion process.

[0288] After the formation and / or fusion are complete, the positioning components can be removed from the finished product. For example... Figure 45 As shown, a positioning element (not shown) has been removed from a portion of article 780, leaving a recess 782 in the sidewall 784 of article 780. The size of the recess or pouch may be determined by the size of the positioning element. In some embodiments, the foam material near the positioning element may be trimmed after fusion.

[0289] Element 786 is shown extending through the article to the outer surface 788 of article 780. Element 786 extends continuously along the outer surface of article 780 (including at the recess).

[0290] Figure 46 An example of a midsole 790 formed using removable positioning members 792 is shown. As shown, an element 794 extends through the midsole 790. During formation, a plurality of positioning members coupled to the element are used to position and secure the element in the desired location. In this way, foam material is loaded and fused around the element and the positioning members in a predetermined configuration, at least partially. As shown, element 794 is visible on a portion of the surface of the midsole 790. Alternative embodiments may include an element completely surrounded by foam material.

[0291] In some embodiments, positioning components may be used during the forming process to position and / or secure one or more elements. This allows for the loading of particles and / or fused particles under predetermined configurations and / or conditions. When foam particles are loaded, particles with specific properties can be loaded into specific areas of the mold portion through an inlet and / or feed tube. This may result in areas within the midsole possessing specific properties of interest. Furthermore, in some embodiments, specific areas of the foam may be subjected to a specific and predetermined set of conditions such that the resulting foam has a desired set of properties.

[0292] After the midsole is formed, the positioning components can be removed from the midsole, allowing the midsole to be used in the finished shoe. For example, Figure 47 The image depicts the positioning component 792, which has been removed from the opening 796 in the midsole 790. Figure 48 An enlarged view of the opening 796 from which the positioning component is removed is shown. Furthermore, a portion of element 794 is visible near the surface of the midsole and / or mold line 798.

[0293] like Figure 49 As shown, the positioning member 800 is coupled to the mold 802 at the engaging member 804. Optionally, the positioning member may be secured in place by a fixing member. In some embodiments, the positioning member may be secured by a combination of the engaging member, the mold, and / or the positioning member. In some embodiments, the positioning member and / or mold portion may include interlocking features. For example, the interlocking features may include a combination of interlocking protrusions and / or openings.

[0294] like Figure 49 As shown, the positioning component 800 includes an engagement structure 806 and a coupling structure 808. The engagement structure can be used to couple the positioning component to one or more of a mold, mold portion, and / or fixing component using engagement members (e.g., protrusions, flanges, overhangs, hooks, pins, pillars, recesses, etc.). Figure 49 As shown, the engagement structure 806 of the positioning member 800 is exposed from the surface of the article 814. This portion of the engagement structure can be used in conjunction with a mold, a fixing member, or a mold portion to secure the positioning member and / or elements during the forming and / or fusion process of the article.

[0295] The coupling configuration 808 includes a slot 810 that engages a portion of element 812. As shown, the coupling configuration 808 is positioned within article 814. A portion of element 812 is shown coupled to positioning member 800 such that segments 816, 818 engage element 812. In some embodiments, the positioning member is designed such that segments of the coupling configuration apply compressive forces to a portion of the element positioned between the segments.

[0296] Figure 50 A perspective view depicting an embodiment of a mold portion 820 includes a plurality of pins 824 positioned on sub-components 826 and 828. As shown, the pins 824 include slots 830 for engaging elements (not shown).

[0297] Sub-components can have different gap heights and / or geometries. For example, sub-components 826 and 828 are controlled individually, so each component has a different gap height. When the mold portion includes individually controllable sub-components, the gap height, particle loading, and / or particle compression can be controlled. Therefore, foam particles can be compressed with different forces in different areas of the mold. In some embodiments, particle foams of different densities in different areas of the mold can be obtained. In some embodiments, density variations caused by different thicknesses within the mold cavity can be balanced or compensated.

[0298] In some embodiments, sub-components of the mold portion are formed to have specific geometries. For example, in Figure 51In this design, sub-component 840 forms a border around sub-component 842. Pin 844 is positioned on sub-component 842 and has a slot 844 for engaging an element (not shown). In one particular embodiment, the border sub-component may provide a larger gap height, allowing the granules compressed by the border sub-component to potentially experience a higher amount of compression compared to another sub-component. The greater the gap height, the greater the compression. In some cases, this may result in the granule foam having a higher density. This may result in the granule foam providing more stability in that area. The inner sub-component may have a lower gap height and compress the granule foam to a lesser extent in its path. This may allow the inner region of the granule foam to provide more cushioning than the border region. Controlling the gap height of sub-components in the mold section can allow for tuning of foam articles, such as insoles.

[0299] Figure 52 A perspective view depicting an embodiment of a mold portion 850 having multiple sub-components 852, 854, 856, a vent 858, and a filling port 860. Sub-components 852, 854, and 856 are movable during formation. Figure 52 As shown, the sub-components of the mold section have varying geometries and clearance heights. Sub-component 854 has a grooved cylindrical geometry. Based on the height of sub-component 854, the clearance height of sub-component 854 can be less than the clearance height of sub-component 852 or sub-component 856. However, to determine the clearance height of each sub-component, the amount of movement between the mold position and / or the open and closed positions of the sub-component is measured. In some cases, the clearance height may correspond to the amount of compression experienced by the particles loaded into the mold cavity during molding.

[0300] When using a double-gap or multi-gap configuration that includes sub-components within the mold section, the gap height can vary along the length of the mold. In particular, the gap height can be the amount by which the molds close together.

[0301] Therefore, as shown in the figure, sub-components can have various geometries, gap heights, and / or positions on the mold section, which can be used to tune areas within the article. In particular, areas of the midsole can be tuned by creating areas of different densities. For example, the density of a midsole area can be increased when the amount of granular foam loaded into the area increases and the area undergoes compression comparable to an area with fewer granules. Furthermore, some sub-components can create voids within the midsole. Voids can allow for designs with cavitation within portions of the midsole. For example, some voids can be used to provide cushioning, airflow, predetermined deformation properties (e.g., shear value, strength), moisture wicking, reinforcement (e.g., an object with predetermined stiffness), or other properties of interest. In some cases, objects can be positioned within the voids to impart specific properties to the midsole. For example, a user may be able to customize the characteristics of a shoe by positioning objects such as reinforcements within voids in the midsole, where the shoe incorporates a midsole formed through the process described herein.

[0302] In one embodiment, a void formed through the midsole during fusion can be positioned to provide access to an element embedded in the midsole. Specifically, a threaded external object connector can be accessed through a void in the granular foam material. For example, a racetrack stud can be coupled to an external object connector positioned within the granular foam midsole using threads on both the stud and the external object connector. In some cases, the void (which provides access to the element in the midsole) can be formed by a component for securing the element during fusion. Alternatively, such a void can be formed by a sub-component of one or more mold sections.

[0303] Figure 53 An example of a mold construction for a two-gap mold process is depicted. Mold 900 includes a fixed mold portion 902 and a movable mold portion 904. As shown, foam particles can be conveyed from hoppers 910 and 912 to mold cavities 906 and 908 via inlets 914 and 916. The surfaces of the mold portions and / or sub-components define the mold cavities. For example, mold cavity 906 is defined by a surface of sub-component 918 and a segment 922 of mold surface 926 of mold portion 902, while mold cavity 908 is defined by a surface of sub-component 920 and another segment 924 of mold surface 926 of mold portion 904. During the formation process from an open mold position to a closed mold position, sub-components 918 and 920 move toward mold surface 926. Different geometries of the sub-components can create different gap heights in the cavities defined by the surfaces of the sub-components and the fixed mold portion. This can create different levels of compression in the particulate foam material loaded into the cavities during use. The material loaded into the hoppers can vary depending on the desired properties of the article. For example, as Figure 53As shown, the materials loaded into hoppers 910 and 912 have different properties. In particular, the particles may have different sizes, compositions, chemical structures, foaming levels, melting temperatures, and / or other properties of interest.

[0304] In comparison, Figure 54 A mold configuration for a two-sided gap process is depicted. Mold portions 930 and 932 are movable during formation. Element 934 is positioned between mold portions 930 and 932. Element 934 is secured by fixing members 936, 938, 940, and 942. The fixing members 936, 938, 940, and 942 are fixed such that they firmly hold element 934 in place during movement of mold portions 930 and 932. During loading, particles from hoppers 944 and 946 flow into cavities 952 and 954 through inlets 948 and 950. In some embodiments, different materials can be loaded into the hoppers, such that the cavities contain particles of different sizes, compositions, chemical structures, foaming levels, melt temperatures, and / or other properties of interest.

[0305] Figure 55 A mold construction for use in a molding process combining a dual-gap and a double-sided gap process is illustrated. Mold cavities 970, 972, and 974 are defined by mold portions 960 and 966, element 976, and fixing components 978, 980, 982, and 984. As shown, mold portion 960 includes sub-components 962 and 964. As shown, multiple hoppers 986, 988, and 990 supply granules into mold cavities 970, 972, and 974 through inlets 992, 994, and 996. In this way, different granular materials can be conveyed into different cavities. For example, the granular material conveyed to a particular cavity can be selected based on the specific properties of the granular material. The conveying of the granular material can be carried out under pressure. Combining a dual-gap and a double-sided gap process can provide the ability to tune the properties of the article. For example, the midsole can have multiple areas with different properties. In one particular embodiment, the midsole can have areas with different levels of cushioning and energy return.

[0306] The method can be largely automated, thus allowing for cost-effective and efficient production. Different arrangements of the components depicted in the accompanying drawings or described above, as well as components and steps not shown or described, are also possible. Similarly, some features and sub-combinations are useful and can be used without reference to other features and sub-combinations.

[0307] The present invention is further described by the following numbered paragraphs.

[0308] 1. A midsole comprising: The first foam particle segment has a predetermined first value; and The second particle foam segment has a second value with predetermined characteristics; and An element positioned near at least one of the said granular foam segments; In this configuration, at least a portion of the first granular foam section and the second granular foam section are coupled to each other via fused particles.

[0309] 2. The midsole according to paragraph 1, wherein at least a portion of the element is positioned within at least one of the first granular foam segment or the second granular foam segment.

[0310] 3. The midsole according to paragraph 1, wherein at least a portion of the element is positioned at the interface between the first granular foam segment and the second granular foam segment.

[0311] 4. The midsole according to paragraph 1, wherein the element comprises at least one of the following: a plate, textile, rod, film, foil, conductive element, electronic component, sensor, optical sensor, electrode, near-field communication tag, chip, pressure sensor, flexible display, control panel, LED, or battery.

[0312] 5. The midsole as described in paragraph 1, wherein the first granular foam segment and the second granular foam segment include a predetermined degree of fusion.

[0313] 6. The midsole according to paragraph 1, wherein the predetermined characteristic is at least one of density, flexural stiffness, compressive stiffness, energy return, stiffness, bonding properties, tear strength, peel strength, abrasion resistance, weight and / or deformation characteristics.

[0314] 7. The midsole according to paragraph 1, wherein the element includes a plate positioned at the mold interface of the first granular foam section and the second granular foam section.

[0315] 8. The midsole according to paragraph 1 further includes one or more voids in at least one of the first granular foam segment or the second granular foam segment.

[0316] 9. An article comprising: Expanded granular foam parts; and At least one element is positioned at a predetermined location, at least partially within the foam component.

[0317] 10. The article of manufacture according to paragraph 9, wherein the at least one element is completely embedded in the foam part.

[0318] 11. The article of manufacture according to paragraph 9, wherein the at least one element comprises a first element and a shielding element positioned in the article of manufacture adjacent to the first element.

[0319] 12. The article of manufacture according to paragraph 11, wherein the shielding element reduces the heat exposure of the first element.

[0320] 13. The article of manufacture according to paragraph 11, wherein the shielding element reduces water exposure of the first element.

[0321] 14. The article of manufacture according to paragraph 11, wherein the shielding element reduces the pressure applied to the first element.

[0322] 15. The article of manufacture according to paragraph 11, wherein the shielding element reduces or prevents electromagnetic fields from contacting the first element.

[0323] 16. The article of manufacture according to paragraph 9, wherein the foam component comprises: a first particulate foam segment having a first value of a predetermined characteristic; and a second particulate foam segment having a second value of a predetermined characteristic.

[0324] 17. A method for manufacturing an article from foam particles, comprising: The component, including the joining structure, is placed into the mold between the first and second parts of the mold. Positioning the retaining component within the mold adjacent to the element reduces movement of the element. The particles are loaded into the cavity, on the first and second sides of the element. Move the first and second portions of the mold to the closed position, and Energy is supplied to the mold so that at least a portion of the particles are fused together.

[0325] 18. The method according to paragraph 17, wherein the element comprises at least one of a plate, textile, rod, membrane, foil, conductive element, electronic component, sensor, optical sensor, electrode, near-field communication tag, chip, pressure sensor, flexible display, control panel, LED or battery.

[0326] 19. The method according to paragraph 17, wherein the first and second portions of the mold move independently of each other.

[0327] 20. The method according to paragraph 17 further includes coupling the positioning component to the element and at least one of the fixing component, mold portion, mold, column, or pin.

[0328] 21. The method according to paragraph 17, wherein at least one of the first portion and the second portion further comprises one or more components for engaging the element.

[0329] 22. The method according to paragraph 17, wherein one or more of the joining structures are located on at least one of the outer portion of the element or the inner portion of the element.

[0330] 23. The method according to paragraph 17, wherein the fixing component includes at least one frame element.

[0331] 24. The method according to paragraph 17, wherein the fixing component includes features for receiving at least one engagement structure or positioning component.

[0332] 25. The method according to paragraph 17, wherein the element comprises a plate, and at least one of the first portion or the second portion comprises one or more pins, and wherein placing the plate into the mold further comprises aligning at least one of the engagement structures with the one or more pins, and wherein at least one of the first portion and the second portion of the mold moves independently of the plate.

[0333] 26. The method according to paragraph 17 further includes applying a primer before moving the first and second portions of the mold to the closed position.

[0334] 27. The method according to paragraph 17, wherein at least one of heated steam or electromagnetic radiation is used to fuse the particles.

[0335] 28. The method according to paragraph 17, wherein at least one surface of one or more of the mold portions is porous, and wherein providing energy includes providing steam to the mold.

[0336] 29. The method according to paragraph 17, wherein vacuum pressure is used to hold the element in the proper position within the mold.

[0337] 30. The method according to paragraph 17 further includes placing a second element into the mold.

[0338] 31. The method according to paragraph 17, wherein loading the particles further includes: Particles of the first type, possessing the first set of characteristics, are loaded into the first cavity portion; and The second type of particles with the second set of characteristics are loaded into the second cavity section.

[0339] 32. A shoe comprising: vamp; The granular foam midsole coupled to the upper of the shoe includes: One or more elements embedded in the midsole; and Outsole.

[0340] 33. A shoe comprising: vamp; A granular foam midsole having a peel strength greater than approximately 3 N / mm width and coupled to the upper comprises: One or more elements embedded in the midsole; and Outsole.

[0341] 34. A shoe comprising: vamp; The granular foam midsole coupled to the upper of the shoe includes: One or more reinforcing elements embedded in the midsole; At least one textile, film, or foil element; and Outsole.

[0342] 35. A shoe comprising: vamp; The granular foam midsole coupled to the upper includes at least one textile, film, or foil element; and Outsole; The at least one textile, film, or foil element is coupled to the surface of at least one of the upper, the midsole, or the outsole.

[0343] 36. A shoe comprising: vamp; The granular foam midsole coupled to the upper of the shoe includes: One or more elements positioned in the midsole; The gaps adjacent to some of the one or more elements; and Outsole.

[0344] 37. A shoe comprising: vamp; The granular foam midsole coupled to the upper of the shoe includes: Includes threaded elements positioned within the midsole; A gap adjacent to the element, wherein the gap provides proximity to the element; and Includes a pin with complementary threads, which is coupled to the element; Outsole; A portion of the nail extends from the element through the gap to the outer surface of the outsole.

[0345] Embodiments of the invention have been described for illustrative and non-limiting purposes, and alternative embodiments will become apparent to the reader of this patent. Therefore, the invention is not limited to the embodiments depicted above or in the drawings, and various embodiments and modifications may be made without departing from the scope of the following claims.

Claims

1. A midsole comprising: The first particle foam segment has a first value of a predetermined characteristic; and The second particle foam segment has a second value with predetermined characteristics; and One or more elements are located near at least one of the granular foam segments; In this configuration, at least a portion of the first granular foam section and the second granular foam section are coupled to each other via fused particles.

2. The midsole according to claim 1, wherein, At least a portion of the element is located within at least one of the first granular foam segment, the second granular foam segment, or the interface between the first granular foam segment and the second granular foam segment.

3. The midsole according to claim 1, wherein, At least a portion of the element is located at the interface between the first granular foam segment and the second granular foam segment.

4. The midsole according to claim 1, wherein, The components include at least one of the following: support structures, rods, torsion bars, plates, cages, frames, caps, textiles, films, foils, strands, filaments, external object connectors, electronic components, transmitters, electrodes, sensors, displays, control panels, LEDs, batteries, conductive elements, shielding elements, cushioning elements, tags, chips, and microprocessors.

5. The midsole according to claim 1, wherein, The predetermined characteristic is at least one of the following: density, flexural stiffness, compressive stiffness, energy feedback, fusion amount, stiffness, bonding characteristics, tear strength, peel strength, abrasion resistance, weight and / or deformation characteristics.

6. The midsole according to claim 1, wherein, The component includes a plate positioned at the mold interface between the first granular foam section and the second granular foam section.

7. The midsole according to claim 1, wherein, The element is fully embedded in the midsole.

8. The midsole of claim 1, further comprising one or more voids in at least one of the first granular foam segment or the second granular foam segment.

9. An article comprising: Expanded granular foam parts; and At least one element is positioned at a predetermined location such that the element is fully embedded in the foam part.

10. The article of claim 9, wherein, The foam component includes: a first particulate foam segment having a first value of a predetermined characteristic; and a second particulate foam segment having a second value of a predetermined characteristic.

11. A method for manufacturing an article from foam particles, the method comprising: The component, including the joining structure, is placed into the mold between the first and second parts of the mold. Positioning the retaining component within the mold adjacent to the element reduces movement of the element. The particles are loaded into the cavity, on the first and second sides of the element. The first and second portions of the mold are moved independently of each other, such that the first and second portions are in a closed position, and Energy is supplied to the mold so that at least a portion of the particles are fused together.

12. The method according to claim 11, wherein, The components include at least one of the following: support structures, rods, torsion bars, plates, cages, frames, caps, textiles, films, foils, strands, filaments, external object connectors, electronic components, transmitters, electrodes, sensors, displays, control panels, LEDs, batteries, conductive elements, shielding elements, cushioning elements, tags, chips, and microprocessors.

13. The method of claim 11, further comprising a positioning member that engages the element and at least one of the fixing member, the first mold portion, the second mold portion, the column, or the pin.

14. The method according to claim 11, wherein, At least one of the first mold portion or the second mold portion includes a sub-component.

15. The method according to claim 11, wherein, At least one of the first mold portion or the second mold portion includes two or more sub-components, each of which has a different gap height.

16. The method of claim 11, further comprising: Before moving the first and second portions of the mold to the closed position, apply a primer.

17. The method according to claim 11, wherein, The particles are fused using at least one of heated steam or electromagnetic radiation.

18. The method of claim 11, further comprising: The element is held in place using vacuum pressure.

19. The method of claim 11, further comprising: The second component is placed into the mold.

20. The method of claim 11, wherein, The loaded particles also include: Particles of the first type, possessing the first set of characteristics, are loaded into the first cavity portion; and The second type of particles with the second set of characteristics are loaded into the second cavity section.

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