System and method for forming a fill structure

Abstract

A method includes forming a base mold including a base surface, a mold surface formed on an opposite side of the base mold, and a plurality of vacuum ports extending between the base mold and the mold surface; and positioning a filler material on the base mold, the filler material including a first surface and a second surface, the first surface being in contact with the mold surface, the second surface being formed on an opposite side of the filler material from the first surface. The method further includes applying a vacuum through the plurality of vacuum ports and against the first surface of the filler material to draw the filler material into contact with the mold surface; and inserting the filler material into an interior void of a bladder.

Description

Cross-references to related applications

[0001] This PCT international application claims priority to U.S. Nonprovisional Application No. 19 / 089,478, filed March 25, 2025, which claims priority to U.S. Provisional Application No. 63 / 569,926, filed March 26, 2024, pursuant to 35 USC §119(e). The disclosures of these earlier applications are considered part of the disclosure of this application and are incorporated herein by reference in their entirety. Technical Field

[0002] This disclosure generally relates to a system and method for forming a filling structure for footwear and / or clothing articles. Background Technology

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

[0004] Cuffs or air bladders are used in footwear and apparel to provide cushioning and other performance characteristics during use. Such bladders typically comprise one or more polymer films that form the outer layer of the bladder and define an internal chamber containing a compressible material such as a fluid, elastomeric material, and / or a stretching member. The fluid and / or elastomeric material provides the bladder with the ability to absorb and cushion forces applied thereto, while the stretching member helps maintain the desired shape of the bladder in a relaxed state.

[0005] In footwear, a bladder is typically concealed within the sole structure to provide cushioning and responsiveness to the wearer during use. Such a bladder can be contained within the midsole and thus hidden from view. Alternatively, the midsole may include one or more openings through which the bladder is visible along the sidewalls of the sole structure. In practice, such openings can be so large that the bladder forms a significant portion of the sole structure's thickness. In such a configuration, the sidewalls of the bladder can extend between and connect the upper and ground contact surfaces of the footwear.

[0006] Regardless of the specific structure of the pouch and its relationship to other components of the sole structure, the shape, color, and overall appearance of the pouch are generally designed to complement the surrounding structure of the footwear and / or apparel, thereby providing the desired look for the footwear and / or apparel. Attached Figure Description

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

[0008] Figure 1This is an exploded perspective view of an example of a bottom mold with a molding filler according to the mold system of this disclosure;

[0009] Figure 2A It is fluidly connected to the vacuum device according to this disclosure. Figure 1 A schematic diagram of an example of a bottom mold and filling material;

[0010] Figure 2B Based on this disclosure Figure 2A A schematic diagram of the bottom mold and filling material under negative pressure applied by the vacuum device;

[0011] Figure 3 This is an exploded top perspective view of another example of a bottom mold with molding filler for a mold system according to the present disclosure;

[0012] Figure 4 This is a top perspective view of another example of a bottom mold used in a mold system;

[0013] Figure 5 It has molded filler. Figure 3 A schematic diagram of the cross-section of the bottom mold and the vacuum device that applies negative pressure;

[0014] Figure 6A This is a cross-sectional view of another example of a mold system according to the present disclosure, wherein a filling material is disposed between a flexible sheet and a bottom mold on a vacuum surface;

[0015] Figure 6B yes Figure 6A A cross-sectional view of a mold system in which filler material is compressed between a flexible sheet and a bottom mold, wherein a vacuum device is applying negative pressure and the flexible sheet is applying positive pressure;

[0016] Figure 7 This is an exploded perspective view of another example of a mold system according to the present disclosure, which includes a bottom mold, a filling material, and a top mold;

[0017] Figure 8 yes Figure 7 A schematic diagram of a mold system, wherein the top mold applies positive pressure to the filling material, and the vacuum device applies negative pressure to the bottom mold and the filling material;

[0018] Figure 9 This is a side perspective view of the filler according to this disclosure;

[0019] Figure 10 It is formed in accordance with this disclosure. Figure 9 Top perspective view of the filling device;

[0020] Figure 11 yes Figure 9 Side elevation view of the filler;

[0021] Figure 12 yes Figure 9 Top view of the filling material;

[0022] Figure 13A This is a side elevation view of an example of a footwear article including a molded insulator according to the present disclosure, the molded insulator being in a relaxed state;

[0023] Figure 13B This includes those in a contracted state. Figure 13A Side elevation view of footwear products with molded filling;

[0024] Figure 14A This is a side perspective view of another example of a footwear article including a molded insulated element according to the present disclosure, the molded insulated element being in a relaxed state; and

[0025] Figure 14B This includes those in a contracted state. Figure 14A Side perspective view of footwear with molded filling.

[0026] In all the accompanying drawings, the corresponding reference numerals indicate the corresponding parts. Detailed Implementation

[0027] The exemplary configurations will now be described more fully with reference to the accompanying drawings. These exemplary configurations are provided so that this disclosure will be thorough and will fully convey the scope of this disclosure to those skilled in the art. Specific details, such as examples of particular components, apparatus, and methods, are set forth to provide a thorough understanding of the configurations of this disclosure. It will be apparent to those skilled in the art that the specific details are not required, that the exemplary configurations may be embodied in many different forms, and that the specific details and exemplary configurations should not be construed as limiting the scope of this disclosure.

[0028] The terminology used herein is for the purpose of describing specific exemplary configurations only and is not intended to be restrictive. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless the context explicitly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and therefore specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or illustrated, unless specifically identified as such. Additional or alternative steps may be employed.

[0029] When an element or layer is referred to as “on another element or layer,” “joined to,” “connected to,” “attached to,” or “linked to” another element or layer, the element or layer may be directly on, joined to, attached to, or linked to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as “directly on another element or layer,” “directly joined to,” “directly connected to,” “directly attached to,” or “directly linked to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (“between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0030] The terms first, second, third, etc., may be used herein to describe various elements, components, areas, layers, and / or segments. These elements, components, areas, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, area, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms do not imply order or sequence. Therefore, without departing from the teachings of the example configuration, the first element, component, area, layer, or segment discussed below may be referred to as the second element, component, area, layer, or segment.

[0031] In one configuration, a method includes: forming a base mold including a base surface, a mold surface formed on an opposite side of the base mold, and a plurality of vacuum ports extending between the base mold and the mold surface; and positioning a filler material on the base mold, the filler material including a first surface and a second surface, the first surface contacting the mold surface, and the second surface formed on a side of the filler material opposite to the first surface. The method further includes: applying a vacuum through the plurality of vacuum ports and to the first surface of the filler material to draw the filler material into contact with the mold surface; and inserting the filler material into an internal void of a bladder.

[0032] The method may include one or more of the following optional steps. For example, the method may include providing a top mold that includes a mating surface that mates with a mold surface. In this configuration, the top mold may be compressed onto a second surface of the filling material.

[0033] A flexible sheet can be positioned above the mold and filler material. Positive pressure can be applied along the second surface by compressing the flexible sheet along the second surface via an applied vacuum. Applying a vacuum can include positioning the mold and flexible sheet along the vacuum surface and applying negative pressure to the flexible sheet via a vacuum port on the vacuum surface.

[0034] In one configuration, heat can be applied to the bottom mold and / or the filler material.

[0035] Forming the bottom mold may include providing a series of peaks and recesses on the mold surface. Additionally or alternatively, positive pressure may be applied along a second surface of the filler material to form the molded filler.

[0036] In another configuration, a method is provided, comprising: forming a base mold including a base surface and a mold surface formed on a side of the base mold opposite to the base surface; and positioning a filler material on the base mold, the filler material including a first surface and a second surface, the first surface contacting the mold surface, the second surface formed on a side of the filler material opposite to the first surface. The method further comprises: drawing the filler material into contact with the mold surface of the base mold to shape the filler material into the shape of the mold surface and form a filler; and inserting the filler into an internal cavity of a bladder.

[0037] The method may include one or more of the following optional steps. For example, the method may include applying positive pressure along a second surface of the filler material to form a filler. A top mold may be provided, and the top mold may include a mating surface that contacts the second surface of the filler material. Providing the top mold may include forming a surface pattern along the mating surface, the surface pattern of the mating surface nesting with a surface pattern of the mold surface. Applying positive pressure along the second surface may include compressing the top mold against the second surface of the filler material.

[0038] In one configuration, a flexible sheet can be disposed above a base mold and a filler material. Drawing the filler material into contact with the mold surface can include applying negative pressure to a first surface of the filler material. In this configuration, positive pressure can be applied along a second surface of the filler material.

[0039] Heat can be applied to the bottom mold and / or filling material. This filling can then be incorporated into footwear or apparel.

[0040] Details of one or more embodiments of this disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will become apparent from the specification, drawings, and claims.

[0041] refer to Figures 1 to 5An example mold system 10 is provided for molding filler material 100 of filler 102 having a textured outer surface 104. The mold system 10 includes a bottom mold 12, which includes a mold surface 16 and a base surface 18. The mold surface 16 is formed on a first side of the bottom mold 12, and the base surface 18 is formed on a side of the bottom mold 12 opposite to the mold surface 16. Compared to the mold surface 16, the base surface 18 of the bottom mold 12 has a substantially flat profile. The mold surface 16 may define a textured profile including a desired surface pattern 20 to be formed on the outer surface of the filler 102. Figure 1 As depicted, the surface pattern 20 includes peaks 22 and recesses 24, with the vacuum port 26 defined in the recesses 24. While the recesses 24 generally refer to the lowest portion of the mold surface 16 relative to the peaks 22, they can also refer to possible wrinkles or other cracks along the mold surface 16 that may at least partially define the surface pattern 20. The surface pattern 20 may include a plurality of structural geometries that cooperate to define a plurality of peaks 22 and recesses 24 along the mold surface 16. The surface pattern 20 may have a generally rhomboid, lath-shaped, or pyramidal pattern to form the textured outer surface 104 of the filler 102, as described below. Alternatively, alternative shapes and configurations of the surface pattern 20 may be contemplated.

[0042] The bottom mold 12 also includes a plurality of vacuum ports 26 extending through the bottom mold 12 from the base surface 18 to the mold surface 16 with a thickness T. 12 Therefore, the negative pressure P supplied to the bottom mold 12 N Vacuum is transferred to the mold surface 16 via vacuum ports 26. For example, these vacuum ports 26 can extend through the thickness T of the bottom mold 12. 12 And it is usually open at the recess 24 to help provide negative pressure P along the mold surface 16 of the bottom mold 12. N Additionally or alternatively, these vacuum ports 26 may also be formed at the peaks 22 to further aid in providing a vacuum. As described below, these vacuum ports 26 help to draw the filler material 100 onto the mold surface 16 to define a surface pattern 20 along the filler material 100.

[0043] refer to Figures 1 to 2BA filler material 100 is disposed on a bottom mold 12. The filler material 100 has a first surface 106 and a second surface 108, the second surface 108 being disposed on a side of the filler material 100 opposite to the first surface 106. In one configuration, the first surface 106 may be disposed on a mold surface 16 during molding. The filler material 100 may be ethylene-vinyl acetate (EVA) foam capable of being molded or otherwise shaped into a specified configuration. For example, the filler material 100 may take the shape of the surface pattern 20 of the mold surface 16.

[0044] EVA foam is flexible and responsive to applied pressure and heat. Therefore, in addition to the applied negative pressure P N In addition, the filler material 100 and the bottom mold 12 can also utilize thermoforming technology. During thermoforming, heat can be applied to one or both of the filler material 100 and the bottom mold 12 to mold the filler material 100 along the mold surface 16. Thus, the filler material 100 can be thermoformed by the bottom mold 12 to define the textured outer surface 104 of the filler 102.

[0045] Thermoforming typically involves applying heat to surfaces such as a first surface 106 or a second surface 108 of the filler material 100, and / or a mold surface 16. This heat increases the flexibility of the filler material 100, which facilitates molding or otherwise shaping the filler material 100 into a desired form. In some configurations, heat may be applied along the mold surface 16 to subsequently heat the first surface 106 of the filler material 100. It is conceivable that heating both the filler material 100 and the mold surface 16 can maximize the clarity and shaping of the surface pattern 20 along the filler material 100, allowing the second surface 108 to at least partially begin to define the surface pattern 20, as further described below.

[0046] refer to Figures 3 to 5 An example of a bottom mold 12a for a mold system 10 according to the present disclosure is shown. The bottom mold 12a has, with respect to, a bottom mold 12a with respect to, a bottom mold 12a. Figures 1 to 2B The bottom mold 12 discussed has a basically similar structure, except that the surface pattern 20a of the bottom mold 12a is different from the surface pattern 20 discussed above.

[0047] The bottom mold 12a includes a mold surface 16a and a base surface 18a. The mold surface 16a is formed on a first side of the bottom mold 12a, and the base surface 18a is formed on a side of the bottom mold 12a opposite to the mold surface 16a. Compared to the mold surface 16a of the bottom mold 12a, the base surface 18a of the bottom mold 12a has a substantially flat profile. The mold surface 16a may define a textured profile, which includes a desired surface pattern 20a to be formed on the outer surface 104a of the filler 102a. Here, the surface pattern 20a includes a plurality of peaks 22a and recesses 24a that alternate along the mold surface 16a to form a wave pattern along the mold surface 16a. For example, the length L of the bottom mold 12a... 12a It can have a wave-like profile, in which the peaks 22a and the recesses 24a are clearly visible. In contrast, the width W of the bottom mold 12a is... 12a It can have a linear profile, such that a single peak 22a can be visible, or only the first peak 22a1 and the second peak 22a2 can be visible. For example... Figure 3 As depicted, these peaks 22a can have varying heights. For example, the first peak 22a1 can have a height H. 22a1 This height is greater than the height H of the second peak 22a2. 22a2 This can be along the length L of the bottom mold 12a. 12a Define the surface pattern 20a. Additionally or alternatively, these peaks 22a may have a consistent height along the length of the mold surface 16a, such as... Figure 4 The description.

[0048] Like the bottom mold 12, the bottom mold 12a also includes a plurality of vacuum ports 26a that extend from the base surface 18a through the thickness of the bottom mold 12a. Therefore, the negative pressure P supplied to the bottom mold 12a by the vacuum device 200... N The vacuum is transmitted to the mold surface 16a via vacuum ports 26a. For example, these vacuum ports 26a may extend through the recess 24a and help apply negative pressure P along the mold surface 16a of the bottom mold 12a. N .

[0049] During operation, filler material 100a is disposed on mold surface 16a of bottom mold 12a. Filler material 100a has a first surface 106a and a second surface 108a, the second surface 108a being formed on the side of filler material 100a opposite to the first surface 106a. Similar to filler material 100, filler material 100a is subjected to a negative pressure P applied through vacuum port 26a. N And it is drawn onto the bottom mold 12a. For example, the first surface 106a responds to the applied negative pressure P. NAnd it is joined to the mold surface 16a, such as Figure 5 The description.

[0050] Refer again Figure 2A and Figure 2B The elevation view of the mold system 10 shows the filling material 100 disposed on the mold surface 16 of the bottom mold 12. Although the mold system 10 is... Figure 2A and Figure 2B The bottom mold 12a is shown together with the mold base 12, but it should be understood that examples of the bottom mold 12a can be used with the mold system 10. The bottom mold 12 is operatively coupled to a vacuum device 200, which is configured to provide a negative pressure P along the mold surface 16 of the bottom mold 12. N The negative pressure P N The vacuum device 200 supplies the filling material 100 to its first surface 106 through the vacuum port 26 of the bottom mold 12. This negative pressure P... N It is provided along the mold surface 16 to draw the filler material 100 into the recess 24 of the mold surface 16. As described above, the filler material 100 and / or the bottom mold 12 can be heated so that the filler material 100 can be thermoformed through the bottom mold 12 while a negative pressure P is applied. N The heated filler material 100 has increased flexibility, which allows for negative pressure P. N The filler material 100 is drawn downwards and drawn into engagement with the surface pattern 20 of the mold surface 16. The engagement between the filler material 100 and the surface pattern 20 of the mold surface 16 causes the filler material 100 to take the shape of the surface pattern 20, thereby providing the surface pattern 20 for the resulting filler 102.

[0051] As the filler material 100 cools along the bottom mold 12, it solidifies into a surface pattern 20 on the mold surface 16, forming a textured outer surface 104 of the filler 102. It is conceivable that, due to the direct contact between the first surface 106 and the mold surface 16 of the bottom mold 12, the surface pattern 20 can be more clearly defined along the first surface 106 of the filler material 100 compared to the second surface 108. Specifically, although the applied negative pressure P... N The entire filler material 100 is drawn toward the bottom mold 12, but the direct contact between the first surface 106 and the bottom mold 12 compared to the second surface 108 can make the first surface 106 of the filler material 100 clearer.

[0052] Now for reference Figure 1 , Figure 6A and Figure 6BAn example of a mold system 10a according to this disclosure is shown. While any of the bottom molds 12, 12a described herein can be used with mold system 10a, mold system 10a is illustrated herein as having a bottom mold 12 and a filler material 100 to ultimately mold the filler 102. Mold system 10a includes a flexible sheet 40a disposed over the bottom mold 12 and the filler material 100. By way of example and not limitation, the flexible sheet 40a may be formed of a silicone material that can be flexibly disposed along the bottom mold 12 to conform to a surface pattern 20. For example, the flexible sheet 40a may be flexible relative to the bottom mold 12 to optionally take on the shape of the bottom mold 12, including the surface pattern 20, as described below. The flexible sheet 40a is coupled to a vacuum surface 42a on which the bottom mold 12 is disposed. The vacuum surface 42a includes a plurality of vacuum ports 44a in fluid communication with vacuum ports 26 formed through the bottom mold 12. negative pressure P N The vacuum device 200 supplies the bottom mold 12 to the mold surface 16 via vacuum port 26 through vacuum port 44a of vacuum surface 42a.

[0053] A flexible sheet 40a is disposed on at least a portion of the bottom mold 12 and the vacuum surface 42a, such that the negative pressure P provided through the vacuum port 44a of the vacuum surface 42a... N It is also applied to the flexible sheet 40a. As described below, the flexible sheet 40a responds to the negative pressure P. N It is drawn towards the bottom mold 12. A positive pressure P is applied to the flexible sheet 40a along the second surface 108 of the filling material 100. P Furthermore, it substantially compresses the filling material 100 between the flexible sheet 40a and the bottom mold 12.

[0054] As described above, heat can be applied to the filler material 100 to facilitate molding of the filler material 100 through the mold surface 16. For example, a thermoforming process can be used at least in part to mold the filler material 100 by increasing its flexibility. The mold system 10a is in fluid communication with a vacuum device 200, which provides a negative pressure P to the bottom mold 12 and the filler material 100 through vacuum ports 26, 44a. N Vacuum device 200 will apply negative pressure P N The negative pressure applied to the first surface 106 of the filler material 100 draws the filler material 100 into contact with the surface pattern 20 of the mold surface 16 of the bottom mold 12. The negative pressure P N The flexible sheet 40a is also drawn toward the filling material 100, and a positive pressure P is applied to the flexible sheet 40a along the second surface 108 of the filling material 100. PThe filler material 100 is compressed along the mold surface 16. Therefore, using the mold system 10a, a positive pressure P can be simultaneously applied to the filler material 100 during the molding process. P and negative pressure P N .

[0055] In other words, the molding of the filler material 100 using the mold system 10a is partly due to the vacuum device 200 removing air between the bottom mold 12 and the flexible sheet 40a. The negative pressure P applied to the flexible sheet 40a... N This causes the flexible sheet 40a to apply a positive pressure P to the filler material 100. P The flexible sheet 40a typically takes the form of a base mold 12 because it is compressed around the base mold 12. Therefore, due to the compression of the flexible sheet 40a, the filler material 100 directly molds the surface pattern 20 of the base mold 12 onto both the first surface 106 and the second surface 108. In other words, the mold surface 16 responds to the negative pressure P from the vacuum device 200. N A surface pattern 20 is formed along the first surface 106 of the filling material 100, and the flexible sheet 40a applies a positive pressure P to the second surface 108. P A surface pattern 20 is formed along the second surface 108 of the filler material 100. This configuration allows the filler material 100 and the flexible sheet 40a to be subjected to a vacuum (i.e., negative pressure P). N Under the action of [unclear], the filler material 100 is compressed between the bottom mold 12 and the flexible sheet 40a. A negative pressure P can be applied to the filler material 100. N The flexible sheet 40a is molded for a predetermined time to allow the surface pattern 20 to solidify and the filler 102 to be formed. After the predetermined time period, the flexible sheet 40a can be removed from the bottom mold 12, and the formed filler 102 can also be removed.

[0056] For details, please refer to the following: Figure 7 and Figure 8 A mold system 10b is provided. While the mold system 10b may include any of the base molds 12, 12a described herein, the mold system 10b is illustrated as having a base mold 12 to mold the filler 102. The mold system 10b includes a base mold 12 and a second top mold 50b configured to be disposed on the base mold 12. The top mold 50b includes a mating surface 52b and a base surface 54b formed on a side of the top mold 50b opposite to the mating surface 52b. The mating surface 52b has a mating pattern 56b configured to mate with a surface pattern 20 of the base mold 12. For example, the top mold 50b is configured to nest with the base mold 12, wherein the peak 58b of the top mold 50b nests within a recess 24 of the base mold 12.

[0057] The filler material 100 can be positioned on the bottom mold 12 such that the first surface 106 contacts the mold surface 16 of the bottom mold 12. The top mold 50b is positioned on the second surface 108 of the filler material 100 to apply a positive pressure P along the second surface 108 of the filler material 100. P Heat can be applied to the bottom mold 12 and / or the top mold 50b to increase the flexibility of the filler material 100 along the first surface 106 and the second surface 108. As previously described, the filler material 100 can be at least partially thermoformed such that when heat is applied to the bottom mold 12 and the filler material 100, the filler material 100 can retract into the recess 24 of the mold surface 16. Heat can also be applied to the top mold 50b when heat is applied to the second surface 108 of the filler material 100. The positive pressure P applied by the top mold 50b... P The surface pattern 20 of the mold surface 16 is further defined by compressing the filler material 100 along the mold surface 16, and the mating pattern 56b of the mating surface 52b is also defined. For example, the top mold 50b is compressed along the second surface 108 of the filler material 100, such that the mating pattern 56b formed along the mating surface 52b is compressed and formed along the second surface 108 of the filler material 100. The top mold 50b can be compressed via a jig or other known compression device to apply a positive pressure P along the filler material 100. P .

[0058] The bottom mold 12 is in fluid communication with the vacuum device 200, which provides a negative pressure P to the mold surface 16. N The negative pressure P N The filling material 100 is drawn into the recess 24 of the bottom mold 12, while the top mold 50b applies positive pressure P along the second surface 108 of the filling material 100. P After a predetermined time period, the top mold 50b can be removed from the filling material 100 and the bottom mold 12, and the formed filling part 102 can be removed from the bottom mold 12.

[0059] Refer again Figure 6A and Figure 6BA method for molding filler material 100 using an example mold system 10a is provided. Although mold system 10a is shown as an example, it should be understood that any of the examples of mold systems 10 to 10b can be used. In one step, a base mold 12 is formed. The base mold 12 includes a base surface 18 and a mold surface 16 formed on opposite sides of the base surface 18. The base mold 12 also includes a plurality of vacuum ports 26 extending between the base surface 18 and the mold surface 16. Filler material 100 is positioned along the mold surface 16. The filler material 100 includes a first surface 106 and a second surface 108, the first surface 106 contacting the mold surface 16, and the second surface 108 formed on the side of the filler material 100 opposite to the first surface 106. In another step, heat is applied to the second surface 108 of the filler material 100.

[0060] For details, please refer to the following: Figure 6B A vacuum is applied to the first surface 106 of the filler material 100 through the vacuum port 26 of the bottom mold 12. The applied vacuum draws the filler material 100 into contact with the mold surface 16. Optionally, a positive pressure P is applied along the second surface 108 of the filler material. P To form a molded filler 102. A flexible sheet 40a can be provided and disposed on the bottom mold 12 and the filler material 100. A positive pressure P is applied by compressing the flexible sheet 40a along the second surface 108 of the filler material 100 via vacuum. P .

[0061] For details, please refer to the following: Figures 9 to 12 Another example of filler 102b is provided. This filler 102b is illustrated as a skeleton structure having a length L along the filler 102b. 102b Defined waveform. The filler 102b can be printed or otherwise defined using additive manufacturing (including but not limited to shape deposition manufacturing (SDM)), during which the filler 102b is formed using progressive deposition of material. It is also conceivable that the filler 102b can be formed using selective laser sintering (SLS), rapid prototyping, and / or computer numerical control (CNC) machining, which can utilize automated high-speed cutting tools to form the waveform of the filler 102b. These are examples, not limitations, of the waveform. Figure 10 The 3D printer 220b depicted in the image performs additive manufacturing, enabling the use of polymer materials to print filler materials through the progressive deposition of these polymer materials.

[0062] The filler 102b can be formed having multiple layers, such that the first layer 110b can be formed separately using additive manufacturing from the second layer 112b, which is also formed using additive manufacturing. The first layer 110b can be welded to the second layer 112b to form the filler 102b. For example, a recess 114b defined along the first layer 110b can be welded to a peak 120b formed along the second layer 112b to form the filler 102b. Figure 11 As depicted, the peak 120b of the second layer 112b is attached to the recess 114b of the first layer 110b at the attachment region 122b. As described above, the first layer 110b and the second layer 112b can be soldered or otherwise attached to form a filler 102b. By way of example and not limitation, radio frequency (RF) soldering can be used to attach the first layer 110b and the second layer 112b at the attachment region 122b. The filler 102b is generally hollow, such that the first layer 110b and the second layer 112b generally form the framework of the filler 102b, while also including a plurality of cutouts 116b defined between a plurality of ribs 118b. These ribs 118b generally form the peak 120b and the recess 114b, and these cutouts 116b are defined between adjacent ribs 118b.

[0063] like Figure 9 As depicted, the filler 102b typically forms a lattice structure, such that the cutouts 116b form openings defined by the lattice structure penetrating the filler 102b. Although described herein as including a first layer 110b and a second layer 112b, it is contemplated that the filler 102b can be configured from any number of layers, which may be welded to each other or otherwise joined to form the filler 102b. It is further contemplated that the filler 102b can be formed from a plurality of rows 124b, which may be joined together to each other via RF soldering or other practical attachment methods. For example, Figure 12 The diagram illustrates multiple rows 124b joined at attachment area 122b to form filler 102b. (See diagram for reference.) Figure 12 As depicted, these attachment areas 122b extend along the width W of the filler 102b. 102b And thus defined. These attachment areas 122b can also be defined between the recesses 114b of the first layer 110b and the second layer 112b, and simultaneously defined along the width W of the filler 102b. 102b Between adjacent rows 124b.

[0064] Figure 13A and Figure 13BAn example of a footwear article 300 is shown, which includes a padding 102 disposed within the throat 302 of the footwear 300. However, the principles of this disclosure can be used to form padding in other parts of the footwear article 300, such as in the upper 304 or sole structure 306 of the footwear article 300. The principles of this disclosure can also be used to form padding in other articles, including but not limited to clothing articles. Although padding 102 is illustrated, it is contemplated that any of padding 102 to 102b can be used with the footwear 300.

[0065] exist Figure 13A and Figure 13B In this structure, filler 102 is received within a bladder. The bladder may be formed from two opposing sheets of flexible material, such as, for example, thermoplastic polyurethane (TPU). These material sheets may be joined together at their peripheries to define an internal void. Filler 102 may be received within the internal void between the first and second sheets.

[0066] During operation, when the bladder is under atmospheric pressure ( Figure 13A The capsule is in a stationary state, and the filler 102 is in an expanded state. When fluid is removed from the internal voids of the capsule, the sheets move toward each other and the filler 102 is compressed. Figure 13B Compression of the filler 102 compresses the material forming the filler 102 and results in structural compression of the filler 102. The structure of the filler 102 is typically designed to compress in a controlled manner based on the shape of the filler 102. For example, when the filler 102 is subjected to a vacuum within the internal voids of the bladder, the filler 102 will respond by contraction, where each recess becomes smaller and each peak moves closer to its adjacent peak. A similar situation occurs with a bladder including filler 100a, which similarly causes adjacent peaks to move toward each other during compression, thereby reducing the overall length of filler 100a (i.e., due to the reduction in the size of each recess and the movement of adjacent peaks toward each other). In doing so, when fluid is removed from the internal voids, the bladder and filler 102 cooperate to tighten around the wearer to help hold the article in the desired position relative to the wearer.

[0067] When the vacuum is released and fluid is allowed to return to the internal voids of the bladder, the filler 102 automatically returns from a tightened state to an expanded state due to the shape of the filler 102 and the resilient properties of the material forming the filler 102. Therefore, the bladder returns to a relaxed state, and the garment no longer tightens around the wearer.

[0068] Figure 14A and Figure 14BAnother example of footwear article 300a is shown, which includes a padding 102a disposed within the throat 302a of the footwear 300a. However, the principles of this disclosure can be used to form padding in other parts of the footwear article 300a, such as in the upper 304a or sole structure 306a of the footwear article 300a. The principles of this disclosure can also be used to form padding for use in other articles, including but not limited to clothing articles. Although padding 102a is illustrated, it is contemplated that any of padding 102 to 102b can be used with the footwear 300. Padding 102a is used in conjunction with the above-mentioned… Figure 13A and Figure 13B The described filler 102 is received within the internal voids of the bladder in a similar manner. Therefore, when fluid is removed from the internal voids to tighten the bladder around the wearer and maintain the bladder in the desired position relative to the wearer, the filler 102a functions in a similar manner to the filler 102.

[0069] The foregoing description has been provided for purposes of illustration and description. This foregoing description is not intended to be exhaustive or limiting of this disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but where applicable, individual elements or features may be interchangeable and may be used in selected configurations, even if not specifically shown or described. Individual elements or features of a particular configuration may also vary in various ways. Such variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A method comprising: A bottom mold is formed, the bottom mold including a base surface, a mold surface formed on an opposite side of the bottom mold, and a plurality of vacuum ports extending between the bottom mold and the mold surface; The filling material is positioned on the bottom mold, the filling material includes a first surface and a second surface, the first surface is in contact with the mold surface, and the second surface is formed on the side of the filling material opposite to the first surface; Vacuum is applied to the first surface of the filling material through the plurality of vacuum ports to draw the filling material into contact with the mold surface; as well as The filling material is inserted into the internal cavity of the bladder.

2. The method according to claim 1, further comprising providing a top mold, the top mold including a mating surface that mates with the mold surface.

3. The method of claim 2, further comprising compressing the top mold onto the second surface of the filling material.

4. The method of claim 1, further comprising providing a flexible sheet disposed on the bottom mold and the filling material.

5. The method of claim 4, further comprising applying a positive pressure along the second surface by compressing the flexible sheet along the second surface via an applied vacuum.

6. The method of claim 4, wherein applying a vacuum comprises positioning the bottom mold and the flexible sheet along a vacuum surface.

7. The method of claim 6, wherein applying a vacuum comprises applying a negative pressure to the flexible sheet via a vacuum port on the vacuum surface.

8. The method of claim 1, further comprising applying heat to the bottom mold and / or the filling material.

9. The method of claim 1, wherein forming the bottom mold includes providing a series of peaks and recesses on the surface of the mold.

10. The method of claim 1, further comprising applying a positive pressure along the second surface of the filler material to form a molded filler.

11. A method comprising: A bottom mold is formed, the bottom mold including a base surface and a mold surface formed on a side of the bottom mold opposite to the base surface; The filling material is positioned on the bottom mold, the filling material includes a first surface and a second surface, the first surface is in contact with the mold surface, and the second surface is formed on the side of the filling material opposite to the first surface; The filling material is drawn into contact with the mold surface of the bottom mold, so that the filling material is shaped into the shape of the mold surface and forms a filling part; as well as The filler is inserted into the internal cavity of the bladder.

12. The method of claim 11, further comprising applying a positive pressure along the second surface of the filler material to form the filler.

13. The method of claim 12, further comprising providing a top mold, the top mold including a mating surface that contacts the second surface of the filler material.

14. The method of claim 13, wherein providing the top mold includes forming a surface pattern along the mating surface, the surface pattern of the mating surface being nested with a surface pattern of the mold surface.

15. The method of claim 13, wherein applying positive pressure along the second surface comprises compressing the top mold onto the second surface of the filler material.

16. The method of claim 12, further comprising providing a flexible sheet disposed on the bottom mold and the filler material.

17. The method of claim 16, wherein drawing the filler material into contact with the mold surface comprises applying a negative pressure to the first surface of the filler material.

18. The method of claim 17, further comprising applying a positive pressure along the second surface of the filler material.

19. The method of claim 11, further comprising applying heat to the bottom mold and / or the filling material.

20. Incorporating the filler of claim 11 into footwear or clothing articles.

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