Patent · US12031007B2 · B2 · US

Foam article with enhanced properties

(11) Publication number

US12031007B2

(21) Application number

18/203,289

(22) Filing date

2023-05-30

(30) Priority date

2020-03-09

(43) Publication date

2024-07-09

(45) Date of grant

2024-07-09

(51) IPC

A43B 1/14; A43D 119/00; B25J 15/00; B29C 44/10; B29C 44/58; B29C 44/60; B29C 45/00; B29C 45/04; B29C 45/78; B29D 35/00; B29D 35/08; B29D 35/12; B29D 35/14; B29K 105/04; B29K 21/00; B29K 67/00; B29L 31/50; C08J 9/12; G06K 19/04

(52) CPC

C08J Working-up; general processes of compounding; after-treatment not covered by subclasses C08B, C08C, C08F, C08G or C08H: 9/12, 2203/06, 2203/08, 2205/044, 2300/30, 2367/00, 2400/30, 2467/00, 9/0061, 9/122, 9/34
A43B Characteristic features of footwear; parts of footwear: 1/00, 1/0063, 1/14, 13/02, 13/026, 13/125, 13/18, 13/187
A43D Machines, tools, equipment or methods for manufacturing or repairing footwear: 119/00, 2200/10
B25J Manipulators; chambers provided with manipulation devices: 15/0019
B29C Shaping or joining of plastics; shaping of material in a plastic state, not otherwise provided for; after-treatment of the shaped products, e.g. repairing: 2945/76531, 2945/76752, 44/10, 44/105, 44/42, 44/424, 44/427, 44/428, 44/58, 44/60, 45/0001, 45/04, 45/16, 45/78
B29D Producing particular articles from plastics or from substances in a plastic state: 35/00, 35/0018, 35/0036, 35/0045, 35/061, 35/062, 35/081, 35/12, 35/122, 35/128, 35/148
B29K Indexing scheme associated with subclasses B29B, B29C or B29D, relating to moulding materials or to materials for {moulds, } reinforcements, fillers or preformed parts, e.g. inserts: 2021/003, 2067/00, 2105/04
B29L Indexing scheme associated with subclass B29C, relating to particular articles: 2031/50, 2031/504
G06K Graphical data reading; presentation of data; record carriers; handling record carriers: 19/045
Y02P Climate change mitigation technologies in the production or processing of goods: 70/62
Y02W Climate change mitigation technologies related to wastewater treatment or waste management: 30/62

(73) Assignee

Nike Inc

(72) Inventors

Paul Irving Archer; Hossein Allen Baghdadi; Jay CONSTANTINOU; Sami Mohamad Fakhouri; Floyd Whitney Miles; Joseph Thomas Muth; Bradley C. Tutmark

(54) Title

Foam article with enhanced properties

(57) Abstract

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.

Full text

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Claims (20)

A foam article for a component of footwear, the foam article comprising: an outer surface comprising a plurality of injection gate vestiges; and a foam article volume comprising a plurality of sub-volumes, each sub-volume being associated with one of the plurality of injection gate vestiges; wherein an aspect ratio for each of the plurality of sub-volumes is greater than 2.7.
The foam article of claim 1, wherein a first gate vestige and a second gate vestige of the plurality of injection gate vestiges define a gate vestige axis, and at least a third gate vestige of the plurality of injection gate vestiges is offset from the gate vestige axis.
The foam article of claim 2, wherein the plurality of injection gate vestiges further comprises a fourth gate vestige that is offset from the gate vestige axis.
The foam article of claim 3, wherein the third gate vestige and the fourth gate vestige are orthogonal to the gate vestige axis.
The foam article of claim 1, wherein the foam article volume comprises an interior microcellular foam structure and the outer surface comprises a closed surface skin with a thickness of between 0.3 millimeters and 1.0 millimeters.
The foam article of claim 1, wherein the foam article is formed by: forming a mixture of molten thermoplastic elastomer composition and a foaming agent; injecting the mixture into a mold cavity through a plurality of injection gates; causing a foaming of said mixture to form the foam article with a microcellular foam structure; and removing the foam article from the mold cavity.
The foam article of claim 6, wherein each of the plurality of injection gate vestiges is associated with one of each of the plurality of injection gates, and the plurality of gate vestiges is formed during the caused foaming.
The foam article of claim 7, wherein each of the sub-volumes is substantially formed from the mixture injected through its corresponding injection gate.
A method for making a foam article for a component of footwear, the method comprising: forming a mixture of molten thermoplastic elastomer composition and a foaming agent; injecting the mixture into a mold cavity of a mold comprising a plurality of injection gates; causing a foaming of said mixture to form a foam article having a microcellular foam structure; and removing the foam article from the mold cavity; wherein: the foam article comprises a volume having a plurality of sub-volumes, with each sub-volume being associated with one of the plurality of injection gates; and each sub-volume has an aspect ratio of greater than 2.7.
The method of claim 9, wherein the injection step comprises injecting the mixture through the plurality of injection gates.
The method of claim 10, wherein each of the sub-volumes is substantially formed from the mixture injected through its corresponding injection gate.
The method of claim 9, further comprising forming a gate vestige for each of the plurality of injection gates during the caused foaming.
The method of claim 8, wherein the causing the foaming the molten polymeric material further comprises forming a foam article with an interior microcellular foam structure with a closed surface skin with a thickness of between 0.3 millimeters and 1.0 millimeters.
A method for making a foam article for a component of footwear, the method comprising: forming a mixture of molten thermoplastic elastomer composition and a foaming agent; injecting the mixture into a mold cavity of a mold, the mold comprising a plurality of injection gates, including a first injection gate and second injection gate defining an injection gate axis, and at least a third injection gate offset from the injection gate axis; causing a foaming of said mixture to form a foam article having a microcellular foam structure; and removing the foam article from the mold cavity.
The method of claim 14, wherein the injection step comprises injecting the mixture through the plurality of injection gates.
The method of claim 15 further comprising forming a gate vestige for each of the plurality of injection gates during the caused foaming.
The method of claim 14, wherein the mold further comprises at least a fourth injection gate offset from the injection gate axis.
The method of claim 17, wherein the third injection gate and the fourth injection gate are orthogonal to the injection gate axis.
The method of claim 14, wherein the causing the foaming the molten polymeric material further comprises forming a foam article with an interior microcellular foam structure with a closed surface skin with a thickness of between 0.3 millimeters and 1.0 millimeters.
The method of claim 15, wherein the foam article comprises a volume having a plurality of sub-volumes, with each sub-volume being associated with one of the plurality of injection gates; wherein each sub-volume has an aspect ratio of greater than 2.7.

Description

Not applicable.

The present invention relates to a foam article, such as a cushioning element, such as a midsole for an article of footwear, having a number of enhanced properties.

Foam articles, such as cushioning elements can be used in an article of footwear, apparel or sporting equipment. An article of footwear may be designed to accommodate a foot of a wearer performing various activities. One component of such articles of footwear is a cushioning element, such as a midsole. The midsole provides cushioning, stability and/or structure to the article of footwear.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential elements of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. The present invention is defined by the claims.

At a high level, aspects herein relate to a foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment. In some aspects, the article comprises a physically foamed, injection molded component, such as a midsole, having a number of beneficial physical characteristics. In some aspects, the physically foamed article is the product of foaming a thermoplastic elastomer material using a physical foaming agent, or a combination of a physical forming agent and a chemical agent.

Citations (86)

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DE4022778A1
JPH05104583A
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JPH08207188A
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TWI256961B
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US20060082010A1
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US20080175942A1
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US20210354349A1

Record as JSON

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  "publication_number": "US12031007B2",
  "country": "US",
  "kind": "B2",
  "title": "Foam article with enhanced properties",
  "abstract": "A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.",
  "claims": [
    "1. A foam article for a component of footwear, the foam article comprising: an outer surface comprising a plurality of injection gate vestiges; and a foam article volume comprising a plurality of sub-volumes, each sub-volume being associated with one of the plurality of injection gate vestiges; wherein an aspect ratio for each of the plurality of sub-volumes is greater than 2.7.",
    "2. The foam article of claim 1, wherein a first gate vestige and a second gate vestige of the plurality of injection gate vestiges define a gate vestige axis, and at least a third gate vestige of the plurality of injection gate vestiges is offset from the gate vestige axis.",
    "3. The foam article of claim 2, wherein the plurality of injection gate vestiges further comprises a fourth gate vestige that is offset from the gate vestige axis.",
    "4. The foam article of claim 3, wherein the third gate vestige and the fourth gate vestige are orthogonal to the gate vestige axis.",
    "5. The foam article of claim 1, wherein the foam article volume comprises an interior microcellular foam structure and the outer surface comprises a closed surface skin with a thickness of between 0.3 millimeters and 1.0 millimeters.",
    "6. The foam article of claim 1, wherein the foam article is formed by: forming a mixture of molten thermoplastic elastomer composition and a foaming agent; injecting the mixture into a mold cavity through a plurality of injection gates; causing a foaming of said mixture to form the foam article with a microcellular foam structure; and removing the foam article from the mold cavity.",
    "7. The foam article of claim 6, wherein each of the plurality of injection gate vestiges is associated with one of each of the plurality of injection gates, and the plurality of gate vestiges is formed during the caused foaming.",
    "8. The foam article of claim 7, wherein each of the sub-volumes is substantially formed from the mixture injected through its corresponding injection gate.",
    "9. A method for making a foam article for a component of footwear, the method comprising: forming a mixture of molten thermoplastic elastomer composition and a foaming agent; injecting the mixture into a mold cavity of a mold comprising a plurality of injection gates; causing a foaming of said mixture to form a foam article having a microcellular foam structure; and removing the foam article from the mold cavity; wherein: the foam article comprises a volume having a plurality of sub-volumes, with each sub-volume being associated with one of the plurality of injection gates; and each sub-volume has an aspect ratio of greater than 2.7.",
    "10. The method of claim 9, wherein the injection step comprises injecting the mixture through the plurality of injection gates.",
    "11. The method of claim 10, wherein each of the sub-volumes is substantially formed from the mixture injected through its corresponding injection gate.",
    "12. The method of claim 9, further comprising forming a gate vestige for each of the plurality of injection gates during the caused foaming.",
    "13. The method of claim 8, wherein the causing the foaming the molten polymeric material further comprises forming a foam article with an interior microcellular foam structure with a closed surface skin with a thickness of between 0.3 millimeters and 1.0 millimeters.",
    "14. A method for making a foam article for a component of footwear, the method comprising: forming a mixture of molten thermoplastic elastomer composition and a foaming agent; injecting the mixture into a mold cavity of a mold, the mold comprising a plurality of injection gates, including a first injection gate and second injection gate defining an injection gate axis, and at least a third injection gate offset from the injection gate axis; causing a foaming of said mixture to form a foam article having a microcellular foam structure; and removing the foam article from the mold cavity.",
    "15. The method of claim 14, wherein the injection step comprises injecting the mixture through the plurality of injection gates.",
    "16. The method of claim 15 further comprising forming a gate vestige for each of the plurality of injection gates during the caused foaming.",
    "17. The method of claim 14, wherein the mold further comprises at least a fourth injection gate offset from the injection gate axis.",
    "18. The method of claim 17, wherein the third injection gate and the fourth injection gate are orthogonal to the injection gate axis.",
    "19. The method of claim 14, wherein the causing the foaming the molten polymeric material further comprises forming a foam article with an interior microcellular foam structure with a closed surface skin with a thickness of between 0.3 millimeters and 1.0 millimeters.",
    "20. The method of claim 15, wherein the foam article comprises a volume having a plurality of sub-volumes, with each sub-volume being associated with one of the plurality of injection gates; wherein each sub-volume has an aspect ratio of greater than 2.7."
  ],
  "description_excerpt": "Not applicable.\n\nThe present invention relates to a foam article, such as a cushioning element, such as a midsole for an article of footwear, having a number of enhanced properties.\n\nFoam articles, such as cushioning elements can be used in an article of footwear, apparel or sporting equipment. An article of footwear may be designed to accommodate a foot of a wearer performing various activities. One component of such articles of footwear is a cushioning element, such as a midsole. The midsole provides cushioning, stability and/or structure to the article of footwear.\n\nThis Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential elements of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. The present invention is defined by the claims.\n\nAt a high level, aspects herein relate to a foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment. In some aspects, the article comprises a physically foamed, injection molded component, such as a midsole, having a number of beneficial physical characteristics. In some aspects, the physically foamed article is the product of foaming a thermoplastic elastomer material using a physical foaming agent, or a combination of a physical forming agent and a chemical agent.",
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  "assignees": [
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  "inventors": [
    "Paul Irving Archer",
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    "Jay CONSTANTINOU",
    "Sami Mohamad Fakhouri",
    "Floyd Whitney Miles",
    "Joseph Thomas Muth",
    "Bradley C. Tutmark"
  ],
  "filing_date": "2023-05-30",
  "publication_date": "2024-07-09",
  "grant_date": "2024-07-09",
  "priority_date": "2020-03-09",
  "application_number": "US-202318203289-A",
  "family_id": "75252868",
  "cited_by_count": 0,
  "citations": [
    "US3447251A",
    "US3682579A",
    "US3891362A",
    "US3871806A",
    "US4372525A",
    "DE3145346A1",
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    "DE3723830A1",
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    "US20150047775A1",
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