US 11,884,005 B2
Methods of manufacturing articles utilizing foam particles
Jay Constantinou, Beaverton, OR (US); Harleigh Doremus, Portland, OR (US); Luis Folgar, Beaverton, OR (US); Brandon Kvamme, Beaverton, OR (US); and Denis Schiller, Vancouver, WA (US)
Assigned to NIKE, Inc., Beaverton, OR (US)
Filed by NIKE, Inc., Beaverton, OR (US)
Filed on Jan. 21, 2021, as Appl. No. 17/154,863.
Application 16/832,717 is a division of application No. 16/693,206, filed on Nov. 22, 2019, granted, now 11,090,863.
Application 17/154,863 is a continuation of application No. 16/832,717, filed on Mar. 27, 2020, granted, now 10,946,583.
Application 16/693,206 is a continuation of application No. 15/995,870, filed on Jun. 1, 2018, granted, now 10,864,676, issued on Dec. 15, 2020.
Claims priority of provisional application 62/626,358, filed on Feb. 5, 2018.
Claims priority of provisional application 62/513,959, filed on Jun. 1, 2017.
Prior Publication US 2021/0206054 A1, Jul. 8, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. C08J 9/228 (2006.01); A43B 13/04 (2006.01); B32B 27/14 (2006.01); B32B 7/12 (2006.01); B32B 5/16 (2006.01); A43B 13/18 (2006.01); B32B 27/36 (2006.01); B29C 64/153 (2017.01); B29D 35/12 (2010.01); B29C 67/20 (2006.01); B33Y 80/00 (2015.01); C08J 9/12 (2006.01); C08J 9/232 (2006.01); C08J 9/16 (2006.01); B29C 64/176 (2017.01); B29C 64/182 (2017.01); B29C 64/264 (2017.01); A43B 13/02 (2022.01); B32B 5/24 (2006.01); B29C 64/268 (2017.01); B33Y 70/00 (2020.01); B29C 64/171 (2017.01); B29C 64/165 (2017.01); B29K 25/00 (2006.01); B29C 35/08 (2006.01); B29K 77/00 (2006.01); B29K 105/24 (2006.01); B29K 79/00 (2006.01); B29K 21/00 (2006.01); B29K 105/00 (2006.01); B29K 75/00 (2006.01); B29L 31/50 (2006.01); B33Y 70/10 (2020.01); B33Y 10/00 (2015.01); B29C 71/00 (2006.01); B29K 67/00 (2006.01); B29K 71/00 (2006.01); B29K 105/04 (2006.01)
CPC B29C 64/153 (2017.08) [A43B 13/02 (2013.01); A43B 13/023 (2013.01); A43B 13/04 (2013.01); A43B 13/188 (2013.01); B29C 64/165 (2017.08); B29C 64/171 (2017.08); B29C 64/176 (2017.08); B29C 64/182 (2017.08); B29C 64/264 (2017.08); B29C 64/268 (2017.08); B29C 67/20 (2013.01); B29C 67/205 (2013.01); B29D 35/122 (2013.01); B32B 5/245 (2013.01); B33Y 70/00 (2014.12); B33Y 80/00 (2014.12); C08J 9/122 (2013.01); C08J 9/16 (2013.01); C08J 9/232 (2013.01); B29C 35/0805 (2013.01); B29C 2035/0822 (2013.01); B29C 2035/0833 (2013.01); B29C 2035/0838 (2013.01); B29C 2035/0855 (2013.01); B29C 2071/0027 (2013.01); B29K 2021/003 (2013.01); B29K 2025/06 (2013.01); B29K 2067/006 (2013.01); B29K 2071/00 (2013.01); B29K 2075/00 (2013.01); B29K 2077/00 (2013.01); B29K 2079/08 (2013.01); B29K 2105/04 (2013.01); B29K 2105/24 (2013.01); B29K 2105/251 (2013.01); B29K 2995/007 (2013.01); B29K 2995/0063 (2013.01); B29K 2995/0091 (2013.01); B29K 2995/0094 (2013.01); B29L 2031/50 (2013.01); B29L 2031/504 (2013.01); B33Y 10/00 (2014.12); B33Y 70/10 (2020.01); C08J 2201/03 (2013.01); C08J 2203/06 (2013.01); C08J 2203/08 (2013.01); C08J 2207/00 (2013.01); C08J 2300/22 (2013.01); C08J 2300/26 (2013.01); C08J 2367/02 (2013.01); Y10T 428/2982 (2015.01)] 20 Claims
OG exemplary drawing
 
1. An article comprising:
a structure formed of a plurality of affixed foam particles, wherein
each individual foam particle of the plurality of affixed foam particles is formed of a thermoplastic elastomer material having a coating, wherein the coating comprises a monomeric or polymeric binder, wherein, in an interior region of the structure, the individual foam particle of the plurality is affixed to one or more adjacent foam particles by one or more binding regions including the coating and excluding the thermoplastic elastomer of the foam particle, wherein a plurality of affixed foam particles have one or more gaps between adjacent foam particles and wherein the gaps are between the one or more binding regions of the individual foam particle separating the individual foam particle from the one or more adjacent foam particles to which it is affixed, the gaps occupying at least 10 percent of a total volume of the structure,
the one or more adjacent foam particles comprise the thermoplastic elastomer material having a coating, wherein the coating comprises a monomeric or polymeric binder,
the binding regions include a portion of coating from the individual foam particle, a portion of coating from at least one of the one or more adjacent foam particles, a portion of the coating from the individual foam particle intermingled with a portion of the coating from at least one of the one or more adjacent foam particles, or any combination thereof.