US 11,987,915 B2
Foamed articles and methods of making the same
Yihua Chang, Portland, OR (US); Lyle R. Hanson, Beaverton, OR (US); Petr Khlyabich, Beaverton, OR (US); and Richard L. Watkins, Portland, OR (US)
Assigned to NIKE, INC., Beaverton, OR (US)
Filed by NIKE, Inc., Beaverton, OR (US)
Filed on Jan. 5, 2022, as Appl. No. 17/647,021.
Claims priority of provisional application 63/246,486, filed on Sep. 21, 2021.
Prior Publication US 2023/0091558 A1, Mar. 23, 2023
This patent is subject to a terminal disclaimer.
Int. Cl. C08J 9/35 (2006.01); C08J 9/00 (2006.01); C08J 9/12 (2006.01); D04H 1/4391 (2012.01)
CPC D04H 1/43916 (2020.05) [C08J 9/0061 (2013.01); C08J 9/122 (2013.01); C08J 9/35 (2013.01); C08J 2203/06 (2013.01); C08J 2323/08 (2013.01); C08J 2329/04 (2013.01); C08J 2375/04 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method for making a foamed article, the method comprising:
placing an article and carbon dioxide (CO2) in a vessel, wherein the article comprises a foamable fibrous element including a first plurality of filaments, fibers, yarns, or any combination thereof, the first plurality of filaments, fibers, yarns, or any combination thereof comprising a solid foamable material which is a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers;
after the placing, maintaining the vessel at a first pressure and first temperature, wherein the first pressure and first temperature are a pressure and temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining includes holding the article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the foamable fibrous element, thereby forming an infused article;
following the maintaining and holding, optionally exposing the infused article to a second pressure and second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material of the foamable fibrous element;
following the maintaining and holding and the optional exposing, subjecting the infused article to a third pressure and third temperature at which the carbon dioxide infused in the solid foamable material of the foamable fibrous element phase transitions to a gas, thereby expanding the solid foamable material of the foamable fibrous element into a foamed material and forming the foamed article including a foamed foamable fibrous element.