US 11,833,747 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 Jul. 9, 2021, as Appl. No. 17/372,177.
Application 17/372,177 is a continuation of application No. 16/693,206, filed on Nov. 22, 2019, granted, now 11,090,863.
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 2022/0040916 A1, Feb. 10, 2022
Int. Cl. B29C 64/153 (2017.01); A43B 13/18 (2006.01); 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); A43B 13/04 (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)] 25 Claims
OG exemplary drawing
 
1. An article made by a method according to the method comprising:
arranging a plurality of foam particles, wherein the arranged plurality of foam particles comprises a thermoplastic elastomer material, and wherein the arranged plurality of foam particles has a number average particle size of about 0.3 millimeters to about 10 millimeters in a longest dimension;
depositing a binding material in a binding material target area, wherein the binding material target area comprises a portion of the arranged plurality of foam beads, and wherein the depositing coats at least a portion of defining surfaces of the portion of the arranged plurality of foam particles with the binding material, and wherein the binding material comprises a thermal energy absorber, which is an infrared energy absorber; and
curing deposited binding material coating at least a portion of the defining surfaces of the portion of the arranged plurality of foam particles within the binding material target area, wherein curing comprises affixing a portion of the arranged plurality of foam particles within the target area;
wherein the curing comprises:
applying energy to the deposited binding material and the arranged plurality of foam particles in an amount and for a duration sufficient to soften the thermoplastic elastomer material of the coated at least a portion of the defining surfaces of the portion of the arranged plurality of foam particles, wherein the applying energy comprises applying energy within the infrared spectrum; and
decreasing a temperature of the region of the arranged plurality of foam particles to a temperature at or below which the softened thermoplastic elastomer material re-solidifies; thereby affixing at least a portion of the coated at least a portion of the defining surfaces of the portion of the arranged plurality of foam particles in the binding material target area.