Method of making foams using partial molds
First Claim
1. A method of making a closed-cell foamed article comprisinga) depositing unfoamed, thermoplastic polymer onto a support surface in a three-dimensional printing process to form an unfoamed article;
- b) heating the article to soften the article and infusing the softened article with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened article; and
c) while the article is softened, reducing the pressure to second pressure below the first pressure to at least partially foam the article, wherein a surface of a partial mold limits foam expansion in at least one direction but less than all directions.
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Accused Products
Abstract
A method of making a foamed article, for example a foamed component for an article or footwear, comprises depositing an unfoamed, thermoplastic polymer onto a support surface in a three-dimensional printing process to form an unfoamed article; heating the article to soften the article and infusing the softened article with at least one inert gas at a first pressure greater than atmospheric pressure that is sufficient to cause the at least one inert gas to permeate into the softened article; and reducing the pressure to second pressure below the first pressure while the article is softened to at least partially foam the article, wherein a surface of a partial mold limits foam expansion in at least one direction but less than all directions. The article or a part of the article may be made by printing a thermoplastic polymeric material with a three-dimensional printer in a structure of interconnected, unfoamed, thermoplastic polymeric members spaced to define openings between the thermoplastic polymeric members.
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Citations
33 Claims
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1. A method of making a closed-cell foamed article comprising
a) depositing unfoamed, thermoplastic polymer onto a support surface in a three-dimensional printing process to form an unfoamed article; -
b) heating the article to soften the article and infusing the softened article with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened article; and c) while the article is softened, reducing the pressure to second pressure below the first pressure to at least partially foam the article, wherein a surface of a partial mold limits foam expansion in at least one direction but less than all directions. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33)
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Specification