Method of making foams using partial molds
First Claim
1. A method of making a closed-cell foamed article comprisinga) forming an unfoamed article at a first location using a three-dimensional printing process, the unfoamed article comprising unfoamed, thermoplastic polymer deposited as interconnected, unfoamed, thermoplastic polymeric members spaced to define openings therebetween;
- b) heating the unfoamed article to a first temperature to soften the unfoamed article and infusing the softened unfoamed 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 unfoamed article;
c) cooling the unfoamed article to a second temperature and reducing the pressure to a second pressure;
d) transferring the cooled unfoamed article to a partial mold at a second location; and
e) heating the unfoamed article in the partial mold to a third temperature to soften the unfoamed article and at least partially foam the unfoamed article, wherein pressure is adjusted to a third pressure sufficient to allow the infused inert gas to partition out of the softened unfoamed article to at least partially foam the unfoamed article into a foamed article, and 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
20 Claims
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1. A method of making a closed-cell foamed article comprising
a) forming an unfoamed article at a first location using a three-dimensional printing process, the unfoamed article comprising unfoamed, thermoplastic polymer deposited as interconnected, unfoamed, thermoplastic polymeric members spaced to define openings therebetween; -
b) heating the unfoamed article to a first temperature to soften the unfoamed article and infusing the softened unfoamed 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 unfoamed article; c) cooling the unfoamed article to a second temperature and reducing the pressure to a second pressure; d) transferring the cooled unfoamed article to a partial mold at a second location; and e) heating the unfoamed article in the partial mold to a third temperature to soften the unfoamed article and at least partially foam the unfoamed article, wherein pressure is adjusted to a third pressure sufficient to allow the infused inert gas to partition out of the softened unfoamed article to at least partially foam the unfoamed article into a foamed article, and 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)
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Specification