Moldable article, method of making and composition for making moldable articles

• US 20040166352A1
• Filed: 03/04/2004
• Published: 08/26/2004
• Est. Priority Date: 06/02/2000
• Status: Active Grant

• Current Assignee: Rockport IP Holdings, LLC
• Original Assignee: The Rockport Company LLC (Authentic Brands Group, LLC)
• Inventors: Snow, Rebecca
• Granted Patent: US 7,029,749 B2
• Time in Patent Office: Days
• US Class Current: 428/522
• CPC Class Codes: A43B 1/14 made of plastics A43B1/028 takes precedence
• CPC Class Codes: A43B 7/28 Adapting the inner sole or the side of the upper of the shoe to the sole of the foot
• CPC Class Codes: B29C 2035/0855 using microwave
• CPC Class Codes: B29K 2031/04 Polymers of vinyl acetate, e.g. PVAc, i.e. polyvinyl acetate
• CPC Class Codes: B29L 2031/463 Grips, handles handgrips as part of the body finishing of the vehicles B29L2031/3029
• CPC Class Codes: B29L 2031/4821 Helmets
• CPC Class Codes: B29L 2031/50 Footwear, e.g. shoes or parts thereof
• CPC Class Codes: B32B 2264/02 Synthetic macromolecular particles
• CPC Class Codes: B32B 2266/0235 Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2266/0292 Thermoplastic elastomer
• CPC Class Codes: B32B 2307/21 Anti-static
• CPC Class Codes: B32B 2307/738 Thermoformability
• CPC Class Codes: B32B 2437/02 Gloves, shoes
• CPC Class Codes: B32B 2437/04 Caps, helmets
• CPC Class Codes: B32B 25/045 of foam
• CPC Class Codes: B32B 2571/00 Protective equipment
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: Y10S 428/922 Static electricity metal bleed-off metallic stock
• CPC Class Codes: Y10T 428/249953 : Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249991 : Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249992 : Linear or thermoplastic
• CPC Class Codes: Y10T 428/31928 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer

Abstract

A moldable article that can be custom-fitted to a particular user. Such an article comprises a thermoplastic material such as ethylene vinyl acetate modified by an antistatic agent selected from the group consisting of polyol amines such as ethoxylated amines, ethoxylated fatty alcohols, phosphoric acid esters, quaternary ammonium salts, and amphoteric compounds such as betaine. The article is heated until the thermoplastic material softens, then pressed against a user'"'"'s body part. The article is allowed to cool, resulting in a custom-fitted article. Such articles may be repeatedly re-heated and re-molded and may include, e.g., moldable footbeds, racquet handles, shin guards, helmets, and seats.

Claims

1. A moldable article including a layer consisting essentially of ethyl vinyl acetate and an antistatic agent.

2. The article of claim 1, wherein said layer comprises between approximately ten percent and approximately thirty percent antistatic agent.

3. The article of claim 1, wherein said layer comprises approximately seventy percent ethyl vinyl acetate and approximately thirty percent antistatic agent.

4. The article of claim 1, wherein said antistatic agent is selected from the group consisting of a polyol amine, an ethoxylated fatty alcohol, a phosphoric acid ester, a quaternary ammonium salt, and an amphoteric compound.

5. The article of claim 1, wherein said antistatic agent is a polyol amine.

6. The article of claim 5, wherein said polyol amine is an ethoxylated amine.

7. The article of claim 1, wherein said antistatic agent is an amine derivative having the formula R¹N(R²)₂, wherein R¹ is a hydrophobic alkyl group and R² is an alkyl group substituted by at least one hydrophobic moiety selected from OH, CO₂H, CO₂R³, wherein R³ is an alkyl.

8. The article of claim 7, wherein R² is a hydroxyalkyl group.

9. The article of claim 8, wherein R² is hydroxyethyl.

10. The article of claim 1, wherein said article is used to cushion a part of the body.

11. The article of claim 10, wherein said article is a footbed.

12. The article of claim 10, wherein said article is a handle.

13. The article of claim 12, wherein said handle is a racquet handle.

14. The article of claim 10, wherein said article is a helmet insert.

15. The article of claim 10, wherein said article is a shin guard insert.

16. The article of claim 10, wherein said article is a seat.

17. A footbed comprising a moldable layer consisting essentially of ethylene vinyl acetate and an antistatic agent.

18. The footbed of claim 17, further comprising:

a cushioning layer below said moldable layer.

19. The footbed of claim 17, wherein said antistatic agent is selected from the group consisting of a polyol amine, an ethoxylated fatty alcohol, a phosphoric acid ester, a quaternary ammonium salt, and an amphoteric compound.

20. The footbed of claim 19, wherein said antistatic agent is a polyol amine.

21. The footbed of claim 20, wherein said polyol amine is an ethoxylated amine.

22. The footbed of claim 17, wherein said antistatic agent is an amine derivative having the formula R¹N(R²)₂, wherein R¹ is a hydrophobic alkyl group and R² is an alkyl group substituted by at least one hydrophobic moiety selected from OH, CO₂H, CO₂R³, wherein R³ is an alkyl.

23. The footbed of claim 22, wherein R² is a hydroxyalkyl group.

24. The footbed of claim 22, wherein R² is hydroxyethyl.

25. A method for molding an article, comprising the steps of:

(a) providing ethylene vinyl acetate;

(b) forming a mixture by mixing said ethylene vinyl acetate with an antistatic agent;

(c) rolling said mixture;

(d) sheet processing said mixture;

(e) heating said mixture;

(f) cooling said mixture;

(g) splitting said mixture;

(h) forming said mixture into a layer;

(i) heating said layer;

(j) bringing an object into contact with said heated layer, thereby allowing said layer to substantially conform to the contour of said object; and

(k) allowing said heated layer to cool.

26. The method of claim 25, wherein said method further comprises the step of forming said layer into an insole of a shoe.

27. The method of claim 25, wherein said layer is heated by microwaves.

28. The method of claim 25, wherein said object is a body part.

29. The method of claim 28, wherein said object is a foot.

30. The method of claim 28, wherein said object is a hand.

31. The method of claim 28, wherein said object is a head.

32. The method of claim 25, wherein said mixture comprises between approximately ten percent to approximately thirty percent antistatic agent.

33. The method of claim 25, wherein said mixture comprises approximately seventy percent ethyl vinyl acetate and approximately thirty percent antistatic agent.

34. The method of claim 25, wherein said antistatic agent is selected from the group consisting of a polyol amine, an ethoxylated fatty alcohol, a phosphoric acid ester, a quaternary ammonium salt, and an amphoteric compound.

35. The method of claim 25, wherein said antistatic agent is a polyol amine.

36. The method of claim 35, wherein said polyol amine is an ethoxylated amine.

37. The method of claim 25, wherein said antistatic agent is an amine derivative having the formula R¹N(R²)₂, wherein R¹ is a hydrophobic alkyl group and R² is an alkyl group substituted by at least one hydrophobic moiety selected from OH, CO₂H, CO₂R³, wherein R³ is an alkyl.

38. The method of claim 37, wherein R² is a hydroxyalkyl group.

39. The method of claim 37, wherein R² is hydroxyethyl.