Method for the manufacture of a plastic component, plastic component, and shoe

• US 10,730,259 B2
• Filed: 12/01/2017
• Issued: 08/04/2020
• Est. Priority Date: 12/01/2016
• Status: Active Grant

• Current Assignee: Adidas AG
• Original Assignee: Adidas AG
• Inventors: Kurtz, Maximilian Philipp, Romanov, Victor, Reuber, Norbert, Le, Tru Huu Minh, Seefried, Andreas Johannes, Robertson, Christopher, Holmes, Christopher Edward, Fathi, Amir
• Primary Examiner(s): Rashid, Abbas
• Assistant Examiner(s): Konves, Adrianna N
• Application Number:
  US15/829,230
• Publication Number:
  US 20180154598A1
• Time in Patent Office: 977 Days
• CPC Class Codes: A43B 13/04 Plastics, rubber or vulcanised fibre
• CPC Class Codes: A43B 13/125 characterised by the midsole or middle layer
• CPC Class Codes: A43B 13/187 Resiliency achieved by the features of the material, e.g. foam, non liquid materials
• CPC Class Codes: B29C 2035/0822 using IR radiation
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2035/0855 using microwave
• CPC Class Codes: B29C 2035/0861 using radio frequency
• CPC Class Codes: B29C 35/0805 using electromagnetic radiation
• CPC Class Codes: B29C 43/02 of articles of definite length, i.e. discrete articles B29C35/0227 takes precedence
• CPC Class Codes: B29C 44/0446 by increasing the density locally by compressing part of the foam while still in the mould
• CPC Class Codes: B29C 44/3426 Heating by introducing steam in the mould
• CPC Class Codes: B29C 44/445 in the form of expandable granules, particles or beads
• CPC Class Codes: B29C 44/585 with adjustable size of the mould cavity
• CPC Class Codes: B29C 67/205 comprising surface fusion, and bonding of particles to form voids, e.g. sintering
• CPC Class Codes: B29D 35/0054 by compression moulding, vulcanising or the like; Apparatus therefor
• CPC Class Codes: B29D 35/0063 Moulds
• CPC Class Codes: B29D 35/122 Soles
• CPC Class Codes: B29D 35/142 Soles
• CPC Class Codes: B29D 35/148 Moulds or apparatus therefor
• CPC Class Codes: B29K 2067/003 PET, i.e. poylethylene terephthalate
• CPC Class Codes: B29K 2067/006 : PBT, i.e. polybutylene terephthalate
• CPC Class Codes: B29K 2067/046 : PLA, i.e. polylactic acid or polylactide
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2105/0005 : containing compounding ingredients releasing, lubricating or separating agents B29C33/56, fibers B29K2105/08, B29K2105/12; fillers B29K2105/16, recycled material B29K2105/26
• CPC Class Codes: B29K 2105/002 : Agents changing electric characteristics
• CPC Class Codes: B29K 2105/048 : Expandable particles, beads or granules
• CPC Class Codes: B29K 2995/0063 : Density
• CPC Class Codes: B29K 2995/0082 : Flexural strength; Flexion stiffness
• CPC Class Codes: B29K 2995/0094 : Geometrical properties
• CPC Class Codes: B29L 2031/504 : Soles

Abstract

Described are methods for the manufacture of a plastic component, in particular a cushioning element for sports apparel, a plastic component manufactured with such a method, for example a sole or a part of a sole for a shoe, and a shoe with such a sole. According to an aspect of the invention, a method for the manufacture of a plastic component, in particular a cushioning element for sports apparel, is provided which includes loading a mold with a first material which includes particles of an expanded material, and, during loading the mold, pre-heating the particles by supplying energy, wherein the energy is supplied in the form of at least one electromagnetic field.

Claims

1. A method for manufacturing a plastic component, consisting of:

loading a mold via a feed line, wherein loading of the feed line consists of loading particles of an expanded material into the feed line and pre-heating the particles in the feed line to the mold or in a container prior to being loaded into the feed line by supplying energy in a form of at least one electromagnetic field;

and

molding the particles to form a plastic component;

wherein the particles comprise at least one of;

expanded thermoplastic polyurethane, eTPU;

expanded polyamide, ePA;

expanded polyetherblockamide, ePEBA;

polylactide, PLA;

polyether-block-amide, PEBA;

polyethylene terephthalate, PET;

polybutylene terephthalate, PBT;

thermoplastic polyester ether elastomer, TPEE;

polyether ketone, PEK;

polyether ether ketone, PEEK;

polyetherketoneketone, PEKK, polyethylene, PE, olefin co-block polymer, OBC;

polyolefin elastomer, POE;

polyethylene co-vinyl acetate, EVA;

polybutylene, PB;

polyisobutylene, PIB;

polyoxymethylene, POM;

polyvinylidene chloride, PVCD;

polyvinyl alcohol, PVAL;

polytetrafluoroethylene, PTFE;

polyvinylidene fluoride, PVDF;

tetrafluoroethylene, FEP;

ethylene-tetrafluoroethylene, ETFE;

polyvinylfluoride, PVF; and

perfluoroalkoxy, PFA.

2. The method according to claim 1, wherein the energy supplied by the at least one electromagnetic field is varied over time.

3. The method according to claim 1, wherein the energy supplied by the at least one electromagnetic field is gradually increased over time.

4. The method according to claim 1, wherein the molding comprises a step of fusing surfaces of the particles by supplying energy in a form of at least one electromagnetic field.

5. The method according to claim 4, wherein the form of the at least one electromagnetic field used for pre-heating the particles is different than the form of the at least one electromagnetic field used for fusing the surfaces of the particles.

6. The method according to claim 1, wherein the energy is supplied in a form of radiation in a microwave range, 300 MHz 300 GHz.

7. The method according to claim 1, wherein the energy is supplied by electromagnetic induction.

8. The method according to claim 4, wherein more energy is supplied to the particles in a first partial region of the mold than in a second partial region of the mold.

9. The method according to claim 4, wherein the energy for fusing surfaces of the particles is supplied to the particles in a first partial region of the mold with an electromagnetic field with a first frequency and in a second partial region of the mold with an electromagnetic field with a second frequency, wherein the second frequency is different from the first frequency.

10. The method according to claim 4, wherein a ratio of an amount of energy absorbed by the particles of the expanded material to a total amount of energy absorbed by the particles of the expanded material and the mold lies in a range of 1.0-0.2.

11. A method for manufacturing a cushioning element for sports apparel, consisting of:

opening a mold by a predetermined amount into a loading position, wherein the mold comprises at least two mold parts and the predetermined amount by which the mold is opened influences an available loading volume of the mold;

loading the mold via a feed line, wherein the loading consists of feeding particles of an expanded material into the loading volume created by opening the mold;

closing the mold into a closed position; and

fusing surfaces of the particles by at least supplying energy in a form of at least one electromagnetic field;

wherein the particles comprise at least one of;

expanded thermoplastic polyurethane, eTPU;

expanded polyamide, ePA;

expanded polyetherblockamide, ePEBA;

polylactide, PLA;

polyether-block-amide, PEBA;

polyethylene terephthalate, PET;

polybutylene terephthalate, PBT;

thermoplastic polyester ether elastomer, TPEE;

polyether ketone, PEK;

polyether ether ketone, PEEK;

polyetherketoneketone, PEKK, polyethylene, PE, olefin co-block polymer, OBC;

polyolefin elastomer, POE;

polyethylene co-vinyl acetate, EVA;

polybutylene, PB;

polyisobutylene, PIB;

polyoxymethylene, POM;

polyvinylidene chloride, PVCD;

polyvinyl alcohol, PVAL;

polytetrafluoroethylene, PTFE;

polyvinylidene fluoride, PVDF;

tetrafluoroethylene, FEP;

ethylene-tetrafluoroethylene, ETFE;

polyvinylfluoride, PVF; and

perfluoroalkoxy, PFA.

12. The method according to claim 11, wherein in the loading position of the mold, the at least two mold parts are in different areas of the mold spaced apart at varying distances compared to the closed position of the mold, so that during the step of closing the mold, the at least two mold parts are moved together over different distances in the different areas.

13. The method according to claim 12, wherein during the step of closing the mold, the particles are differently compressed in the different areas of the mold.

14. The method according to claim 12, wherein the predetermined amount by which the mold is opened influences mechanical properties of the cushioning element.

15. The method according to claim 12, wherein the cushioning element is a shoe sole or part of a shoe sole.

16. A method for manufacturing a plastic component, consisting of:

loading a mold via a first feed line, wherein the loading of the feed line consists of loading particles of an expanded material into the feed line and pre-heating the particles in the feed line to the mold or in a container prior to being loaded into the feed line by supplying energy in a form of at least one electromagnetic field;

loading the mold via at one or more additional feed lines with an additional material, wherein the additional material remains substantially unaltered by the at least one electromagnetic field; and

molding the particles to form a plastic component;

wherein the particles comprise at least one of;

expanded thermoplastic polyurethane, eTPU;

expanded polyamide, ePA;

expanded polyetherblockamide, ePEBA;

polylactide, PLA;

polyether-block-amide, PEBA;

polyethylene terephthalate, PET;

polybutylene terephthalate, PBT;

thermoplastic polyester ether elastomer, TPEE;

polyether ketone, PEK;

polyether ether ketone, PEEK;

polyetherketoneketone, PEKK, polyethylene, PE, olefin co-block polymer, OBC;

polyolefin elastomer, POE;

polyethylene co-vinyl acetate, EVA;

polybutylene, PB;

polyisobutylene, PIB;

polyoxymethylene, POM;

polyvinylidene chloride, PVCD;

polyvinyl alcohol, PVAL;

polytetrafluoroethylene, PTFE;

polyvinylidene fluoride, PVDF;

tetrafluoroethylene, FEP;

ethylene-tetrafluoroethylene, ETFE;

polyvinylfluoride, PVF; and

perfluoroalkoxy, PFA.

17. The method according to claim 16, wherein the additional material comprises a foamed material.

18. The method according to claim 16, wherein the additional material comprises an unfoamed material.

19. The method according to claim 16, wherein the additional material comprises rubber.

20. The method according to claim 16, wherein the additional material and the expanded material are positioned in layers.