# US 10,864,676 B2 · Methods of manufacturing articles utilizing foam particles

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- Number: US 10,864,676 B2
- Document ID: US10864676B2
- Status: Granted
- Kind: B2
- Application number: 15/995,870
- Filed: 2018-06-01
- Published: 2018-12-06
- Granted: 2020-12-15
- Earliest claimed: 2017-06-01
- Assignees: NIKE, Inc.
- Applicants: NIKE, Inc.
- Inventors: Jay Constantinou; Harleigh Doremus; Luis Folgar; Brandon Kvamme; Denis Schiller
- Web page: https://patentgrep.com/patent/US10864676B2

## CPC

- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- A43B 13/023: {Soles with several layers of the same material}
- A43B 13/04: Plastics, rubber or vulcanised fibre
- A43B 13/188: {Differential cushioning regions}
- B29C 64/165: using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
- B29C 64/171: specially adapted for manufacturing multiple 3D objects
- B29C 64/176: Sequentially
- B29C 64/182: in parallel batches
- B29C 64/264: Arrangements for irradiation
- B29C 64/268: using laser beams; using electron beams [EB]
- B29C 67/20: for porous or cellular articles, e.g. of foam plastics, coarse-pored {(chemical aspects of working up macro-molecular substances to porous or cellular articles C08J9/00)}
- B29C 67/205: {comprising surface fusion, and bonding of particles to form voids, e.g. sintering}
- B29D 35/122: {Soles}
- B32B 5/245: {another layer next to it being a foam layer}
- B33Y 70/00: Materials specially adapted for additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C08J 9/122: {Hydrogen, oxygen, CO2, nitrogen or noble gases}
- C08J 9/16: Making expandable particles
- C08J 9/232: by sintering expandable particles
- C08J 9/236: using binding agents
- B29C 35/0805: {using electromagnetic radiation}
- B29C 2035/0822: {using IR radiation}
- B29C 2035/0833: {using actinic light}
- B29C 2035/0838: {using laser}
- B29C 2035/0855: {using microwave}
- B29C 2071/0027: {Removing undesirable residual components, e.g. solvents, unreacted monomers}
- B29K 2021/003: {Thermoplastic elastomers}
- B29K 2025/06: {PS, i.e. polystyrene}
- B29K 2067/006: {PBT, i.e. polybutylene terephthalate}
- B29K 2071/00: Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material
- B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material
- B29K 2077/00: Use of {PA, i.e.} polyamides, e.g. polyesteramides {or derivatives thereof}, as moulding material
- B29K 2079/08: {PI, i.e. polyimides or derivatives thereof}
- B29K 2101/12: Thermoplastic materials
- B29K 2105/04: cellular or porous
- B29K 2105/24: crosslinked or vulcanised
- B29K 2105/251: {Particles, powder or granules (expandable particles B29K2105/046)}
- B29K 2995/0063: Density
- B29K 2995/007: Hardness
- B29K 2995/0091: Damping, energy absorption
- B29K 2995/0094: Geometrical properties
- B29L 2031/48: Wearing apparel
- B29L 2031/50: Footwear, e.g. shoes or parts thereof
- B29L 2031/504: {Soles}
- B29L 2031/52: Sports equipment {; Games; Articles for amusement}; Toys (B29L2031/54 takes precedence)
- B33Y 10/00: Processes of additive manufacturing
- B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
- C08J 2201/03: Extrusion of the foamable blend
- C08J 2203/06: CO2, N2 or noble gases
- C08J 2203/08: Supercritical fluid
- C08J 2207/00: Foams characterised by their intended use
- C08J 2300/22: Thermoplastic resins
- C08J 2300/26: Elastomers
- C08J 2367/02: Polyesters derived from dicarboxylic acids and dihydroxy compounds; (C08J2367/06 takes precedence)
- Y10T 428/2982: Particulate matter [e.g., sphere, flake, etc.]
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Methods for manufacturing articles of footwear are provided. In various aspects, the methods comprise utilizing additive manufacturing methods with foam particles. In some aspects, the disclosed methods comprise selectively depositing a binding material on foam particles in a target area such that the binding material coats at least a portion of defining surfaces of the foam particles with the binding material. The binding material is then cured to affix foam particles in the target area to one another. In various aspects, the disclosed methods can be used to manufacturer articles with sub-regions that differential levels of affixing between the foam particles, and thereby resulting in sub-regions with different properties such as density, resilience, and/or flexural modulus. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

## Claims

### Claim 1

A method according to forming an article, 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.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the applying energy comprises applying energy to substantially all of the arranged plurality of foam particles.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the plurality of foam particles comprise foam particles having a density of about 0.1 grams per cubic centimeter to about 0.8 grams per cubic centimeter.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the plurality of foam particles has a bulk density of about 80 grams per liter to about 200 grams per liter.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the thermoplastic elastomer material is selected from a thermoplastic polyurethane elastomer, a thermoplastic polyurea elastomer, a thermoplastic polyether elastomer, a thermoplastic copolyetherester elastomer, a thermoplastic polyamide elastomer, a thermoplastic polystyrene elastomer, a thermoplastic polyolefin elastomer, a thermoplastic copolyetheramide elastomer, a thermoplastic styrene diene copolymer elastomer, a thermoplastic styrene block copolymer elastomer, a thermoplastic polyamide elastomer, a thermoplastic polyimide elastomer, any copolymer thereof, and any blend thereof.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the thermoplastic elastomer material is characterized by a melting temperature range of at least 10 degrees Celsius over which both the first thermoplastic elastomer material and the second thermoplastic elastomer material exhibit softening and melting behavior as determined using differential scanning calorimetry.

### Claim 7 (depends on 1)

The method according to claim 1, wherein one or more of the arranging the plurality of foam particles, the depositing the binding material in the binding material target area, and the curing the deposited binging material are carried out for multiple iterations.

### Claim 8 (depends on 7)

The method according to claim 7, wherein the article is formed layer-wise from a plurality of layers.

### Claim 9 (depends on 1)

The method according to claim 1, wherein the arranged plurality of foam particles has a number average particle size of about 0.3 millimeters to about 7 millimeters in a longest dimension.

### Claim 10 (depends on 1)

The method according to claim 1, wherein the infrared energy source has a wavelength of from about 1 to about 10 micrometer.

### Claim 11 (depends on 1)

The method according to claim 1, wherein the infrared energy absorber comprises a metal oxide, a metal complex compound, an infrared absorbing dye, or combinations thereof.

### Claim 12 (depends on 11)

The method according to claim 11, wherein the metal oxide is a tin oxide, zinc oxide, copper oxide; antimony-doped tin oxide, indium-doped tin oxide, or combinations thereof.

### Claim 13 (depends on 11)

The method according to claim 11, wherein the metal complex compound comprises a zinc oxide comprising at least one element selected from the group consisting of In, Ga, Al, and Sb, or combinations thereof.

### Claim 14 (depends on 11)

The method according to claim 11, wherein infrared absorbing dye is an anthraquinone dye, cyanine dye, polymethine dye, azomethine dye, azo dye, polyazo dye, diimonium dye, aminium dye, phthalocyanine dye, naphthalocyanine dye, indocyanine dye, naphthoquinone dye, indole phenol dye, triallylmethane dye, metal complex dye, dithiol nickel complex dye, azo cobalt complex dye, a squarylium dye, or combinations thereof.

### Claim 15 (depends on 11)

The method according to claim 11, wherein the infrared energy absorber is present in the binding material at from about 0.001 weight percent to about 0.08 weight percent based on the total weight of the binding material.

### Claim 16 (depends on 11)

The method according to claim 11, wherein the infrared energy absorber is present in the binding material at from about 0.005 weight percent to about 0.06 weight percent based on the total weight of the binding material.

### Claim 17 (depends on 1)

The method according to claim 1, wherein the infrared spectrum is the far infrared spectrum.

### Claim 18 (depends on 1)

The method according to claim 1, wherein the infrared spectrum is near infrared spectrum.

### Claim 19 (depends on 1)

The method according to claim 1, wherein the infrared spectrum is the mid infrared spectrum.

### Claim 20 (depends on 19)

The method according to claim 19, wherein the infrared spectrum has a wavelength of about 700 nanometers to about 1 millimeter.

### Claim 21 (depends on 19)

The method according to claim 19, wherein the infrared spectrum has a wavelength of about 1 micrometer to about 20 micrometers.

### Claim 22 (depends on 19)

The method according to claim 19, wherein the infrared spectrum has a wavelength of about 3 micrometers to about 15 micrometers.

### Claim 23 (depends on 19)

The method according to claim 19, wherein the infrared spectrum has a wavelength of about 3 micrometers to about 8 micrometers.

### Claim 24 (depends on 19)

The method according to claim 19, wherein the infrared spectrum has a wavelength of about 8 micrometers to about 15 micrometers.

### Claim 25 (depends on 19)

The method according to claim 19, wherein the infrared spectrum has a wavelength of about 9 micrometers to about 11 micrometers.