US 12,059,857 B2 · Method for forming a composite sole structure component

Abstract

A method of forming a composite article includes constructing a preform having a strand layer including an interior portion and a peripheral portion surrounding the interior portion. The strand layer includes a plurality of strand segments traversing the interior portion and defining a first strand segment population density and a second strand segment population density. The preform is inserted into the mold cavity so that the interior portion of the preform is received in a molding region of the mold cavity. The molding region has a first thickness corresponding to the first strand segment population density and a second thickness corresponding to the second strand segment population density. Following the inserting, the mold is closed and the interior portion of the preform is compressed within the molding region. In the closed mold, the peripheral portion of the strand layer may be maintained in a loose state within the relief region.

Claims20

Dependent claims

A method of forming a composite article, the method comprising:

inserting a preform into a mold cavity of a mold, the preform having a strand layer including strand segments disposed in an interior portion of the strand layer and strand loops that connect adjacent ones of the strand segments in a peripheral portion of the strand layer, wherein the inserting includes inserting the interior portion of the preform into a molding region of the mold cavity and inserting the peripheral portion of the preform into a relief region of the mold cavity;
closing the mold following insertion of the preform into the mold cavity;
compressing the interior portion of the preform within the molding region in the closed mold;
maintaining the peripheral portion loose within the relief region during compression of the interior portion;
and
removing the strand loops after compression of the interior portion.

3 more elements

A method of forming a composite article, the method comprising:

constructing a preform having a strand layer including an interior portion and a peripheral portion surrounding the interior portion, the strand layer including a plurality of strand segments traversing the interior portion and defining a first strand segment population density in a first area of the interior portion, a second strand segment population density in a second area of the interior portion, and strand loops disposed in the peripheral portion and connecting adjacent segments of the plurality of strand segments;
inserting the preform into a molding region of a mold cavity of a mold including inserting the first area of the interior portion in a first portion of the molding region having a first thickness corresponding to the first strand segment population density and inserting the second area of the interior portion in a second portion of the molding region having a second thickness corresponding to the second strand segment population density;
closing the mold following insertion of the preform into the molding region;
compressing the interior portion of the preform within the molding region in the closed mold;
and
removing the strand loops after compression of the interior portion.

3 more elements

Dependencies are inferred from the claim text.

Method for forming a composite sole structure component

Life of this patent

Method for forming a composite sole structure component

Life of this patent

Abstract

Claims20