# US 2021/0276293 A1 · Footwear mold assembly for injection-molding

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- Number: US 2021/0276293 A1
- Document ID: US20210276293A1
- Status: Published application
- Kind: A1
- Application number: 17/194,815
- Filed: 2021-03-08
- Published: 2021-09-09
- Earliest claimed: 2020-03-09
- Assignees: NIKE, Inc.
- Applicants: NIKE, Inc.
- Inventors: Hossein Allen Baghdadi; Sami Mohamad Fakhouri; Floyd Whitney Miles; Joseph Thomas Muth; Bradley C. Tutmark
- Web page: https://patentgrep.com/patent/US20210276293A1

## CPC

- B29D 35/0018: {Moulds}
- C08J 9/12: by a physical blowing agent
- A43B 1/0063: {made at least partially of material that can be recycled}
- A43B 13/026: {Composites, e.g. carbon fibre or aramid fibre; the sole, one or more sole layers or sole part being made of a composite}
- A43B 13/125: {characterised by the midsole or middle layer}
- A43B 13/187: {Resiliency achieved by the features of the material, e.g. foam, non liquid materials}
- A43D 119/00: Driving or controlling mechanisms of shoe machines; Frames for shoe machines
- B25J 15/0019: {End effectors other than grippers}
- B29C 44/10: Applying counter-pressure during expanding
- B29C 44/105: {the counterpressure being exerted by a fluid}
- B29C 44/42: using pressure difference, e.g. by injection or by vacuum
- B29C 44/424: {Details of machines}
- B29C 44/427: {having several injection gates}
- B29C 44/428: {Mould constructions; Mould supporting equipment}
- B29C 44/58: Moulds
- B29C 44/60: Measuring, controlling or regulating
- B29C 45/0001: {characterised by the choice of material}
- B29C 45/04: using movable moulds {or mould halves}(B29C45/08 takes precedence)
- B29C 45/78: of temperature
- B29D 35/0036: {with displaceable sole plates}
- B29D 35/0045: {Sealing means for the mould cavity}
- B29D 35/061: {by injection moulding}
- B29D 35/062: {using means to bond the moulding material to the preformed uppers}
- B29D 35/081: {by injection moulding}
- B29D 35/122: {Soles}
- B29D 35/128: {Moulds or apparatus therefor}
- B29D 35/148: {Moulds or apparatus therefor}
- C08J 9/0061: {characterized by the use of several polymeric components}
- C08J 9/122: {Hydrogen, oxygen, CO2, nitrogen or noble gases}
- C08J 9/34: Chemical features in the manufacture of articles consisting of a foamed macromolecular core and a macromolecular surface layer having a higher density than the core
- G06K 19/045: {the record carrier being of the non-contact type, e.g. RFID, and being specially adapted for attachment to a disc, e.g. a CD or DVD}
- A43D 2200/10: Fully automated machines, i.e. machines working without human intervention
- B29C 2945/76531: Temperature
- B29C 2945/76752: runners, nozzles
- B29K 2021/003: {Thermoplastic elastomers}
- B29K 2067/00: Use of polyesters {or derivatives thereof}, as moulding material
- B29K 2105/04: cellular or porous
- B29L 2031/50: Footwear, e.g. shoes or parts thereof
- B29L 2031/504: {Soles}
- C08J 2203/06: CO2, N2 or noble gases
- C08J 2203/08: Supercritical fluid
- C08J 2205/044: Micropores, i.e. average diameter being between 0,1 micrometer and 0,1 millimeter
- C08J 2300/30: Polymeric waste or recycled polymer
- C08J 2367/00: Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
- C08J 2400/30: Polymeric waste or recycled polymer
- C08J 2467/00: Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers
- Y02P 70/62: related technologies for production or treatment of textile or flexible materials or products thereof, including footwear
- Y02W 30/62: Plastics recycling; Rubber recycling
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- 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)
- A43B: CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43D: MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
- B25J: MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES ({manipulators specially adapted for use in surgery A61B34/70; manipulators used in cleaning hollow articles B08B9/04}; manipulators associated with rolling mills B21B39/20; manipulators associated with forging machines B21J13/10; {manipulators associated with picking-up and placing mechanisms B23P19/007}; means for holding wheels or parts thereof B60B30/00; {vehicles with ground-engaging propulsion means, e.g. walking members B62D57/02, B62D57/032; devices for picking-up and depositing articles or materials between conveyors B65G47/90, B65G47/91; manipulators with gripping or holding means for transferring packages B65H67/065}; cranes B66C; {manipulators used in the protection or supervision of pipe-line installations F17D5/00; walking equipment adapted for nuclear steam-generators F22B37/006}; manipulators specially adapted for, or associated with, nuclear reactors G21C; {apparatus used for handling wafers during manufacture or treatment of semiconductor H10P72/50})
- 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)
- G06K: GRAPHICAL DATA READING (image or video recognition or understanding G06V); PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
- 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
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02W: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT

## Abstract

Tooling and components of an injection-molding system may be used to mold a foam article. The tooling and components may include features that control parameters of the injection-molding and foaming process, such as temperature, pressure, shot size, shot placement, and the like.

## Claims

### Claim 1

A mold assembly for injection molding a component of an article of footwear, the mold assembly comprising:
a first carrier plate;
a first mold plate coupled to the first carrier plate and comprising a first mold cavity wall;
a mold ring plate abutting the first mold plate and comprising a second mold cavity wall;
a second mold plate abutting the mold ring plate and comprising a third mold cavity wall; and
a second carrier plate coupled to the second mold plate.

### Claim 2 (depends on 1)

The mold assembly of claim 1, wherein at least one of the first carrier plate and the second carrier plate compositionally comprises steel, and wherein the at least one of the first carrier plate and the second carrier plate compositionally comprising steel also comprises a plate-manipulator interface to releasably engage a plate manipulator.

### Claim 3 (depends on 2)

The mold assembly of claim 2, wherein the plate manipulator further comprises a protrusion, and wherein the plate-manipulator interface of the at least one of the first carrier plate and the second carrier plate comprises a recess to receive the protrusion of the plate manipulator.

### Claim 4 (depends on 1)

The mold assembly of claim 1 further comprising, a tooling latch assembly that is selectively convertible back and forth between a connected state and a disconnected state and that is coupled to the first carrying plate, the second carrying plate, or any combination thereof, wherein in a connected state the releasable latch connects the first carrying plate to the second carrying plate, such that the releasable latch impedes the second carrying plate from moving away from the first carrying plate, and wherein in a disconnected state the second carrying plate is free to move away from the first carrying plate.

### Claim 5 (depends on 1)

The mold assembly of claim 1 further comprising, a seal assembly positioned between the first mold plate and the mold ring plate.

### Claim 6 (depends on 1)

The mold assembly of claim 1 further comprising, a seal assembly positioned between the ring mold plate and the second mold plate.

### Claim 7 (depends on 1)

The mold assembly of claim 1, wherein the second mold plate includes a plurality of gates having a gate outlet in the third mold cavity wall.

### Claim 8 (depends on 7)

The mold assembly of claim 7, wherein the plurality of gate outlets are spaced a distance from the first mold cavity wall in a range of about 16 millimeters to about 40 millimeters.

### Claim 9 (depends on 1)

The mold assembly of claim 1, wherein the second mold plate includes a single gate having a single gate outlet in the third mold cavity wall.

### Claim 10 (depends on 1)

The mold assembly of claim 1, wherein the second mold plate includes a side facing away from the mold ring plate and a plate body between the side and the third mold cavity wall; and wherein the second mold plate includes one or more runners having a runner inlet in the side facing away from the mold ring plate.

### Claim 11 (depends on 10)

The mold assembly of claim 10, wherein the second mold plate includes fewer runner inlets than gates.

### Claim 12 (depends on 10)

The mold assembly of claim 10, wherein each runner of the one or more runners is in fluid connection with one or more gates.

### Claim 13 (depends on 1)

The mold assembly of claim 1, wherein the mold ring plate includes a first pin-receiving aperture having a threaded interior wall and the second mold plate includes a second pin-receiving aperture aligned with the first pin-receiving aperture, the second pin-receiving aperture extending entirely though a thickness of the second mold plate; and wherein the mold assembly includes a threaded fastener with a set of threads at one end engaged with the threaded interior wall, a head at the other end, and a fastener body that extends between the set of threads and the head and that includes a length larger than the thickness of the second mold plate.

### Claim 14 (depends on 1)

The mold assembly of claim 1, wherein the first mold plate, the mold ring plate, and the second mold plate comprise a first mold; and wherein the mold assembly further comprises a second mold comprising a third mold plate, another mold ring plate, and a fourth mold plate, the second mold being coupled to the first carrier plate and the second carrier plate.

### Claim 15 (depends on 14)

The mold assembly of claim 14, wherein the first mold comprises a first mold cavity enclosed by the first mold cavity wall, the second mold cavity wall, and the third mold cavity wall; wherein the first mold comprises a second mold cavity; and wherein the second mold comprises a third mold cavity and a fourth mold cavity.

### Claim 16 (depends on 15)

The mold assembly of claim 15, wherein the first mold cavity, the second mold cavity, the third mold cavity, and the fourth mold cavity each comprise a respective three-dimensional (3D) shape of a footwear sole, and wherein the respective 3D shape of the first mold cavity and the third mold cavity comprises a left footwear sole and the respective 3D shape of the second mold cavity and the fourth mold cavity comprises a right footwear sole.

### Claim 17

A mold assembly for injection molding a component of an article of footwear, the mold assembly comprising: a first mold plate comprising a first mold cavity wall; a mold ring plate abutting the first mold plate and comprising a second mold cavity wall; and a second mold plate abutting the mold ring plate and comprising a third mold cavity wall, wherein the second mold plate comprises a first side facing towards the mold ring plate, a second side facing away from the mold ring plate, and a plate body between the first side and the second side; and wherein the second mold plate comprises one or more runner inlets on the second side and one or more gate outlets in the third mold cavity wall.

### Claim 18 (depends on 17)

The mold assembly of claim 17, wherein the second mold plate includes a first gas channel extending entirely through the plate body from the first side to the second side; wherein the mold ring plate includes a second gas channel extending entirely through a plate body of the mold ring plate; wherein the mold assembly includes a vent positioned between the mold ring plate and the first mold plate; and wherein the second gas channel fluidly connects with the first fluid passage and fluidly connects with the vent.

### Claim 19 (depends on 17)

The mold assembly of claim 17, wherein the mold assembly comprises a mold cavity enclosed by the first mold cavity wall, the second mold cavity wall, and the third mold cavity wall; wherein the mold cavity comprises a 3D shape of a footwear sole; and wherein a vent is positioned at least partially around a perimeter of the mold cavity.

### Claim 20 (depends on 17)

The mold assembly of claim 17, wherein the mold assembly comprises a mold cavity enclosed by the first mold cavity wall, the second mold cavity wall, and the third mold cavity wall; wherein the mold cavity comprises a 3D shape of a footwear sole; wherein the one or more gate outlets comprises a single gate outlet that is in the third mold cavity wall and that is in fluid communication with the four runner inlets.