US 11,806,924 B2
Methods of manufacturing articles utilizing foam particles
Jay Constantinou, Beaverton, OR (US); Harleigh Doremus, Portland, OR (US); Luis Folgar, Beaverton, OR (US); Brandon Kvamme, Beaverton, OR (US); Denis Schiller, Vancouver, WA (US); and Krissy Yetman, Portland, OR (US)
Assigned to NIKE, INC., Beaverton, OR (US)
Filed by NIKE, Inc., Beaverton, OR (US)
Filed on Dec. 17, 2021, as Appl. No. 17/644,822.
Application 17/644,822 is a continuation of application No. 16/690,091, filed on Nov. 20, 2019, granted, now 11,241,826.
Application 16/690,091 is a continuation of application No. 15/995,587, filed on Jun. 1, 2018, granted, now 10,974,447, issued on Apr. 13, 2021.
Claims priority of provisional application 62/626,358, filed on Feb. 5, 2018.
Claims priority of provisional application 62/513,959, filed on Jun. 1, 2017.
Prior Publication US 2022/0111586 A1, Apr. 14, 2022
Int. Cl. B29C 64/153 (2017.01); A43B 13/18 (2006.01); B29D 35/12 (2010.01); B29C 67/20 (2006.01); B33Y 80/00 (2015.01); C08J 9/12 (2006.01); C08J 9/232 (2006.01); C08J 9/16 (2006.01); A43B 13/04 (2006.01); B29C 64/176 (2017.01); B29C 64/182 (2017.01); B29C 64/264 (2017.01); A43B 13/02 (2022.01); B32B 5/24 (2006.01); B29C 64/268 (2017.01); B33Y 70/00 (2020.01); B29C 64/171 (2017.01); B29C 64/165 (2017.01); B29K 25/00 (2006.01); B29C 35/08 (2006.01); B29K 77/00 (2006.01); B29K 105/24 (2006.01); B29K 79/00 (2006.01); B29K 21/00 (2006.01); B29K 105/00 (2006.01); B29K 75/00 (2006.01); B29L 31/50 (2006.01); B33Y 70/10 (2020.01); B33Y 10/00 (2015.01); B29C 71/00 (2006.01); B29K 67/00 (2006.01); B29K 71/00 (2006.01); B29K 105/04 (2006.01)
CPC B29C 64/153 (2017.08) [A43B 13/02 (2013.01); A43B 13/023 (2013.01); A43B 13/04 (2013.01); A43B 13/188 (2013.01); B29C 64/165 (2017.08); B29C 64/171 (2017.08); B29C 64/176 (2017.08); B29C 64/182 (2017.08); B29C 64/264 (2017.08); B29C 64/268 (2017.08); B29C 67/20 (2013.01); B29C 67/205 (2013.01); B29D 35/122 (2013.01); B32B 5/245 (2013.01); B33Y 70/00 (2014.12); B33Y 80/00 (2014.12); C08J 9/122 (2013.01); C08J 9/16 (2013.01); C08J 9/232 (2013.01); B29C 35/0805 (2013.01); B29C 2035/0822 (2013.01); B29C 2035/0833 (2013.01); B29C 2035/0838 (2013.01); B29C 2035/0855 (2013.01); B29C 2071/0027 (2013.01); B29K 2021/003 (2013.01); B29K 2025/06 (2013.01); B29K 2067/006 (2013.01); B29K 2071/00 (2013.01); B29K 2075/00 (2013.01); B29K 2077/00 (2013.01); B29K 2079/08 (2013.01); B29K 2105/04 (2013.01); B29K 2105/24 (2013.01); B29K 2105/251 (2013.01); B29K 2995/007 (2013.01); B29K 2995/0063 (2013.01); B29K 2995/0091 (2013.01); B29K 2995/0094 (2013.01); B29L 2031/50 (2013.01); B29L 2031/504 (2013.01); B33Y 10/00 (2014.12); B33Y 70/10 (2020.01); C08J 2201/03 (2013.01); C08J 2203/06 (2013.01); C08J 2203/08 (2013.01); C08J 2207/00 (2013.01); C08J 2300/22 (2013.01); C08J 2300/26 (2013.01); C08J 2367/02 (2013.01); Y10T 428/2982 (2015.01)] 20 Claims
OG exemplary drawing
 
1. An article comprising:
a structure formed of a plurality of layers, wherein each layer comprises a plurality of fused foam particles, wherein the structure is formed layerwise from the plurality of layers,
each individual foam particle of the plurality of fused foam particles includes a first surface formed of a first thermoplastic elastomer material, and the first surface also includes one or more fused regions affixing the individual foam particle to a second surface of one or more adjacent foam particles, the second surface of the one or more adjacent foam particles comprises a second thermoplastic elastomer material;
the fused regions include a portion of the first thermoplastic elastomer material from the first surface of the individual foam particle intermingled with a portion of the second thermoplastic elastomer material from the second surface of the one or more adjacent foam particles;
the structure formed of the plurality of fused foam particles includes a plurality of gaps between particles, with the gaps occupying at least 10 percent of a total volume of the structure; and
prior to fusing, at least 20 percent of the plurality of foam particles are spheroid or ellipsoid in shape and have a number average particle size of about 0.04 millimeters to about 10 millimeters in a longest dimension, and at least 20 percent of the spheroid or ellipsoid foam particles in the structure retain a substantially spheroid or ellipsoid shape.