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 additive manufacturing methods comprise increasing the temperature of a plurality of foam particles with actinic radiation under conditions effective to fuse a portion of the plurality of foam particles comprising one or more thermoplastic elastomers. Increasing the temperature of the foam particles can be carried out for one or multiple iterations. The disclosed methods can be used to manufacturer articles with sub-regions that exhibit differing degrees of fusion between the foam particles, 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.

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.

A composite seat core material is configured from: a base portion that is formed by fusing thermoplastic resin foamed particles having no through-hole to each other; and a connecting portion that is provided on the upper side of the base portion, and is formed by fusing foamed particles having through-holes to each other, the connecting portion having interconnected void spaces that communicates with the outside. With the outer surface of the connection portion partially exposed at the top surface of the composite seat core material, the base portion and the connecting portion are fixed and integrated with each other. A seat member is formed by laminating a polyurethane foam pad on the top surface of the composite seat core material.

Described are methods for manufacturing a plastic component, in particular a cushioning element for sports apparel, a plastic component manufactured with such methods, for example a sole or a part of a sole for a shoe, and a shoe with such a sole. The method for the manufacture of a plastic component includes loading a mold with a first material includes particles of an expanded material and fusing the surfaces of the particles by supplying energy. The energy is supplied in the form of at least one electromagnetic field.

The present invention relates to an enhanced method for the manufacture of a plastic component (135), in particular a cushioning element for sports apparel, the method comprising: opening a mold (100) by a predetermined amount into a loading position, wherein the mold comprises at least two mold parts (110, 112) and wherein the amount by which the mold is opened influences an available loading volume of the mold, loading a material comprising expanded particles (130) into the loading volume, closing the mold into a closed position, wherein during closing of the mold the mold parts are moved together over different distances (140) in different areas of the mold, compressing the expanded particles by closing the mold and fusing at least the surfaces of the expanded particles to mold the plastic component.

A process for producing shaped parts from particle foams comprising providing particle foam particles, wetting the particle foam particles with an aqueous emulsion of at least one polyolefin and thereby obtaining functionalisable particle foam particles, drying the wetted and functionalisable particle foam particles, shaping the functionalisable particle foam particles, heating the shaped functionalisable particle foam particles to a temperature below the melting range of the particle foam particles and thereby functionalising the shaped functionalisable particle foam particles, heating the shaped, functionalisable particle foam particles to a temperature below the melting range of the particle foam particles and thereby functionalising the shaped, functionalisable particle foam particles, wherein the particle foam particles are bonded together, and cooling and thereby obtaining the particle foam moulding, wherein the aqueous emulsion of the at least one polyolefin is an aqueous emulsion comprising at least one polyolefin converted to the liquid state with an anhydride of an unsaturated carboxylic acid and modified with methacrylic acid ester copolymers.

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.

Ultra high molecular weight polyethylene (UHMWPE) polymers that have an average molecular weight of at least 500,000 g/mol and an enthalpy of at least 190 J/g is provided. The UHMWPE polymer may include at least one comonomer. The UHMWPE polymer is used to form a membrane, that, when expanded, has a node and fibril structure. The UHMWPE membrane has an endotherm of about 150 C. associated with the fibrils in the membrane. The membrane has a percent porosity of at least 25%, and in exemplary embodiments, the percent porosity is at least 60%. Additionally, the UHMWPE membrane has a thickness less than 1 mm. An UHMWPE membrane may be formed by lubricating the UHMWPE polymer, subjecting the lubricated polymer to pressure at a temperature below the melting point of the UHMWPE polymer to form a tape, and expanding the tape at a temperature below the melting temperature of the UHMWPE polymer.

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.

Compositions including a sintered porous ultra-high-molecular-weight polypropylene material having a viscosity average molecular weight over 500,000, an average porc size ranging from 10 m to 200 m, and a porosity ranging from 20% to 60%. Devices and methods including such compositions.