Components for articles of footwear and athletic equipment are provided including a high energy return foam having improved abrasion resistance. A variety of foams and foam components and compositions for forming the foams are provided. In some aspects, the foams and components including the foams can have exceptionally high energy return while also having improved durability and softness and an improved abrasion resistance. In particular, midsoles including the foams are provided for use in an article of footwear. Methods of making the compositions and foams are provided, as well as methods of making an article of footwear including one of the foam components. In some aspects, the foams and foam components can be made by injection molding or injection molding followed by compression molding.

The present invention generally relates to methods of printing articles using three-dimensional printing and other printing techniques, and to articles formed from such techniques, including the printing of articles of footwear containing particles. Certain embodiments are generally directed to composites comprising particles (e.g., reinforcing particles), for example, rubber particles. The particles may be used, for example, to increase slip or abrasion resistance. The composites may also contain polyurethanes or other compounds, e.g., to facilitate fabrication, e.g., using three-dimensional printing and other printing techniques. Other embodiments are directed to methods of making or using such articles. For example, in some embodiments, a composite may be prepared by mixing particles (e.g., reinforcing particles) with at least a first fluid and a second fluid within a nozzle, such as a microfluidic printing nozzle, which may be used to direct the resulting product onto a substrate.

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 method of manufacturing an article includes forming a fluid-filled bladder element from polymeric material. The method further includes securing an overlay to the polymeric material. At least one portion of the overlay is substantially transparent, and an image on one of the fluid-filled bladder element and the overlay is aligned with and exposed to view through the at least one portion of the overlay that is substantially transparent. The fluid-filled bladder element is assembled in the article so that a first portion of the fluid-filled bladder element and the image are exposed to view, and a second portion of the fluid-filled bladder element is blocked from view by the article. An article includes the fluid-filled bladder element with the image, and with the overlay secured to the fluid-filled bladder element.

A method of making a foamed article comprises (a) injection molding a molten thermoplastic elastomer to form an precursor; (b) crosslinking the thermoplastic elastomer; (c) heating the thermoplastic elastomer to a first temperature to soften the thermoplastic elastomer; (d) infusing the thermoplastic elastomer with at least one inert gas at a first pressure that is sufficient to cause the at least one inert gas to permeate into the softened thermoplastic elastomer; and (e) while the article is softened, reducing the pressure to a second pressure below the first pressure to at least partially foam the precursor into a foamed article, wherein the foamed article is substantially the same shape as the precursor.

This document discloses a process for manufacturing recyclable injection molded microcellular foams for use in, footwear components, seating components, protective gear components, and watersport accessories. The process includes the steps of providing a thermoplastic polymer which comprises at least one monomer derived from depolymerized post-consumer plastic, inserting a fluid into a barrel of a molding apparatus. The fluid is introduced under temperature and pressure conditions to produce a super critical fluid. The process further includes mixing the thermoplastic polymer and super critical fluid so as to create a single phase solution, and injecting the single phase solution into a mold of an injection molding machine under gas counter pressure. The process further includes foaming the single phase solution by controlling the head and temperature conditions within the mold.

A foaming process and a method for operation of the foaming process are provided. The method includes flowing a molten polymeric material into a mold from an upstream device, receiving the molten polymeric material in a cavity of the mold, and maintaining a repeatable, uniform pressure profile as the molten polymeric material is delivered into the mold.

A cushioning article comprises a first and a second polymeric sheet bonded to one another and enclosing an interior cavity. The polymeric sheets retain a gas in the interior cavity. A tensile component disposed in the interior cavity includes a first tensile layer, a second tensile layer, and a plurality of tethers spanning the interior cavity and connecting the first tensile layer to the second tensile layer. An inwardly-protruding bond joins the first polymeric sheet to the first tensile layer, protrudes inward from the first polymeric sheet toward the second polymeric sheet, and partially traverses the plurality of tethers. The first polymeric sheet is displaced from the first tensile layer adjacent to the inwardly-protruding bond by the gas. A method of manufacturing a cushioning article is disclosed.

Compression molded foam articles are provided having a closed cell foam structure comprising a plurality of cells having an anisotropic cell shape. The disclosed compression molded foam articles can be used as components or parts of a variety of articles, including articles of footwear and athletic equipment. Methods are disclosed for making the disclosed compression molded foam articles from a foamed preform having an elastomeric closed cell foam with substantially isotropic cell shape. 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.

The present invention provides a method of producing the composite comprising: a) melt blending the matrix with the fibers to produce a melted composite, b) injecting the melted composite into a mold and allowing the melted composite to solidify and, c) removing at least a portion of the outermost layer of a composite such that the fibers protrude from the surface of the composite. Also provided is composite produced by the methods of the invention comprising soft and hard fibers embedded in a soft rubber-like matrix, wherein the fibers protrude from the composite's surface. In specific embodiments, the composite comprises carbon fibers and poly(p-phenylene-2,6-benzobisoxazole) (PBO) fibers in a thermoplastic polyurethane (TPU) matrix, wherein the fibers protrude from the composite's surface. Slip-resistant product comprising the composite are also provided.