An article of footwear may have an upper and a sole structure secured to the upper. The sole structure has a plurality of support elements, and each of the support elements include a shell and a core. The shell defines an interior void and is formed from a polymer material that extends around substantially all of the void. The core has a shape of the void and is located within the void, with at least a portion of the core being a polymer foam material. The polymer foam material of at least two of the support elements may have different densities.

The present invention relates to a method for producing a PUR/PIR foam body, comprising the steps of providing a mold adapted for applying an underpressure to the interior of the mold; introducing a reaction mixture comprising an isocyanate-reactive component A and an isocyanate B into the mold, and applying an underpressure to the interior of the mold, so the underpressure acts on the introduced reaction mixture. The underpressure is applied to the interior of the mold no later than the reaction mixture has started to set in the mold, and the isocyanate index of the reaction mixture is 300.

A composite structure includes a first face sheet, a second face sheet, and a foam member located between the first face sheet and the second face sheet. The foam member has a molded contour, the mold contour being configured to provide tooling surface for at least one of the first face sheet and the second face sheet prior to curing of the composite structure. A method of making the foam member includes creating a mold tool having an interior surface which resembles the desired outer contour of the foam member. A mixture is poured into a pour opening in the mold tool. The mixture is allowed to polymerize into a foam as the foam expands and distributes within the mold tool. Vent openings in the mold tool are selectively tailored to control the density of the foam member. The foam member is cured in the mold tool.

The present invention is directed to a deep draw microcellularly foamed polymeric container comprising a polymeric sidewall integrally connected to a polymeric base along a bottom edge. The polymeric sidewall and base are contiguous with each other and define a shape of an open top container. The polymeric sidewall and base have a contiguous inner microcellular foam structure (having average cell diameters ranging from about 5 to about 100 microns) surrounded by a smooth outer skin layer integrally connected therewith. The polymeric sidewall defines a container height and a top opening, wherein the top opening defines a top opening width, and wherein the polymeric base defines a container base width, and wherein the area defined by the top opening is greater than the area defined by the polymeric base, and wherein the ratio of the container height (h) to the top opening width (w) is greater than about 1:1 (h:w).

A method of producing a container product comprises providing a mold including a first part and a second part. The mold is closed to define a cavity having a first area and a second area. A molten plastic composition including a polymer and a physical blowing agent is filled into the cavity. Then, the molten plastic composition in the cavity is cooled, such that the molten plastic composition in the first area is completely cooled and solidifies or a central portion of the first area has micro uncooled molten plastic composition. The second area has the plastic composition in the molten state. The first part of the mold is moved in the axial direction. The molten plastic composition in the second area forms a beehive foam after foaming and expansion. Then, the foamed container product in the mold is cooled to take shape and then removed after opening the mold.

A method for producing a molded part, in particular a component of a sporting good, includes providing a mixture of a polymer melt and a foaming agent and injecting the mixture into a mold. The method includes solidifying at least a first portion of the molded part without foaming and at least a second portion of the molded part after foaming inside the mold, wherein the mixture includes a polymer having an average molecular mass corresponding to a viscosity number 130 ml/g, preferably 170 ml/g, more preferably 190 ml/g and most preferably 225 ml/g, wherein the viscosity number is determined via solution viscometry according to the ISO 307 standard.

A variable pressure controlled injection method, a semi-finished injection product, and a co-injection product manufacturing method are provided. The variable pressure controlled injection method includes providing an injection molding system, injecting a first foaming material, and performing a foaming step. The injection molding system includes a first variable pressure mold and a second variable pressure mold. In the foaming step, the first variable pressure mold and the second variable pressure mold apply a first pressure and a second pressure to the first foaming material respectively, and then the first foaming material is heated to form a semi-finished injection product. The semi-finished injection product includes a microporous layer and a solidified layer. The co-injection product manufacturing method includes injecting a second foaming material onto the semi-finished injection product and heating under a stable internal pressure to complete foam and obtain a co-injection product.