Patent Publication Number: US-2022219377-A1

Title: System and methods for thermoforming articles

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional application No. 62/662,624, filed on Apr. 25, 2018, and entitled System and Methods for Thermoforming Articles, the entire contents of which are incorporated by reference herein. 
    
    
     TECHNICAL FIELD 
     The present disclosure is directed to a system and methods for thermoforming articles and for preparing articles for thermoforming. 
     BACKGROUND 
     Thermoforming an article can include heating the article to, or above, a specific temperature and then cooling the article to, or below, a specific temperature. In certain processes, during this heating and cooling, the article may be formed into a particular shape or structure. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Illustrative aspects of the present invention are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein: 
         FIG. 1  depicts a top perspective view of a thermoforming system having a heating station including a plurality of heating chambers, a cooling station, a dryer, a loading/unloading station, and an article movement mechanism, in accordance with aspects hereof; 
         FIG. 2  depicts a top perspective view of a heating chamber with a portion removed to reveal an article of footwear positioned within the heating chamber and coupled to the article movement mechanism, in accordance with aspects hereof; 
         FIG. 3  depicts a top perspective view of a cooling station with a portion removed to reveal an article of footwear positioned within the cooling chamber, and where the cooling chamber is coupled to a secondary cooling source, in accordance with aspects hereof; 
         FIG. 4  depicts a top perspective view of a dryer with a portion removed to reveal an article of footwear positioned within the dryer, in accordance with aspects hereof; 
         FIG. 5A  depicts a top perspective view of a liner being placed on a last, in accordance with aspects hereof; 
         FIG. 5B  depicts a top perspective view of a chassis positioned on a sole portion of the liner that is positioned on a last, in accordance with aspects hereof; 
         FIG. 5C  depicts a top perspective view of a heel counter positioned on a heel portion of the liner of  FIG. 5B , in accordance with aspects hereof; 
         FIG. 5D  depicts a top perspective view of a bootie being positioned over the liner, chassis, and heel counter from  FIG. 5C , in accordance with aspects hereof; 
         FIG. 5E  depicts a top perspective view of a film being position on the bootie from  FIG. 5D , in accordance with aspects hereof; 
         FIG. 6  depicts a top perspective view of a compression bootie being positioned on the upper assembly from  FIG. 5E , in accordance with aspects hereof; 
         FIG. 7A  depicts a side and partial cutaway view of the compression bootie and the upper assembly from  FIG. 6 , in accordance with aspects hereof; 
         FIG. 7B  depicts a close up view of the cutaway portion of  FIG. 7A , particularly showing the layers of the compression bootie, the film, the bootie, the heel counter, and the liner, in accordance with aspects hereof; 
         FIG. 8A  depicts a side view of a compression assembly system, particularly showing a negative pressure vessel partially cutaway to reveal a compression material positioned within the negative pressure vessel, in accordance with aspects hereof; 
         FIG. 8B  depicts a side view of the compression assembly system of  FIG. 8A , where the compression material is in an expanded configuration or position and has expanded to the dimensions of the negative pressure vessel, in accordance with aspects hereof; 
         FIG. 8C  depicts a side view of the compression assembly system of  FIG. 8B , with a lasted upper inserted inside the compression material while the compression material is in the expanded configuration or position, in accordance with aspects hereof; 
         FIG. 8D  depicts a side view of the compression assembly system of  FIG. 8C , with the lasted upper inserted inside the compression material and the compression material shifted away from the expanded configuration and is positioned adjacent the article, in accordance with aspects hereof; 
         FIG. 9  depicts a top perspective view of a portion of the article movement mechanism, particularly showing a lasted upper positioned inside of a compression material, where the compression material is coupled to a coupling member of the article movement mechanism, in accordance with aspects hereof; 
         FIG. 10  depicts a flow diagram of a method for preparing an article for thermoforming, in accordance with aspects hereof; and 
         FIG. 11  depicts a flow diagram of a method for thermoforming an article, in accordance with aspects hereof. 
     
    
    
     DETAILED DESCRIPTION 
     The subject matter of aspects of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. 
     Aspects herein are directed to methods and systems for thermoforming articles and/or for preparing articles for thermoforming. Certain thermoforming systems can include heating an article and then cooling the article, while the article is formed into a desired shape. Certain current thermoforming systems may only provide inefficient or uneven exposure of the article to the various temperatures required in the heating and/or cooling processes of thermoforming. Further, certain current thermoforming processes can result in defects to the thermoformed article, e.g., by misalignment or creasing of a material utilized to aid in shaping or forming the thermoformed article, which may result in creases or other defects on the surface of the thermoformed article. 
     The systems and methods disclosed herein can alleviate one or more of the above-mentioned problems. For instance, a system is disclosed for preparing an article for thermoforming and the subsequent thermoforming of the article. At a high level, the system and methods disclosed herein can aid in inserting an article into a shaped compression material. In such aspects, vacuum or negative pressure can be applied to such a shaped compression material to apply a compressive force to all or a portion of the article during the thermoforming process. In certain aspects a compressive material or vacuum bag can be utilized that is shaped similar to the article and/or is substantially similar in size to the article, which can limit creases and other defects forming on the surface of the thermoformed article. However, the insertion of the lasted upper into the compression material can be manually difficult due to the minimal size and/or shape difference between the lasted upper and the compression material. 
     The system and methods described herein allow for efficient and aligned insertion of the article into a compression material, e.g., a shaped compression material. For example, in one aspect, the compression material can be placed in a vessel and negative pressure or vacuum pressure can be applied to expand the compression material to the dimensions of the vessel thereby allowing for ease of insertion of the article into the compression material. In aspects, an identifier on the vessel and/or the compression material can guide the article for proper aligned insertion into the compression material. In such an aspect, once the article is inserted into the expanded compression material, ambient atmospheric pressure (or a pressure above the negative pressure applied previously) can be applied to cause the compression material to shift from the expanded configuration to a more neutral configuration, with the article inserted therein. In aspects, vacuum pressure can then be applied so that the compression material can compress onto the article to allow for thermoforming. 
     Further, in certain aspects, systems and methods disclosed herein can provide for efficient and even exposure to the temperatures that may be required for each of the thermoforming process steps. For example, in aspects, the system and methods disclosed herein can introduce and rotate an article within a heating station so that each side of an article is exposed to the thermal elements present within a heating station, which can allow for more even heating of the article. Further, in aspects, the article can be exposed to vacuum pressure so that a compression material applies a compressive force to the article while being introduced and rotated within the heating station. Further, in certain aspects, the article can also be introduced and rotated within a cooling station, to allow for efficient cooling of the heated article. In such aspects, the cooling station may include a liquid, and the rotation of the heated article may facilitate more rapid conduction of the heat to the liquid from the upper to thereby cool down the upper more efficiently. In such aspects, the article can be exposed to vacuum pressure so that a compression material applies a compressive force to the article while being introduced and rotated within the cooling station. In various aspects, the vacuum pressure may be a continuous draw while the article is exposed to the heating and cooling stations, or can be a single initial draw prior to exposure to the heating and/or cooling stations, and the compression material can be sealed so as to maintain the compressive force on the article throughout the thermoforming process. 
     Accordingly, in one aspect a method for preparing an article for thermoforming is provided. The method can include inserting a compression material into a vessel, where the compression material can be present in a first position or configuration in the vessel. In this aspect, at least a portion of the compression material can form an interior portion adapted to receive an article. In aspects, the method can also include exposing an area between an outer surface of the compression material and an inner surface of the vessel to a pressure less than atmospheric pressure to shift the compression material from the first position to an expanded position, where, in the expanded position, at least a portion of the compression material is closer to the inner surface of the vessel than compared to the first position. In aspects, the method can also include inserting at least a portion of the article into the interior portion of the compression material while the compression material is in the expanded position. In aspects, the article can be present on a forming material. In various aspects, the method can also include exposing the area between the outer surface of the compression material and the inner surface of the vessel to a pressure at about atmospheric pressure so that the compression material shifts from the expanded position to a second position, where in the second position, at least a portion of the article is in the interior portion of the compression material and at least a portion of the compression material is closer to the article than when the article was inserted into the compression material in the expanded position. 
     In another aspect, a system for preparing an article for thermoforming is provided. The system can include a vessel. In aspects, the vessel can have an interior volume defined at least by a bottom portion and at least one sidewall extending up from the bottom portion to a top portion. In aspects, the vessel can include a port. In aspects, the system can also include a negative pressure generation system, which can be coupled to the port of the vessel. The system can further include, in aspects, a compression material, which can be positioned inside the interior volume of the vessel, where at least a portion of the compression material forms an interior portion adapted to receive an article. In aspects, the negative pressure generation system and the port are cooperatively adapted to expose an area between an outer surface of the compression material and an inner surface of the at least one sidewall to a pressure less than atmospheric pressure so that the compression material expands. 
     In yet another aspect, a method for thermoforming an article is provided. The method can include receiving a compression material having an article positioned inside the compression material. In aspects, the method can also include exposing an area between an inner surface of the compression material and an outer surface of the article to a pressure less than atmospheric pressure so that the compression material applies a compressive force onto the outer surface of the article. In aspects, the method can also include introducing the article to one or more heating stations and rotating the article within the one or more heating stations. Further, in aspects, the method can include introducing the article to a cooling station and rotating the article within the cooling station. 
     In yet another aspect, a system for thermoforming an article is provided. The system can include one or more heating stations. In aspects, each of the one or more heating stations can include a heating chamber. In various aspects, the system can also include a cooling station that includes a cooling chamber. In certain aspects, the system can also include an article movement mechanism. In aspects, the article movement mechanism can include at least one coupling member adapted to couple an article to the article movement mechanism. In aspects, the article movement mechanism can be adapted to rotate the article inside the heating chamber, the cooling chamber, or both. 
     Turning now to the figures,  FIG. 1  depicts a system  100  for thermoforming articles. It should be understood, that while the system  100  depicts a portion of an article of footwear, e.g., an upper  110 , being exposed to the system  100 , other types of articles or other portions of an article of footwear can be utilized in the system  100  described herein. In the aspect depicted in  FIG. 1 , the system  100  includes a heating station  200 , a cooling station  300 , a dryer  400 , a loading/unloading station  600 , and an article movement mechanism  500 . 
     As can be seen in  FIG. 1 , the article movement mechanism  500  is coupled to the upper  110  for delivery to the various stations and areas of the system  100 . In the aspect depicted in  FIG. 1 , the article movement mechanism  500  is coupled to one article, the upper  110 , via a coupling member  520  at one end of a radially extending member  510 . The coupling of an article to the article movement mechanism  500  is discussed further below. 
     It should be understood that the article movement mechanism  500  can be coupled to any number of articles. For example, in one aspect, the article movement mechanism  500  can include more than one radially extending member, with each member coupled to an article. In such an aspect, the system  100  can expose a plurality of articles to a portion of the thermoforming system simultaneously, e.g., with each article being exposed to one station or chamber at a time. Further, in such an aspect, each article can be exposed to each station or chamber for substantially the same amount of time. 
     As can be seen in the aspect of  FIG. 1 , the system  100  is configured such that each station or chamber is circumferentially positioned with the article movement mechanism  500  at the center. In such an aspect, this circumferential design can provide a reduced footprint in a processing area as well as increased productivity, as article movement and/or additional operator contact with an article are reduced. Although not depicted in the figures, the system  100  may include an enclosure for housing the entire system  100  or a portion thereof. For instance, in one aspect, the system  100  can include an enclosure that encloses the heating station  200 , the cooling station  300 , the dryer  400 , and the loading/unloading station  600 . 
     In the aspect depicted in  FIG. 1 , the heating station  200  includes a plurality of heating chambers  210 . In such an aspect, the plurality of heating chambers  210  can include five heating chambers  212 ,  214 ,  216 ,  218 , and  220 . In various aspects, by having individual heating chambers, the upper  110  or another article, may be exposed to different heating temperatures or environments in each individual heating chamber. For instance, in one aspect, the upper  110  may be exposed to a ramping up of temperature throughout the heating station  200  such that the upper  110  is exposed to increasing temperatures at each heating chamber, which may provide for more effective melting of the thermoformable or thermoplastic materials or portion of the upper  110 . It should be understood that while the heating station  200  depicted in  FIG. 1  includes five heating chambers, any number of heating chambers can be utilized and are contemplated for use in the invention described herein. 
     In aspects, in order to expose the upper  110  or other article to the heating station  200 , e.g., by introducing the upper  110  into the heating chamber  212 , the article movement mechanism  500  can rotate about an axis, e.g., an axis  501 , and then lower the upper  110  through an opening  214  in the top portion  216  of a first heating chamber  212  of the heating station  200 . In such an aspect, the article movement mechanism  500  can include any mechanism for moving the upper  110 , and/or the radially extending member  510  up away from the heating chamber  212  and down towards the heating chamber  212 . Further, in aspects, as discussed further below, the article movement mechanism  500  is adapted to rotate the upper  110  or other article, while the upper  110  is within the heating chamber  212 , or any of the other heater chambers  214 ,  216 ,  218 , or  220 . 
     One specific example of a heating chamber, heating chamber  212 , is depicted in  FIG. 2 . As can be seen in  FIG. 2 , the upper  110  is positioned in an interior portion  226  of the heating chamber  212 , e.g., by the vertical shifting of the radially extending member  510  down towards the heating chamber  212 . In the aspect depicted in  FIG. 2 , when the upper  110  or other article is positioned within the heating chamber  212 , the coupling member  520  can at least partly or fully cover the opening  222  of the top portion  224 , which may aid in retaining the thermal energy in the interior portion  226 . In alternative aspects, the coupling member  520  may not cover the opening  222  of the top portion  224 . 
     In the aspect depicted in  FIG. 2 , the heating chamber  212  can include one or more thermal elements  228 . In this aspect, the thermal element  228  is positioned on a sidewall  230  of the heating chamber  212 . It should be understood that other positions for thermal elements within the heating chamber  212  are also contemplated for use in the system  100  described herein. It should also be understood that more than one thermal element can be utilized in the heating chamber  212  and that one thermal element  228  is depicted as just one example. Further, the thermal element  228  in  FIG. 2  is depicted schematically and such depiction is not intended to be limiting on the type and/or shape of thermal elements that can be utilized in the system  100  disclosed herein. For example, in one aspect, the thermal element  228  can be an Infrared (IR) lamp. In the same or alternative aspects, the thermal element  228  can include a heated fluid, such as air. In an aspect not depicted in the figures, the thermal element  228  can include an IR lamp or other thermal source adjacent a fan for distribution of the thermal energy emitted from the IR lamp or other thermal source. 
     In certain aspects, the heating station  200  and/or the heating chamber  212  is adapted to expose an article, such as the upper  110 , to a temperature sufficient to cause at least a portion of a material of the article to melt and/or deform. For example, in one aspect, the heating station  200  and/or the heating chamber  212  is adapted to expose an article, such as the upper  110 , to a temperature above the melting temperature of a thermoplastic material of the upper  110  or other article. In the same or alternative aspects, the heating station  200  and/or the heating chamber  212  is adapted to expose an article, such as the upper  110 , to a temperature in the range of about 100° C. to about 350° C., about 150° C. to about 340° C., or about 200° C. to about 330° C. 
     As discussed above, in certain aspects, the system  100  can provide for rotation of the upper  110  while positioned within the heating chamber  212 . For example, as depicted in  FIG. 2 , at least a portion of the article movement mechanism  500  can rotate about an axis  232  so that the upper  110  can be more evenly heated in the heating chamber  212 . For instance, in one aspect, the coupling member  520  can rotate about the axis  232  relative to the radially extending member  510  to facilitate the rotation of the upper  110  in the interior portion  226  of the heating chamber  212 , which can provide direct exposure of each side of the article  110  to the thermal element  228 . The article movement mechanism  500  is discussed in more detail below. 
     It should be understood that while the heating chamber  212  is discussed in detail above, the description of any or all of the features of the heating chamber  212  are applicable to the other heating chambers, e.g., one or more of the heating chambers  214 ,  216 ,  218 , and  220 . 
     As discussed above, the heating station  200  can include a plurality of heating chambers  210 . In such an aspect, the plurality of heating chambers  210  can be utilized to ramp up the temperature that the upper  110  is exposed to in a sequential manner. For instance, in one aspect, the upper  110  is exposed to an increased temperature at each subsequent heating chamber. In such aspects, the upper  110  can be exposed to a temperature that is at least about 2° C. higher, at least about 5° C. higher, or at least about 7° C. higher at an immediate subsequent heating chamber compared to the prior heating chamber. For example, in one aspect, the upper  110  can be exposed to a temperature at the heating chamber  214  that is about 2° C. higher or about 5° C. higher than a temperature that the upper  110  was exposed to in the heating chamber  212 . 
     In certain aspects, after the upper  110  is exposed to the heating station  200 , e.g., to one or more heating chambers of the plurality of heating chambers  210 , the upper  110  is exposed to a cooling station, e.g., a cooling station  300 .  FIG. 3  depicts one example of a cooling station  300 . As can be seen in the aspect depicted in  FIG. 3 , the cooling station  300  includes a cooling chamber  310  and a secondary cooling source  320 . In certain aspects, the article movement mechanism  500 , e.g., by rotation of the radially extending member  510 , can transfer the upper  110  from the heating station  200  to the cooling station  300 . 
     In certain aspects, the cooling station  300  can expose the upper  110  to a cooled fluid, e.g., a cooled liquid. For example, as can be seen in  FIG. 3 , the cooling station  310  can include a liquid  311  in an interior portion  312  of the cooling chamber  310 . In such aspects, the liquid  311  can be cooled to facilitate a rapid decrease in temperature of the heated upper  110 . In certain aspects, the liquid  311  can be maintained at a specific temperature by circulation of the liquid  311  between the cooling chamber  310  and the secondary cooling source  320 , which can in aspects, cool the liquid  311 . The secondary cooling source  320  can cool the liquid  311  using conventional liquid cooling techniques. In certain aspects, such as that depicted in  FIG. 3 , liquid  311  from the cooling chamber  310 , which may in aspects have been warmed up due to contact with the heated upper  110 , can travel to the secondary cooling source  320  via the conduit  321 . Further, in such aspects, the cooled liquid  311  can travel back to the cooling chamber  310  via the conduit  322 . It should be understood that other configurations for maintaining the fluid  311  at a specific temperature can be utilized and are contemplated for use in the system described herein. 
     In aspects, the cooling station  300  can expose the upper  110  to a temperature in the range of about 0° C. to about 30° C., about 2° C. to about 25° C., about 3° to about 20° C., or a temperature of about 4° C., or about 5° C. In certain aspects, the fluid  311  can comprise water or one or more other aqueous solvents. In the same or alternative aspects, the fluid  311  can comprise glycol or one or more other coolant liquids. 
     In certain aspects, the circulation of the liquid  311  can provide agitation or circulation within the cooling chamber  310  so that heat from the heated upper  110  is effectively transferred from the upper  110  to the liquid  311 . In the same or alternative aspects, the upper  110  can rotate about an axis  324  to provide agitation of the liquid  311 , e.g., the coupling member  520  can rotate about the axis  324  relative to the radially extending member  510  to facilitate the rotation of the upper  110  in the interior portion  312  of the cooling chamber  310 . The article movement mechanism  500  is discussed in more detail below. 
     In certain aspects, not depicted in the figures, the upper  110  can be exposed to more than one cooling chamber  310 . For instance, in one aspect, the system  100  can include an additional cooling chamber so that the upper is first exposed to the cooling chamber  310  and then subsequently exposed to a second cooling chamber. In such an aspect, the second cooling chamber can include any or all of the features of the cooling chamber  310  discussed above. 
     As discussed further below, the upper  110  can be positioned inside of a compression material. In such an aspect, the compression material can be water- or liquid-impermeable so that when the upper  110  is submerged in the liquid  311  the upper  110  does not absorb or otherwise attract the liquid  311  thereto, or come into contact with the liquid  311 . Further, in such an aspect, after the upper  110  is removed from the cooling chamber  310 , the compression material may harbor liquid  311  on its outer surface, which may be removed by the dryer  400 . 
       FIG. 4  depicts one example of a dryer  400 . In certain aspects, the upper  110  can optionally be transferred to the dryer  400  after exposure to the cooling station  300 , e.g., via the by rotation of the radially extending member  510  from adjacent the cooling station  300  to the dryer  400 . It should be understood that the dryer  400  depicted in  FIG. 4  is just one example dryer  400  and that other drying mechanisms are contemplated for use in the present system  100 . The dryer  400  depicted in  FIG. 4  includes one or more air nozzles  410  for providing a stream of air to the upper  110  in order to remove at least a portion of the liquid  311  that may be present thereon, or on the compression material. In one aspect, the stream of air can be room temperature, e.g., air that is approximately 25° C. 
     In certain aspects, the upper  110  can vertically shift, e.g., via the vertical shifting of the radially extending member  510 , while the air nozzles  410  provide a stream of air over all or a portion of the upper  110 . In certain aspects, the dryer  400  can optionally include a reservoir  420  for collecting the fluid  311  removed from the upper  110  or the compression material positioned on the upper  110 . 
     In one aspect, the upper  110  may rotate about the vertical axis  522 , via the rotation of the coupling member  520 , as discussed herein. In alternative aspects, the upper  110  may not be rotated about the vertical axis  522  while the upper  110  is exposed to the stream of air from the air nozzles  410 . 
     In certain aspects, once the upper  110  is exposed to the dryer  400  or the cooling station  300 , the upper  110  may be transferred to the loading/unloading station  600  for removal from the system  100  and/or for further processing. In such an aspect, the upper  110  can be transferred to the loading/unloading station  600  via rotation of the radially extending member  510 . 
     As discussed above, in aspects, the system  100  can expose the upper  110  or other article to a heating station  200 , a cooling station  300 , and a dryer  400 . In certain aspects, in operation, the upper  110  is loaded into the system  100 , e.g., at the loading/unloading station  600 , by coupling the upper  110  to the article movement mechanism  500 . The coupling of an article to the article movement mechanism  500  is discussed in more detail below. Further in aspects, once the upper  110  is coupled to the article movement mechanism  500 , the article movement mechanism  500  can rotate about an axis, e.g., an axis  501 , and then lower the upper  110  through an opening  214  in the top portion  216  of a first heating chamber  212  of the heating station  200 . In such an aspect, the article movement mechanism  500  can include any mechanism for moving the upper  110 , and/or the radially extending member  510  up away from the heating chamber  212  and down towards the heating chamber  212 . Further, in aspects, the article  110 , via the article movement mechanism  500 , may be exposed to the heating chamber  214 , then exposed to the heating chamber  216 , then to the heating chamber  218 , and then to the heating chamber  220  (or to any number of heating chambers suitable for a particular system configuration or process). Further, in certain aspects, the upper  110  is then transferred to the cooling station  300  for cooling the heated upper  110 . Optionally, the upper  110  is then transferred to the dryer  400  for removing at least a portion of the liquid  311  present thereon, or on the compression material. Further, in such aspects, the upper  110  may be transferred back to the loading/unloading station  600  for removal from the system  100 . 
     As discussed above, in certain aspects, the article movement mechanism  500  can be utilized to transfer the upper  110  from one station to the next station. Further, as discussed above, the article movement mechanism  500  can include a plurality of radially extending members with each member coupled to an upper. In such an aspect, the article movement mechanism  500  can transfer each upper attached to each of a plurality of radially extending members to a subsequent processing station substantially at the same time. Stated differently, in one aspect the plurality of radially extending members can be fixedly coupled to a central portion  530  that rotates, thereby causing each of the plurality of radially extending members and the articles coupled thereto to rotate. In such an aspect, each article or upper is exposed to each station for a substantially similar amount of processing time. For example, the upper  110  may be exposed to a single cooling station  300  for about 30 seconds, while the upper  110  is exposed to each of the five heating chambers for 30 seconds each, so that the upper  110  is exposed to the heating station  200  for about 150 seconds. In aspects, where there may be six heating chambers, the upper  110  may be exposed to the heating station for about 180 seconds, while being exposed to the cooling station for 30 seconds (or 60 seconds in the aspect where there are two cooling chambers). It should be understood that the 30 second per station or per step time mentioned above is only one example for timing of exposure to the various stations or steps discussed above. In alternative aspects, the upper  110  or other article can be exposed to each station or step from about 10 seconds, about 20 seconds, about 28 seconds, about 45 seconds, or about 60 seconds. 
     As discussed above, one example article for use with the system  100  disclosed herein can be an upper  110  for an article of footwear.  FIGS. 5A-5D  depict the various components of the upper  110  and the assembly of the upper  110  components on a last  700 . It should be understood that, in certain aspects, the upper  110  and the components of the upper  110  mentioned below may be assembled in other manners not depicted in the figures. For instance, in one aspect, the components of the upper  110  may be assembled off the last  700  and, once assembled, may then be applied to the last  700 . 
       FIG. 5A  depicts a liner  120  being placed on the last  700 . In certain aspects, the last  700  can be formed of a rigid material that is capable of withstanding the temperatures and other processing parameters discussed herein with respect to the system  100 . In various aspects, the liner  120  can include a heel portion  122 , a forefoot portion  124 , and a ground-facing portion  126 . 
     In certain aspects, the liner  120  can be formed from any type of material. In certain aspects, the liner  120  can include a knit textile, a braided textile, a woven textile, and a non-woven textile, a film, a sheet, or a molded article, such as an injection molded article, a foamed material, or a combination thereof. In the same or alternative aspects, the liner  120  can include natural materials, synthetic materials, or a combination of natural and synthetic materials. In one aspect, the liner  120  can include a non-woven textile. In various aspects, the liner  120  may include multiple pieces of one or more materials that are secured together, e.g., by bonding or stitching. In one or more aspects, the liner  120  can optionally include a plurality of eyestays  128 . In aspects, the liner  120  is positioned on the last  700  by inserting the last  700  into a void  129  of the liner  120 . 
       FIG. 5B  depicts a chassis  130  that is positioned on the ground-facing portion  126  of the liner  120  positioned on the last  700 . In one aspect, the chassis  130  can be formed of any type of material as long as such a material can provide support and stability to the upper  110  and the article of footwear formed therefrom. In one aspect, the chassis  130  can include a material that may fuse with other portions of the upper throughout the thermoforming process. In such an aspect, the chassis can include a thermoplastic material that has a melting temperature, a Vicat softening temperature, a heat deflection temperature, or any combination thereof, in the range of about 80° C. to about 135° C., or from about 90° C. to about 120° C. The melting temperature can be determined according to the test method detailed in ASTM D7138-16. The Vicat softening temperature can be determined according to the test method detailed in ASTM D1525-09, preferably using Load A and Rate A. The heat deflection temperature can be determined according to the test method detailed in ASTM D648-16, using a 0.455 MPa applied stress. In aspects, all or a portion of the chassis  130  can be made from such a material or the chassis  130  can be coated with such a material for fusing to another portion or portions of the upper  110 , such as the liner  120  and/or the bootie  150  discussed further below. In one aspect, an adhesive, such as a hot melt adhesive, may be utilized to secure at least a portion of the chassis  130  to the liner  120 . 
       FIG. 5C  depicts a heel counter  140  placed on the heel portion  122  of the liner  120 . In certain aspects, the heel counter  140  can provide stability to the heel region of the upper. In certain aspects, an adhesive, such as a hot melt adhesive, can be utilized to secure at least a portion of the heel counter  120  to the liner  120 . In aspects, the heel counter  140  can be formed from any material as long as such a material can provide heel support upon exposure to the system  100  and processes described herein. 
     In aspects, the heel counter  140  can include one or more of the fusable materials discussed above with reference to the chassis  130 . In such an aspect, upon exposure to the system  100  and/or processes described herein, at least a portion of the heel counter  140  may melt or deform and fuse or bond to another component of the upper  110 , such as the liner  120  and/or the bootie  150 . 
       FIG. 5D  depicts the bootie  150  being placed on the liner  120 , chassis  130 , and the heel counter  140  positioned on the last  700 . The bootie  150  of  FIG. 5D  includes a ground-facing portion  152 , a heel portion  154 , a forefoot portion  156 , and a plurality of eyestays  158 . In certain aspects, the bootie  150  may not include the eyestays  158 . In one aspect, the bootie  150  may be sock-like in that it can, by itself, substantially cover a forefoot region, a heel region, a ground-facing region of a wearer&#39;s foot. 
     In aspects, the bootie  150  can include a woven, braided, knit, or non-woven textile. In aspects, such a textile may include one or more yarns or fibers comprising a yarn or fiber composition that includes a thermoplastic material. In such aspects, the thermoplastic material and/or the yarn or fiber composition can exhibit a melting temperature (or melting point), Vicat softening temperature, heat deflection temperature, or a combination thereof, that is from about 80° C. to about 135° C., or from about 90° C. to about 120° C. In one aspect, the thermoplastic material and/or the yarn or fiber composition can exhibit a melting temperature, Vicat softening temperature, heat deflection temperature, or a combination thereof, that is about 135° C. or less, about 125° C. or less, or about 120° C. or less. In the same or alternative aspects, the bootie  150  can include one or more materials that will not melt or deform under the processing conditions disclosed herein. In such an aspect, in the case of such a thermoplastic material, such material can exhibit a melting temperature greater than about 135° C., greater than about 140° C., or greater than about 150° C. Further, in such aspects, another material that may be present in the article, such as a material other than a thermoplastic material, may not degrade below a temperature of about 150° C., about 140° C., or about 135° C. 
     In aspects, the eyestays  158  on the bootie  150  can align with the eyestays  128  present on the liner  120 . In various aspects, an alignment mechanism can be utilized to achieve alignment of the eyestays  158  with the eyestays  128 . 
     Turning now to  FIG. 5E  a film  160  is depicted that has been placed on the outside of the bootie  150  present on the last  700 . In certain aspects, the film  160  can include a ground-facing portion  162 , a heel portion  164 , and a toe-covering portion  166 . In certain aspects, through exposure to the system  100  and the thermoforming processes disclosed herein, the film  160  can include a thermoplastic material that can melt and cool to form a film on the upper  110  to provide support, stability, and/or a moisture barrier, for example. In certain aspects, the thermoplastic material can exhibit the melting temperature, heat deflection temperature, Vicat sofetening temperature, or a combination thereof, in the range of 80° C. to about 135° C., or from about 90° C. to about 120° C., or about 135° C. or less, about 125° C. or less, or about 120° C. or less. It should be understood that the film  160  depicted in  FIG. 5E  is one example and other films of films having varying coverage of varying portions of the upper  110  can be utilized depending upon the desired properties. 
       FIG. 6  depicts the assembled upper  110  discussed above with reference to  FIGS. 5A-5E  positioned on the last  700 . As discussed above, the upper  110  can include materials that may melt and flow upon exposure to the system  100  and thermoforming processes disclosed herein. Further as discussed above, in certain aspects, one or more of the upper  110  components may include a material that is to fuse or bond to another material or component of the upper  110  upon exposure to the system  100  and thermoforming processes disclosed herein. In one or more of these aspects, it may be desirable to provide a compressive force to the upper  110  to facilitate the fusing or bonding, to restrict the flow of the melted thermoplastic material, and/or to aid in forming the upper  110  or portion thereof to the forming material, e.g., the last  700 . In such aspects, a compression bootie can be utilized to provide such a compressive force to an outer surface  112  of the upper  110 . 
       FIG. 6  depicts one example compression bootie  800  that is being applied onto the upper  110  positioned on the last  700 . As can be seen in  FIG. 6 , the compression bootie  800  can be sock-like in that includes a ground-facing portion  802 , a heel portion  804 , and a forefoot portion  806 . In one or more aspects, the compression bootie  800  can be formed or comprise an elastomeric material in order to provide a compressive force on the outer surface  112  of the upper  110 . In certain aspects, the compression bootie  800  can be formed from any elastomeric material as long as the elastomeric material exhibits a melting temperature or degradation temperature that is at least 10° C. greater, or at least 20° C. or greater, than the processing temperatures described above with reference to the heating station  200 . In one aspect, the compression bootie  800  can include polysiloxane. 
       FIG. 7A  depicts the lasted upper  110  with the compression bootie  800  positioned over the lasted upper  110 . The partial cross-section in  FIG. 7A  shows the arrangement of the various components of the upper  110  discussed above with reference to  FIGS. 5A-5E . As can be seen in  FIG. 7A , the liner  120  is in contact with the last  700 , with the chassis  130  and heel counter contacting the liner  120  and the bootie  150 , and the film  160  is positioned between the bootie  150  and the compression bootie  800 .  FIG. 7B  provides a close up view of the heel region of the lasted upper  110  of  FIG. 7A . 
     As discussed above, in certain aspects, the compression bootie  800  can apply a compressive force onto the upper  110  pressing the upper  110  against the rigid last  700 . In such an aspect, this compressive force can aid in restricting the flow of the film  160  upon melting so that it cools and hardens in the desired position on the upper  110 . Further, in aspects, this compressive force may facilitate the bonding of one or more of the upper  110  components, e.g., the heel counter  140  fusing or bonding to the bootie  150  and/or the liner  120 . 
     In certain aspects, an additional increased level of compressive force on the upper  110  may be desired, in addition the compressive force applied by the compression bootie  800 . In such aspects, the lasted upper  110  covered with the compression bootie  800  may have a compression material compressed onto the outer surface of the compression bootie  800  to apply this additional level of compressive force to the lasted upper  110 . In certain aspects, the compression material can be a vacuum bag. The compression material can be formed of any material as long as such a material will not melt or deform throughout exposure to the system  100  and processes disclosed herein. In one aspect, the compression material may be utilized directly on the upper  110  in the absence of the compression bootie  800 . 
     In one or more aspects, the vacuum bag or compression material can be at least partly shaped similar to the forming material and/or article that is to be thermoformed. For example,  FIG. 8A  depicts a compression material  910  that includes a portion  912  that is at least partly or substantially shaped like a last  700  and/or the upper  110 , at least in that the portion  912  generally includes a bootie shape having a ground-facing portion  914 , a heel portion  918 , and a forefoot portion  916 . 
     In certain aspects, it may be desirable that the portion  912  of the compression material  910  is similar or slightly larger in size to that of the lasted upper  110  inserted therein. However, in such an aspect it may be difficult to efficiently insert a lasted upper  110  into a similarly-sized compression material  910 . In such an aspect, a system or mechanism may be utilized to facilitate the assembling of the compression material  910  on the lasted upper  110 . 
       FIGS. 8A-8D  depict a compression assembly system  900  that can be utilized to facilitate inserting a lasted upper  910  into a similarly sized and/or similarly shaped compression material  910 . As can be seen in  FIG. 8A , the compression assembly system  900  can include the compression material  910  and a negative pressure vessel  920 . It should be understood that the compression assembly system  900  is just one example system to facilitate assembling a compression material  910  onto a lasted upper  110 , or other article, and that other system components or designs are also contemplated by the present disclosure. 
     As can be seen in  FIG. 8A , the compression material  910  has been inserted into the interior portion  926  of the negative pressure vessel  920 . As discussed above, since the compression material  910  may be similarly sized or similarly shaped to the lasted upper  110 , the neutral configuration or position of the compression material  910  in  FIG. 8A  may make it difficult to efficiently insert the lasted upper  110  into an interior portion  911  of the compression material  910 . In such an aspect, the compression material  910  can be shifted to an expanded configuration to expand the interior portion  911  to allow for more efficient insertion of the lasted upper  110 . For example, as seen in  FIGS. 8A-8D , the negative pressure vessel  920  can include a port  921 , which can provide negative pressure, or vacuum pressure, to the volume  921   a  between the outer surface  913  of the compression material  910  and the inner surface  928  of the negative pressure vessel  920 . In such an aspect, at least a portion of the compression material  910  can couple to, or otherwise provide or form a seal, at a top portion  922   a  and  922   b  of the negative pressure vessel  920  to allow for the drawing of the vacuum pressure in the volume  921   a . In certain aspects not depicted in the figures, the port  921  can be coupled to a negative pressure generation device to provide the vacuum pressure to the volume  921   a.    
     As can be seen in  FIG. 8B , upon exposing the volume  921   a  between the outer surface  913  of the compression material  910  and the inner surface  928  of the negative pressure vessel  920  to negative or vacuum pressure, the compression material  910  can shift into an expanded configuration, such that at least a portion of the compression material  910  is closer to the sidewalls  924   a  and  924   b  of the negative pressure vessel  920  than in the neutral configuration of the compression material depicted in  FIG. 8A . In one aspect, upon exposing the volume  921   a  between the outer surface  913  of the compression material  910  and the inner surface  928  of the negative pressure vessel  920  to negative or vacuum pressure, the compression material  910  can form to the dimensions of the negative pressure vessel  920 . 
     In certain aspects, in this expanded configuration of the compression material  910 , such as that depicted in  FIGS. 8B and 8C , an upper  110  positioned on a last  700  can be more easily inserted into the interior portion  911  of the compression material  910 . In an aspect not depicted in the figures, an identifier on the compression material  910 , the negative pressure vessel;  920 , or both, may be provided to identify the orientation at which the upper  110  should be placed in the compression material for the proper fit. In aspects, the port  921  can provide a continuous draw of vacuum pressure or exposure of vacuum pressure to the volume  921   a  while the lasted upper  110  is being inserted into the interior portion  911 . In alternative aspects, the port  921  can provide an initial, non-continuous, draw of vacuum pressure or exposure of vacuum pressure to the volume  921   a  and is then sealed to maintain the compression material in the expanded configuration while the lasted upper  110  is being inserted into the interior portion  911 . 
     In certain aspects, once the lasted upper  110  is inserted into the interior portion  911  of the compression material  910 , the port  921  may cease to provide the negative or vacuum pressure to the volume  921   a , or a seal is removed, so that the compression material  910  may shift from the expanded configuration depicted in  FIGS. 8B and 8C  to a closed configuration or position depicted in  FIG. 8D . In one aspect, the port  921  may supply a pressure at or about atmospheric pressure to the volume  921   a , which can cause the compression material  910  to shift away from the sidewalls  924   a  and  924   b  and towards the lasted upper  110 . Further, in such an aspect, the compression material  910  can be de-coupled from the top portions  922   a  and  922   b  and removed for further processing, such as compressing the compression material  910  onto the lasted upper  110  and exposing the lasted upper  110  to the system  100  and/or the thermoforming processes described herein. 
     In certain aspects, once the lasted upper  110  is inserted into the compression material  910 , the lasted upper  110  can be coupled to the article movement mechanism  500 . A close up view of one example article movement mechanism  500  that includes the radially extending member  510  and coupling member  520  are depicted in  FIG. 9 .  FIG. 9  also depicts one example of how the lasted upper  110  can be coupled to the article movement mechanism  500 . 
     In certain aspects, a portion  910   a  of the compression material  910  that extends beyond the lasted upper  110  can be coupled to the article movement mechanism  500 . As can be seen in the aspect depicted in  FIG. 9 , the portion  910   a  of the compression material  910  can extend through the coupling member  520  with a top portion  522  utilized to seal off the interior portion  911  of the compression material  910 . In an aspect not depicted in the figures, a port within the coupling member  520  of the article movement mechanism  500  can provide vacuum or negative pressure to the interior portion  911  of the compression material  910  in order to cause the compression material  910  to apply a compressive force onto the lasted upper  110 . In such an aspect, a negative pressure generation device  950 , depicted in  FIG. 1 , can be coupled to the article movement mechanism  500 . The negative pressure generation device  950  can be any type of vacuum pressure device and can be coupled to the article movement mechanism  500  using any couple mechanism, with a particular device or coupling mechanism chosen for a particular design or purpose. 
     In one aspect, the interior portion  911  of the compression material  910  can be exposed to vacuum or negative pressure in a continuous manner as the upper  110  is transferred between stations or chambers of the system  100  described above. In such an aspect, the article movement mechanism  500  can provide this continuous negative pressure via the negative pressure generation system  950 . 
     In alternative aspects, the interior portion  911  of the compression material  910  can be exposed to vacuum or negative pressure at an initial single step, in order to compress the compression material  910  onto the lasted upper  110  and then the coupling member  520  can seal off the interior portion  911  of the compression material  910 , e.g., via the top portion  522  or other member, in order to maintain the vacuum pressure within the interior portion  911 . In such an aspect, the article movement mechanism  500  can provide this initial single exposure of negative pressure via the negative pressure generation system  950 . In one aspect, another negative pressure source, other than the negative pressure generation system  950 , can be utilized to provide the vacuum pressure to the interior portion  911 , and the compression material  910  can be sealed either by the coupling member  520  or through another sealing mechanism. 
     As discussed above, in certain aspects, the upper  110  can rotate when positioned within the heating station  200 , e.g., within the heating chamber  212 , and/or when positioned within the cooling citation  300 , e.g., within the cooling chamber  310 . Further, as discussed above, in such an aspect, the article movement mechanism  500  can rotate the upper  110 . As can be seen in  FIG. 9 , the coupling member  520  can rotate, relative to the radially extending member  510 , about the vertical axis  501 . In one aspect, in order to have a continuous draw of the vacuum pressure in the interior  911  of the compression material  910 , the vacuum can be drawn through an axis of rotation, e.g., the axis  501 , from which the compression material  910  and the lasted upper  110  rotate. 
     Further, as can be seen in  FIG. 9 , the coupling member  520  can include a downward-extending hook  524  that is coupled to at least another portion of the coupling member  520 . In such an aspect, as the coupling member  520  rotates, the hook  524  can also rotate. In such an aspect, a portion of the lasted upper  110  can interface with or removably couple to the hook  524  to allow for the rotation of the upper  110  as the coupling member  520  and hook  524  rotate. In certain aspects, the hook  524  can also provide for the efficient loading and unloading of the lasted upper  110 , in combination with ease of removal of the compression material  910  from the coupling member  520 , e.g., by release of the top portion  522  of the coupling member  520 . 
     In certain aspects, as discussed above, the compression material  910  may be similarly sized and/or similarly shaped to the last  700  and/or the upper  110 . After exposure to the thermoforming process, in certain aspects, it may be desirable to utilize assistance in order to facilitate the removal of the compression material  910  from the upper  110 . In such an aspect, an air stream may be blown into the interior  911  of the compression material  910  to aid in the release of the compression material  910  from the surface of the upper  110 , or to enlarge the interior  911  to make removal of the upper  110  easier. In one aspect, a port associated with the article movement mechanism  500  can provide such an air stream. In alternative aspects, the air stream may be supplied by another air nozzle or port not associated with the article movement mechanism  500  or other components of the system  100  discussed above. 
       FIG. 10  depicts a flow diagram of a method  1000  for preparing an article for thermoforming. The method  1000  can include the step  1010  of inserting a compression material into a vessel. In aspects, the compression material can include any or all of the features, properties, and parameters of the compression material  910  discussed above with reference to  FIGS. 8A-9 . In certain aspects, the vessel can include any or all of the features, properties, and parameters of the negative pressure vessel  920  discussed above with reference to  FIGS. 8A-8D . In aspects, the compression material is present in a first position in the vessel. In one aspect, the first position can be similar to the position or configuration of the compression material  910  depicted in  FIG. 8A . In aspects, the compression material can include an interior portion adapted to receive an article. 
     The method  1000  can include a step  1020  of exposing an area between an outer surface of the compression material and an inner surface of the vessel to a pressure less than atmospheric pressure. In such an aspect, this pressure, less than atmospheric pressure, can shift the compression material from the first position to an expanded position. In such an aspect, in the expanded position, at least a portion of the compression material can be closer to the inner surface of the vessel than that compared to the first position. In one or more aspects, in the expanded position, the compression material can exhibit at least a portion of the dimensions of the vessel, such as that depicted in  FIG. 8B . 
     The method  1000  can also include the step  1030  inserting at least a portion of an article inside an interior portion of the compression material. As discussed above, in certain aspects, the article can include an upper positioned on a last. In such aspects, the upper can include any or all of the features, properties, and parameters of the upper  110  discuss above with reference to  FIGS. 5A-7B . In aspects, the entire upper, or a portion of the upper, can be positioned inside the compression material. 
     The method  1000  can include the step  1040  of exposing the area between the outer surface of the compression material and the inner surface of the vessel to a pressure at about atmospheric pressure so that the compression material shifts from the expanded position to a second position. In such an aspect, in the second position, at least a portion of the article is in the interior of the compression material and the compression material is closer to the article than when the article was inserted into the compression material in the expanded position. For instance, in one aspect, the second position of the compression material can be similar to that depicted in  FIG. 8D , where the compression material has moved away from the sidewalls of the vessel and is positioned adjacent to the article. 
       FIG. 11  depicts a flow diagram of a method  1100  for thermoforming an article. The method  1100  can include the step  1110  of receiving a compression material having an article positioned inside the compression material. In aspects, the compression material can include any or all of the features, properties, and parameters of the compression material  910  discussed above with reference to  FIGS. 8A-9 . In certain aspects, the article can include a lasted upper, such as the lasted upper  110  discussed above with reference to  FIGS. 5A-7B . 
     The method  1100  can include the step  1120  of exposing an area between an inner surface of the compression material and an outer surface of the article to a pressure less than atmospheric pressure. In such an aspect, the compression material can apply a compressive force onto the outer surface of the article. In certain aspects, the article movement mechanism  500  and the negative pressure generation system  950  can be utilized to provide the negative pressure and expose the area to a pressure less than atmospheric pressure. 
     The method  1100  can include the step  1130  of introducing the article to one or more heating stations. In aspects, the one or more heating stations can include any or all of the features, properties, and parameters of the heating station  200  discussed above with reference to  FIGS. 1 and 2 . The method  1100  can also include the step  1140  of rotating the article within each of the one or more heating stations. In such aspects, the article movement mechanism  500  discussed above with reference to  FIGS. 1, 2, and 9  can be utilized to couple the article thereto and to rotate the article within each of the one or more heating stations. 
     The method  1100  can also include the step  1150  of introducing the article to a cooling station. In aspects, the cooling station can include any or all of the features, properties, and parameters of the cooling station  300  discussed above with reference to  FIGS. 1 and 3 . In one aspect, the article movement mechanism  500  discussed above with reference to  FIGS. 1, 3 , and  9  can be utilized to transfer the article from the one or more heating stations to the cooling station. The method  1100  can also include the step  1160  of rotating the article within the cooling station. In such an aspect, the article movement mechanism  500  discussed above with reference to  FIGS. 1, 2, and 90  can be utilized to rotate the article within the cooling station. 
     While specific reference in  FIGS. 10 and 11  is made to one or more steps, it is contemplated that one or more additional or alternative steps may be implemented while achieving aspects provided herein. As such, blocks may be added or omitted while still staying within the scope hereof. 
     From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. 
     It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. 
     While specific elements and steps are discussed in connection to one another, it is understood that any element and/or steps provided herein is contemplated as being combinable with any other elements and/or steps regardless of explicit provision of the same while still being within the scope provided herein. Since many possible embodiments may be made of the disclosure without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.