Patent Description:
A press compresses two or more materials to join the materials. Heat may optionally be applied to further aid in the bonding of the materials during the pressing operation. The bond between materials may be formed with an adhesive that responds to the pressure and/or thermal energy from the press.

<CIT> describes that an electrical heating bonding device bonds a member to be bonded, which is made of a metal, and a member to be bonded, which is made of a resin.

<CIT> describes that the method is configured so that the lami-nated body is held by forming pressure which is <NUM> or lower than the forming pressure in pressure ratio for <NUM> minutes or longer from a point <NUM> minutes prior to starting to cool at a temperature lower by <NUM> than a temperature where a pre-preg has the minimum melt viscosity, and that the laminated body is formed by laminating the prepregs on both surfaces of an inner layer circuit board, and arranging metal foil on outer surfaces of the prepregs.

<CIT> describes that a press includes an upper platen assembly having a first heating element, a lower platen assembly disposed beneath the upper platen assembly, the lower platen assembly having a second heating element, and a support head adapted to move the upper platen assembly between an open position and a closed position with respect to the lower platen assembly.

Aspects hereof provide a method as defined in claim <NUM>.

Aspects herein also contemplate a hot press as defined in claim <NUM>.

This summary is provided to enlighten and not limit the scope of methods and systems provided hereafter in complete detail.

The present invention is described in detail herein with reference to the attached drawing figures, wherein:.

Aspects hereof provide apparatuses, systems and/or methods to press an article in a press using a closed loop feedback system. Specifically, to reduce a pressing time used to bond a materials forming an article, the press determines an amount of pressure being applied to the materials and adjusts a position of one or both platens of the press to maintain a constant pressure. The press is a closed loop feedback press because it measures the force applied and adjusts a position of one or both platens in response to the measured force. This constant measure of force and adjustment of platen position is beneficial when a state-changing material is included in the collection of materials being pressed. For example, a thermal-melt adhesive (e.g., hot-melt, low-melt polymer adhesive) may be a film-like state at ambient conditions, but under pressure and/or thermal energy from the press may change states to a liquid-like state or deformed solid state. As the state changes of the state-changing material while under pressure, an amount of pressure experienced by the materials may reduce, which prevents the press from providing a constant pressure over time. A closed feedback loop measuring the pressure and adjusting a position of one or both platens as the state-changing material changes states is beneficial to maintain constant pressure, as will be discussed herein.

In a manufacturing environment, a cycle time is an amount of time required to complete a process cycle. In the context of a press for bonding materials, the cycle time includes a material transport time into the press, a pressing time, and a transport out of the press time. The pressing time may be broken down into additional increments, such as a press time at a first pressure, a press time at a second pressure, and the like. When a thermally-responsive material, such as a thermal-melt adhesive is included in the materials to be pressed, the press time may be influenced, at least in part, by an amount of time to transfer thermal energy to the thermally-responsive material such that the thermally-responsive material achieves at least a target temperature (e.g., <NUM> - <NUM> degrees C), such as a deformation temperature or a melt temperature, for a sufficient period of time (e.g., <NUM>-<NUM> seconds). The press time may also be influenced by an amount of time it takes for the thermally-responsive material to reduce in temperature below the target (or any specified) temperature. This cooling period allows the thermally-responsive material form a sufficient tack or bond with the other pressed material(s).

To influence the press time in a cycle, a pressure variable may be adjusted, an order of operations may be adjusted, and/or a thermal energy variable may be adjusted. Aspects herein contemplate adjusting all of the above in different combinations with one or more omitted in some aspects. In a specific example, the thermal energy producing portion of a press (e.g., heating element) is maintained constant as there is thermal mass and the press elements may be relatively slow to adjust a temperature of a press portion relative to an amount of time that pressure can be adjusted. Therefore, the amount of pressure exerted on the materials is adjusted in this example. A greater amount of pressure is applied initially to enhance thermal conductivity through the materials, but as the materials increase in temperature, the amount of pressure applied is reduced to prevent deforming or otherwise damaging the materials being pressed. This varied pressure is effective, in this example, to reduce the press time of the cycle time through efficient conduction of thermal energy by increased pressure and reducing pressure as the material approaches a target temperature to prevent deforming or damaging the material at the elevated temperatures.

In addition (or alternatively) to reducing a cycle time during manufacturing, it is desired to reduce defects caused by the pressing operation. Defects may be formed in a pressing operation through an unintentional deformation or deterioration of the material(s) being pressed. Defects may alternatively be formed when a thermally-responsive material, such as an adhesive, is pressed such that it is exposed on one or more materials in an unintended location. For example, a thermal-melt adhesive may be sandwiched between two materials to be bonded. During the pressing of the three materials, the adhesive may melt and bleed beyond a perimeter of one or more of the to-be-bonded materials to an exposed surface. This exposure of the thermal-melt adhesive may form an aesthetic defect causing the article to be rejected. As such, prevention of this unintended bleeding is a goal in some aspects.

Prevention of bleeding of adhesive is accomplished, in an example, through varied pressure application at different portions of a press time. For example, while an adhesive is in a stable geometric shape (e.g., in a film-like state before approaching a target temperature) a greater amount of pressure is applied as the adhesive will not bleed while in the stable geometric state. However, as the adhesive approaches a target temperature and may begin transitioning to a less stable geometric state (e.g., flowing characteristic), the pressure is reduced to lessen the potential bleeding effect of the adhesive outside of the intended coverage area on the one or more materials. Therefore, the closed loop feedback press that adjusts a position of one or both platens in response to a detected pressure (e.g., force) applied to the materials is effective to reduce defects through a reduction in material bleeding.

To further reduce defects, aspects herein contemplate a conforming surface on one or both platens. As will be discussed in <FIG>, a transition between thicknesses of a material stack may result in an uneven distribution of pressure with a rigid platen surface. As such, a higher concentration of force and therefore a greater pressure may be applied to a raised (e.g., thicker) portion of the material stack when using a non-conforming surface on the platens. This lack of conformance may cause bleeding (e.g., flowing of material outside of an intended location) of material from the raised portion experiencing a higher pressure than intended. To combat an unequal distribution of force, aspects contemplate a conforming surface for at least one platen. The conforming surface is a resilient polymeric composition, i.e., a silicon-based material. Further, it is contemplated that the silicon-based material is a foamed composition having a durometer in a Shore 'A' hardness range of <NUM> to <NUM>, in an example. This durometer allows for sufficient compliance while still effectively conducting pressure from the platen through the material.

The conformance of a compliant material may also be influenced by a thickness of the material. In aspects, the conforming material is sufficiently thick to conform around the anticipated varied thicknesses of the materials to be pressed, but not so thick that the material is ineffective to transfer the compression force and/or thermal energy in a heat press configuration. Therefore, in the use of forming portions of an article of footwear or an article of apparel, it is contemplated that the conforming material on a platen has an uncompressed thickness in a range of <NUM> to <NUM>. Within this range, the conforming material has a compressed thickness that is <NUM>%-<NUM>% that of the uncompressed thickness when pressing a component for use in an article of footwear to achieve a sufficient compression and/or heat transfer to the pressed materials.

In yet other aspects, it is contemplated that the closed loop feedback system is capable of maintaining a consistent pressure, and in the case of a heat press, a consistent temperature. As will be discussed, sensors, such as a load cell and/or thermal coupler, measure a variable and provide that reading to a computing device that instructs one or more changes to be made. For example, a load cell measure an amount of force being applied through an actuator to a platen. The system, in an exemplary aspect, is effective to maintain a desired pressure, even with a state-changing material under compression, within plus or minus <NUM> PSI (<NUM>,<NUM> mbar) of the target pressure. This narrow range of pressure deviation aids in achieving a short cycle time and a reduction in material defects from the pressing operation. Similarly, the closed feedback loop on a heat press system is effective for maintaining a temperature of a platen within plus or minus <NUM> degrees Celsius. This narrow range of temperature deviation aids in achieving a short cycle time and a reduction in material defects from the pressing operation.

As will be disclosed in greater detail, aspects contemplate methods and system for pressing an article with a closed-loop feedback press to quickly and effectively join two or more materials.

<FIG> depicts an example of a system <NUM> for pressing an article with a closed loop feedback system, in accordance with exemplary aspects hereof. The system <NUM> is comprise of a hot press <NUM>, a cold press <NUM>, and a controller <NUM> logically coupled thereto by one or more logical couplings <NUM>. While the system <NUM> is depicted with both the hot press <NUM> and the cold press <NUM>, it is understood that either of the presses may be omitted from the system <NUM>. Additionally, it contemplated that the system <NUM> may be comprised of any number of the hot press <NUM> and/or the cold press <NUM>.

As depicted in <FIG>, a material flow direction extends from the hot press <NUM> to the cold press <NUM> such that an article is first pressed in the hot press <NUM> and then pressed or maintained compressed in the cold press <NUM>. This order of operation may be adjusted, in an example the order of operation allows for efficient use of the system <NUM> through a quick thermal activation of an adhesive in the hot press <NUM> followed by a setting (e.g., curing, cooling) of the thermally-activated adhesive while under compression in the cold press. This transfer from the hot press <NUM> to the cold press <NUM> allows the hot press <NUM> to maintain a relatively consistent temperature without having to be cooled to allow for the thermally-activated adhesive to set and allows the hot press to press and thermally activate a second article while a first article if setting in the cold press <NUM>. Therefore, for increased throughput with reduced cycle times, the system <NUM> of <FIG> includes both the hot press <NUM> and the cold press <NUM>.

The hot press <NUM> is a closed-loop feedback press in both a pressure system and a temperature system. Stated differently, the hot press <NUM> adjusts a position of one or more platens in response to a measured pressure applied to the platens without human intervention, which allows for tighter pressure tolerance maintenance and real-time adjustments. Additionally, the hot press <NUM> leverages a thermometer or other thermal measuring device (e.g., infrared thermometer, thermocouple) to determine a temperature of one or more portions of the hot press and appropriately adjust a thermal generation (e.g., heating element) to maintain an intended or desired temperature in real time without human intervention, which allows for tighter temperature tolerances to be maintained during a pressing operation than a non-closed-loop feedback system.

The hot press <NUM> is comprised of a frame <NUM> from which the other components are supported. The hot press <NUM> is comprised of both a top platen <NUM> and a bottom platen <NUM>. One or both of the top platen <NUM> and the bottom platen <NUM> adjust positions to converge on one another to generate the pressure used to compress the article for the pressing operation. This adjustment of position is accomplished from an actuator, such as an actuator <NUM>, as will be discussed in greater detail hereinafter.

With focus on the bottom platen <NUM>, a base <NUM> is joined with the frame <NUM> to support the bottom platen <NUM> and the forces transferred therethrough. The base <NUM> extends into a bottom member <NUM>, which may optionally be a load cell. The bottom member <NUM> as a load cell may be omitted in some examples as a top load cell <NUM> may be solely used. Alternatively, the bottom member <NUM> as a load cell may be exclusively used and the top load cell <NUM> may be omitted in some examples. A load cell is a mechanism capable of measuring a force (e.g., load) exerted through the load cell. In an example, a load cell is a transducer that creates an electrical signal whose magnitude is directly proportional to a force being measured. Examples of a load cell include, but are not limited to, a hydraulic load cell, a pneumatic load cell, a strain gauge load cell, a piezoelectric load cell, and/or a capacitive load cell. A load cell is effective to capture an amount of force being transferred therethrough to an article being pressed. The force measured at a load cell may be converted to a pressure experienced by the article based on a distribution area (e.g., platen size) over which the pressure is spread. As the article changes states or deforms (e.g., melting of a thermally-activated adhesive) a thickness of the article may change (e.g., reduce) causing a reduced compression on the article between the top platen <NUM> and the bottom platen <NUM>. This change in article thickness and resulting reduced compression can lead to a longer press time for a target temperature to be reached by the article and/or for sufficient bonding to occur. As a result, a load cell is capable of detecting a change in the compression through a deviation in force transferring through the load cell. In response to the load cell detecting a reduction in force, a signal may be communicated from the load cell to the controller <NUM>. The controller <NUM> in response may instruct the actuator <NUM> to change a position (e.g., lower) of the top platen <NUM> that increases the force exerted through the load cell as the top platen <NUM> and the bottom platen <NUM> compress the article therebetween.

As stated earlier, a single load cell may be implemented, such as the top load cell <NUM> or the bottom member <NUM> as load cell. Or, in an optional and alternative example, two or more load cells may be implemented to measure a force passing therethrough and a resulting compression on the article may be determined. In the example, of <FIG>, only the top platen <NUM> is moveably positioned by an actuator, but other aspects contemplate the bottom platen <NUM> also (or exclusively) being positioned by an actuator. Therefore, any combination (e.g., number, position, collection) of actuators and/or load cells are contemplated to achieve a closed-loop feedback system for applying a compressive force to an article.

The bottom member <NUM> joins with a bottom consolidation plate <NUM>. The bottom consolidation plate consolidates forces transmitted through supports <NUM> from the bottom platen <NUM>. In an example, supports <NUM> are rigid members. The supports <NUM> may be positioned at periphery locations of the bottom platen <NUM> to provide a stable platform. The supports <NUM> transfer a load from the bottom platen <NUM> to the bottom consolidation plate <NUM>. In the example of <FIG>, the consolidation plate allows for the collective force transmitted from the supports <NUM> to be measured by the bottom member <NUM> as an optional load cell through the consolidation effect provided by the bottom consolidation plate <NUM>. The consolidation plate is a rigid material, such as steel, that has minimal deformation and flex that could skew force measurements by the bottom <NUM> when a load cell in those scenarios where a bottom load cell is implemented.

The supports <NUM> extend from the bottom platen <NUM>. The bottom platen <NUM> is comprised of a bottom plate <NUM>, a bottom heating plate <NUM>, and a bottom contacting material <NUM>. The bottom plate <NUM> may be a rigid plate, similar to the bottom consolidation plate <NUM>, and effective to support the bottom heating plate <NUM> and the bottom contacting material <NUM> during a compression of the hot press <NUM>. The bottom plate <NUM> may be formed from a metal, such as steel.

The bottom heating plate <NUM> is a thermal source. The bottom heating plate may be comprised of one or more heating elements. A heating element may be effective to convert electrical energy to thermal energy through resistance or induction. One or more heating elements may be included in the bottom heating plate <NUM>. It is contemplated that a plurality (i.e., <NUM> or more) of heating elements may be included in the bottom heating plate <NUM>. The plurality of heating elements allows for zonal control of heating in the bottom platen <NUM>. The zonal control may be used to maintain an equal temperature across a surface area of the bottom platen <NUM> or it may be used to provide a differential temperature across a surface area of the bottom platen <NUM>. The differential temperature may be leveraged for an article having different thicknesses at different locations and/or for an article constructed from different materials having different deformation temperatures (e.g., melt temperature, state-change temperature, glass-transition temperature, ignition temperature). As such, it is contemplated that the bottom platen <NUM> may provide a homogenous temperature across a surface area or it may provide an intentionally varied temperature across a surface area.

The closed-loop feedback for temperature comprises a thermometer. A thermometer is a mechanism for measuring a thermal energy or temperature of a component of the system. Examples of a thermometer contemplated include, but are not limited to, thermocouple, resistance thermometer, thermistor, quart thermometer, infrared thermometer, and/or thermal expansion thermometer. The bottom platen <NUM> is comprised of a thermometer. The thermometer is effective to measure a temperature of the bottom platen <NUM> at one or more locations. For example, a temperature of the bottom platen <NUM> at a material contacting surface of the bottom contacting material <NUM> may be measured to account for thermal loss from the heating elements through the bottom contacting material <NUM>. Alternatively or additionally the temperature may be measured at the heating elements or at the bottom heating plate <NUM>. As with the example above having zonal heating or a plurality of heating elements, it is contemplated that a plurality of thermometers may be used in connection with one or more of the zones. In an example, each heating zone may have a dedicated thermometer allowing for a one-to-one closed-loop feedback between a heating element and a thermometer.

The bottom contacting material <NUM> forms a material contacting surface and overlays the bottom heating plate <NUM> on an opposite side to the material contacting surface. The material contacting surface is a surface presented to an article (e.g., a portion of a shoe upper) that is intended to be pressed. The bottom contacting material <NUM> may be a sacrificial, removable, and/or disposable material. For example, the bottom contacting material <NUM> may be removable such that contaminants (e.g., adhesive, deformed material) that could damage or interfere with the processing of future articles could be removed from the press by removing of the bottom contacting material <NUM> from the press. In an aspect, the bottom contacting material <NUM> is maintained to other portions of the bottom platen <NUM> through a heat-activated adhesive. The heat-activated adhesive may be activated at temperature that is above a traditional temperature of operation for the hot press <NUM> while pressing an article. For example, the heat-activated adhesive joining the bottom contacting material <NUM> may be activated at temperatures <NUM> degrees Celsius, <NUM> degrees Celsius or more above an operating temperature of the hot press <NUM> when pressing an article. In an example, the bottom contacting material <NUM> is a polymeric material. In a specific example, the bottom contacting material <NUM> is formed from polytetrafluoroethylene (PTFE). The bottom contacting material <NUM> is a substantially non-compressible material in a first example. In an alternative example the bottom contacting material <NUM> is a resilient compressible material, such as will be discussed in connection with a top contacting material <NUM>.

The hot press <NUM> as depicted in <FIG> has a statically positioned bottom platen <NUM>. However, alternative aspects contemplate a positionable bottom platen, such as through an actuator. The ability to position the bottom platen may allow for a removal of one or more moveable elements on the conveyance system that will be discussed hereinafter.

The hot press <NUM> is also comprised of the top platen <NUM>. The top platen <NUM> is comprised of a top plate <NUM>, a top heating plate <NUM>, and a top contacting material <NUM>. The top contacting material forms a material contacting surface of the top platen <NUM>. As discussed with the bottom contacting material <NUM>, a material contacting surface is a surface of the platen exposed to and forming a surface for contacting an article to be compressed between the platens. The top contacting material <NUM> may be any material, such as a polymer-based material. In a specific aspect, the top contacting material <NUM> is a foam material. The top contacting material <NUM> is a silicon-based composition. In a specific example, the top contacting material <NUM> is a silicon-based material, such as a silicon-based foam material.

The top contacting material <NUM> may be resilient and compressible. The compressibility of the material translates to a conformance to varied thicknesses of the article to be compressed, as seen in <FIG> hereinafter. The conformability of the top contacting material <NUM> aids in the effectiveness of the hot press <NUM> to press the article without unintentionally deforming or otherwise marking the article while still achieving an effective bonding. For example, having the top contacting material <NUM> a conforming material, a more uniform pressure may be applied a varied thickness surface as the top contacting material <NUM> compresses and conforms to areas of greater thickness such that the top contacting material <NUM> contacts the surface of the article as the article thickness transitions. Stated differently, a conforming material allows for more uniform and complete contact and pressure across a varied thickness article than a non-conforming material contacting surface.

A suitable amount of conformance of the top contacting material <NUM> is represented through a durometer measure. In specific examples that are appropriate for hot pressing of an article for use in an article of footwear and/or an article of apparel, include a Shore 'A' hardness of <NUM> to <NUM>. Shore 'A' hardness durometer type as provided herein is measured using the ASTM D2240-15e1 standard for the Durometer type 'A'. In a specific example, the durometer of the top contacting material <NUM> has a Shore 'A' hardness of <NUM> to <NUM>. These durometer ranges are effective to conform to the article being pressed by the hot press <NUM> while still effectively transferring the compression force.

With the given durometer ranges, it is contemplated that the top contacting material <NUM> has a thickness of <NUM> millimeters (mm) to <NUM>. This thickness of the top contacting material <NUM> allows for sufficient deformation and conformance to the article being pressed. For example, it is contemplated that the top contacting material <NUM> has a compressed thickness that ranges from <NUM>% to <NUM>% of the uncompressed thickness when an article is being pressed by the hot press <NUM>. This level of compressibility provide sufficient conformance without sacrificing the thermal conductivity of the top platen <NUM> from the top contacting material <NUM>. As the top contacting material <NUM> is thicker, additional insulation results from the conveyance of thermal energy from the top heating plate <NUM> towards the article being pressed.

However, in an example, the thermal insulating aspect of the top contacting material <NUM> is intentional. In some aspects an intended temperature differential between the top platen <NUM> and the bottom platen <NUM> is provided. The temperature differential may be achieved through varied outputs of thermal energy from the respective heating plates. Alternatively, the temperature differential is achieved through an insulation attribute of the top contacting material <NUM> relative to the bottom contacting material <NUM>. For example, the top contacting material <NUM> is less thermally conductive than the bottom contacting material <NUM>, in an example. This lower thermal conductivity allows for a thermal difference to be maintained between the material contacting surfaces of the top platen <NUM> and the bottom platen <NUM>.

A temperature differential between the top platen <NUM> and the bottom platen <NUM> is advantageous in aspects. For example, the article may be positioned in the hot press <NUM> such that materials having a lower temperature tolerance (e.g., lower deformation temperature, lower melt temperature, lower deterioration temperature) are oriented toward the top contacting material <NUM> than material in closer proximity to the bottom contacting material <NUM>. In a specific example, a shoe upper component having an exterior surface of the to-be-formed shoe may be formed from an aesthetically pleasing material (e.g., cosmetic material) that is more susceptible to damage or defects caused by heat than a more interior material of the to-be-formed shoe, such as an intermediate material or a shoe liner material. As such, having a temperature differential between the top platen <NUM> and the bottom platen <NUM> allows for materials having different thermal response temperatures to be pressed concurrently as a common article without adversely deforming or otherwise creating a defect in the materials while minimizing the press time to increase system throughput. In an example, the top platen material contacting surface is <NUM> degrees Celsius to <NUM> degrees Celsius less than the bottom platen material contacting surface. In an example, the top platen material contacting surface and the bottom platen material contacting surface are both at a temperature above a temperature at which an adhesive layer of the to-be-pressed article bonds with another material (e.g., a melting temperature). It is contemplated that the bottom platen material contacting surface is maintained below a deformation temperature (e.g., melt temperature, deterioration temperature, glass transition temperature) of the portion of the article in contact with the bottom platen material contacting surface.

The top heating plate <NUM> is similar to the bottom heating plate <NUM>, in an example. The top heating plate <NUM> includes one or more heating elements. The heating elements are effective to generate thermal energy in the form of heat that is effective to raise a temperature of an article being pressed by the hot press <NUM>. The heating elements are controllable through the closed-loop feedback system in a manner similar to that described with respect to the bottom platen <NUM>. For example, one or more thermometers may monitor and provide feedback to a controller to adjust a temperature of the top heating plate <NUM>. Further, it is contemplated that two or more heating zones may exist in the top heating plate <NUM> that are individually or uniformly controlled. In the closed-loop feedback system of the present application it is contemplated that a consistent temperature is maintained at the material contacting surfaces of the platens. A consistent temperature for purposes of the present disclosure is in a range of plus or minus <NUM> degrees Celsius. This level of consistency is achieved by having the closed-loop feedback system of a thermometer monitoring the temperatures and a controller controlling the heating elements in response to the measured temperature(s). This level of consistency allows for temperature closer to deformation temperature or critical temperatures of the article to be used without causing a deformation or deterioration of the article materials as the temperature is controlled within a tight temperature range. An ability to operate with this level of consistency near the critical temperatures of the material allows the system to operate with faster cycle times that increase the throughput of the system. Systems not having a closed-loop feedback system may instead only maintain a temperature that is within a range of target that is plus or minus <NUM> degrees C, which is insufficient for aspects contemplated herein.

The top plate <NUM> provides a rigid structure for transferring the force applied through the actuator <NUM> to the article being pressed without excessive flexing or deformation. This rigidity may be achieved with a metallic material, such as steel. The top plate <NUM> serves as a connection of the top platen <NUM> with the force generation of the actuator <NUM>. The top plate <NUM> also may serve as a connection for one or more stabilizers. The stabilizers aid in maintaining a parallel travel of the top platen <NUM> through stages of compression. The stabilizers are depicted as rod-like elements extending from the top plate <NUM> through the frame <NUM> that provide parallel travel of the stabilizers, which translates to a parallel positioning of the top platen <NUM> as it moves through a range of vertical positions. The stabilizers aid in ensuring a consistent application of force across the article being pressed even when the article has varied thicknesses or is oriented in an offset manner to the top platen <NUM>. In some examples, the stabilizers are referred to a linear bearings.

A load cell <NUM> is depicted as extending between the top platen <NUM> and a consolidation plate <NUM> that is joined with a piston <NUM> (or pistons) of the actuator <NUM>. The load cell <NUM> is similar to the load cell previously discussed. The load cell <NUM> is effective to measure an amount of force transferred from the actuator <NUM> to the top platen <NUM>. The consolidation plate <NUM> is optional in some examples. However, in the configuration of <FIG>, the actuator <NUM> has more than one piston <NUM> and therefore the consolidation plate <NUM> is effective to consolidate the forces of the various pistons to be measured by a common load cell. On other examples, the actuator may have a single piston applying a force. In a single piston example, the load cell may be positioned in line with the piston and the top platen <NUM> without the consolidation plate <NUM>, for example.

The actuator <NUM> is capable of generating a linear movement that is converted into a force for compression. The actuator <NUM> may be hydraulic, pneumatic, or mechanical actuator. In an example, the actuator <NUM> is a screw actuator that converts a rotational force to a linear force through a screw mechanism. The screw actuator may be a standard planetary roller screws, inverted roller screws, ball screws, and the like. In a specific example, a screw actuator is used having a high tolerance nut assembly that allows for a reduced backlash due to the high precision between the screw and nut mating. To further drive efficiencies in the screw assembly of the actuator, it is contemplated that one or the screw or the nut (or both) are coated in a friction reducing materials, such as PTFE. A lower backlash from the high precision mating of the screw and nut provides for greater control of the force applied by the actuator to the top platen <NUM>. For example, if there is rotational movement of the screw (or the nut) by a servo motor before the screw engages with the nut because of low tolerances, the rotational energy is not converted into linear movement that affects the amount of pressure applied. Similarly, if after applying rotational energy a low tolerance between the screw and the nut allows for a change in near position with affecting the rotational position of the screw (or nut). As such, when achieving a consistent pressure through a closed-loop feedback system of a controller and a load cell, minimizing of backlash of the actuator additionally allows for greater consistency of the force.

Multiple pistons <NUM> may be used in connection with the actuator <NUM>. The multiple pistons aids in a reduction in backlash in one example, allows for greater control over linear motion as the piston diameters may be smaller while achieving a similar force than when done with a single piston. However, it is contemplated that some aspects leverage a sole piston configuration.

The hot press <NUM> is effective to compress an article with a force up to <NUM> pounds per square inch (psi) i.e. (<NUM>,<NUM> bar) In an example, the press operates in a pressure range of <NUM>-<NUM> psi. At this range, an effective compression of an article of footwear or an article of apparel may be bonded without over compressing that may cause bleeding or other defects resulting from over compression. The closed-loop feedback system including the load cell <NUM> and the controller <NUM> in connection with the actuator <NUM> allows for a force tolerance range of plus or minus <NUM> psi (<NUM>,<NUM> mbar), in an example. As with the temperature tolerance range, a consistent pressure allows the system to operate at maximum pressures without causing defects, which increases the system throughput. As such, the closed-loop feedback system of the force generation able to maintain a plus/minus pressure range of <NUM> psi (<NUM>,<NUM> mbar) is advantageous to the system. In yet other examples, the press operates at <NUM> psi (<NUM>,<NUM> bar) or less with a compression of the top contacting material <NUM> of <NUM>-<NUM> while having a durometer of Shore 'A' type <NUM>-<NUM> range. With this configuration an effective bond between an article without causing bleeding is achieved in an example.

The hot press <NUM> is also comprised of a conveyance system effective to convey and position an article within the system <NUM>. As depicted and as will be shown in <FIG> and <FIG>, the conveyance system and the article, in an example, are configured to use a frame for conveying and positioning the article. The conveyance system includes a conveyor <NUM> having a first end <NUM> and a second end <NUM> with a material flow direction traditionally extending from the first end <NUM> to the second end <NUM>. As will be more clearly depicted in <FIG>, the conveyance system is configured to adjust vertically relative to the bottom platen <NUM> by motion of actuators <NUM>. The vertical positioning allows the article to be placed on and supported, at least in part, by the bottom platen <NUM> for effective pressing by the system. Additional details of the conveyance system will be provided in connection with <FIG> and <FIG> hereinafter.

The system <NUM> is depicted as including the cold press <NUM> in a material flow downstream position from the hot press <NUM>. As used herein, a hot press is a press effective to transfer thermal energy to the article being pressed. A cold press is a press that is not actively adding thermal energy to the article being pressed, but it provides a compression force. As such, the difference between the hot press <NUM> and the cold press <NUM> is an active heating element. Therefore, a hot press may be considered a cold press when heating elements, such as the top heating plate <NUM> and the bottom heating plate <NUM>, are not activated. Similarly, a cold press may be similar in structure and design to a hot press with the heating elements, such as the heating plates, omitted altogether, as is shown in the cold press <NUM>. Therefore, the cold press <NUM> includes similar components as previously discussed in connection with the hot press <NUM>, but labeled with a "b" for differentiation purposes. Absent from the cold press <NUM> relative to the hot press <NUM> is a top heating plate and a bottom heating plate. As the cold press <NUM> is intended to provide a compressive force on the article while one or more thermally-activated adhesive cool, heating elements are not included in the cold press. Also absent are the associated thermometers of the temperature regulating closed-feedback loop system of the hot press <NUM>. In this example, the cold press operates at ambient temperature, which may be at least <NUM> degrees C less than the top platen.

The cold press <NUM>, unless expressed to the contrary, is formed from components as similarly discussed in connection with the hot press <NUM>. For example, the cold press <NUM> is comprised of a base 112b, a bottom member 114b, a bottom consolidation plate 116b, support 118b, a bottom platen <NUM>, a bottom plate <NUM>, a bottom contacting material <NUM>, a top platen <NUM>, a top contacting material <NUM>, a top plate <NUM>, a load cell 132b, a top consolidating plate 130b, pistons 128b, and actuator 126b, and a conveyor140b having a first end 142b and a second end 144b. Those elements numerated with a 'b' are similar to similarly numbered elements from the hot press <NUM>. The top platen <NUM> and the bottom platen <NUM> of the cold press <NUM> are similar to the top platen <NUM> and the bottom platen <NUM> of the hot press <NUM> except for the omission of the hot plates and associated components, such as thermometers. For example, the bottom plate <NUM> is similar to the bottom plate <NUM> in function and material. The bottom contacting material <NUM> and the bottom contacting material <NUM> are similar in function and material. The top contacting material <NUM> and the top contacting material are similar in function and material. The top plate <NUM> and the top plate <NUM> are similar in function and material. However, it is contemplated that dimensions, size, material, and connections may be altered between the hot press configuration and the cold press configuration.

The controller <NUM> and the logical couplings <NUM> are depicted as connecting the hot press <NUM> and the cold press <NUM>. It is depicted in this manner for illustration purposes, but it is understood that the couplings could be wireless or in other configurations. Further, while a single controller <NUM> is depicted, it is contemplated that any number of controllers logically coupled or not logically coupled may also be included. The controller <NUM> includes a computing processor and memory that are effective to receive inputs from one or more components and to send instructions to one or more components. For example, the controller <NUM> receives measurements from the load cell <NUM> and directs the actuator <NUM> to adjust a position of the top platen <NUM> and therefore pressure exerted by the top platen <NUM> according to a recipe for the article. A graphical representation of a recipe will be depicted in <FIG> hereinafter. Another example of an implementation of the controller <NUM> is receiving one or more measurements from a thermometer and then instructing one or more heating elements, such as heating elements of the top heating plate <NUM> and the bottom heating plate <NUM> to adjust accordingly to maintain a temperature as prescribed by the recipe. The controller <NUM> is also effective to control the conveyance mechanisms for conveying and positioning the article. For example, the conveyance mechanism may start and stop at various locations in response to a detected or known location of the article, as controlled by the controller <NUM>. Further, the conveyance mechanism may adjust a vertical position of the article in response to a processing step sequence or a position of the article, as controlled by the controller <NUM> instructing one or more actuators, such as the actuators <NUM>.

The logical coupling <NUM> is connection for communicating information. The logical coupling may be wired or wireless. A wired logical coupling may be any communication format, such as a local area network. A wireless logical coupling may implement any communication protocol, such as those commonly used over Wi-Fi, Bluetooth, and the like. As such, it is contemplated that any communication standards may be used in connection with the logical couplings that connect, logically, one component with another component in the system.

<FIG> depicts a plan view of a conveyance portion of the system <NUM> from <FIG>, in accordance with aspects hereof. The first conveyor having the first end <NUM> and the second end <NUM> is comprised of a first track <NUM> and a second track <NUM>. A track is a belt, chain, mesh, links, or other surface that is effective to move an article through a press. The first track <NUM> and the second track <NUM> are contemplated to operate in unison such that as one track conveys, the second track similarly conveys. This may be accomplished through a common drive motor, such as a servo or other stepper motor configuration whose drive force is distributed to both the first track <NUM> and the second track <NUM>. In an alternative example, separate drive sources, such as a separate servos or stepper motors may independently drive each track, but their movements may be coordinated. The coordinated movement of the first track <NUM> and the second track <NUM> allows for the parallel movement of the article relative to the platens, as represented by the bottom contacting material <NUM>. The first track <NUM> and the second track <NUM> are associated with the hot press from <FIG>. A first track 202b and a second track 204b are associated with the cold press of <FIG>.

The first track <NUM> and the first track 202b are linearly aligned in the depicted example to serve as a substantially continuous movement mechanism. Similarly, the second track <NUM> and the second track 204b are linearly aligned in the depicted example to serve as a substantially continuous movement mechanism. The track associated with a first press and the track associated with a second press are separate tracks, in an example, to allow independent vertical movement of the track in connection with the individual presses, as will be discussed in connections with <FIG>. For example, the first track <NUM> and the second track <NUM> may be in a lowered configuration allowing an article to be pressed on the bottom contacting material <NUM> while the first track 202b and the second track 204b are in a raised configuration in preparation for receiving the article from the first track <NUM> and the second track <NUM> after the pressing operation.

The first track <NUM> and the second track <NUM> are spaced apart a width <NUM>. The platens that the conveyance mechanisms convey over have a width <NUM>. To prevent interference in the movement of the platens and the pressing of an article, it is contemplated that the width <NUM> is greater than the width <NUM> to allow the conveyance mechanism to raise and lower above and below the platens to position an article for pressing. Additionally, the first track <NUM> and the second track <NUM> have a length in the material flow direction between the first end <NUM> and the second end <NUM> that is greater than a length of the platen having a length <NUM>. This greater length of the conveyance mechanism allows for the conveyance and positioning of the article into, through and out of the press without interference with the platen.

<FIG> depicts an example of a frame assembly <NUM> having an article as a shoe upper <NUM>, in accordance with aspects hereof. The frame assembly <NUM> is effective to be conveyed through a press by a conveyance system, such as the first track <NUM> and the second track <NUM> of <FIG>. Further, the frame assembly <NUM> is effective to aid in positioning and maintaining the article at a platen for pressing and the automated movement of the article into the press, through the press, and out of the press. The frame assembly <NUM> is comprised of a frame <NUM> formed from a plurality of frame members <NUM>, <NUM>, <NUM>, and <NUM>. The frame members may be portions of a continuous (i.e., monolithic) material or they may be discreet members that are joined together to form the frame <NUM>. The frame <NUM> may be formed from any material, such as a polymer composition or a metallic composition. The frame <NUM> may be rigid and able to withstand a plurality of duty cycles for different articles.

The size of the frame <NUM> is correlated with the size of the platens and the conveyance system of <FIG> and <FIG>, in an example. The frame <NUM> has an outside width <NUM> and an inside width <NUM>. The frame <NUM> has an inside length of <NUM> and an outside length <NUM>. The inside width <NUM> and the inside length <NUM> are contemplated as being greater than the platen width and length, respectively. Stated another way, it is contemplated that the frame <NUM> is sized such that a platen may extend into an interior space of the frame such that the frame does not interfere with a pressing of an article between two platens while the article is associated with the frame. The outside width <NUM> is sized such that the frame <NUM> is supported by the conveyance system as depicted in <FIG>. For example, the outside width <NUM> is similar to the conveyor width <NUM> of <FIG>.

The frame assembly, in an aspect, includes a foundation material <NUM>. The foundation material <NUM> may be part of the frame assembly <NUM> independent of the article to be pressed. In an alternative aspect, the foundation material <NUM> is present with the frame when the article is maintained with the frame. Stated differently, the foundation material <NUM> may either be part of the frame independent of the article or the foundation material <NUM> may be part of the article to be pressed and associated with the frame only when using the frame to convey the article. The foundation material <NUM> may be any materials, such as a textile, a film, a sheet, or the like. In an example, the foundation material is a non-woven textile formed from a material having a higher deformation temperature (e.g., melt temperature) than an operating temperature of a hot press and/or the material of the article to be thermally activated by the hot press. The foundation material <NUM> provides a surface onto which the article is supported and maintained during transportation through one or more presses. In a specific example, the foundation material <NUM> provides a surface to which the article is temporarily or permanently secured to maintain a consistent position relative to the frame <NUM> during transit and/or pressing operations.

The article is depicted as an upper <NUM>. An upper is the portion of an article of footwear (e.g., a shoe) effective to secure a wearer's foot to a sole of the article of footwear. In some examples the uppers is a textile, polymer film, leather or other traditional materials that extend above a sole portion of the footwear. The upper <NUM> may be formed from any material. For example, the upper <NUM> may be a textile in the form of a woven, braided, non-woven, or knit material. Further, the upper <NUM> may be formed from any material composition. The material compositions include, but are not limited to, polymer materials (e.g., nylon, polyester), organic materials (e.g., cotton, wool), leather, and the like. It is contemplated that the upper <NUM> may be formed from a variety of materials at different locations. The upper <NUM> may be permanently secured with the foundation material <NUM>, temporarily secured with the foundation material <NUM>, or not secured with the foundation material <NUM>. It is contemplate that the entirety of the article to be pressed is maintained within the frame <NUM> in an example. Alternatively, it is contemplated that less than a whole of the article to be pressed is maintained within the frame <NUM>, but the portion maintained within the frame is a portion to be pressed.

The article is contemplated as comprising a plurality of material layers that are to be joined through a pressing activity. In the example of <FIG>, the article is the upper <NUM> formed from a base material <NUM> having a plurality of overlays. Any number of overlays in any shape, size, orientation, and/or location are contemplated. The overlay may be a similar material to the underlying material or it may be a different material to the underlying material. The overlay may be formed from a polymeric composition, an organic composition, and/or a metallic composition. The overlay may be aesthetic and/or functional (e.g., cushioning, rigidity, tension transferring, stiffening). The overlay may be intended to be bonded to another material or the overlay may be intended to integrate Further, as will be shown in <FIG>, it is contemplated that an adhesive may be present between one or more layers of the article. It is this adhesive that may be activated to join the materials in the presence of heat and/or pressure from a pressing operation. A first overlay <NUM>, a second overlay <NUM>, and a third overlay <NUM> are depicted.

<FIG> depicts a cross sectional view of the frame assembly <NUM> from <FIG> along a cut line A-A, in accordance with aspects hereof. The frame is depicted as having a top frame portion and a bottom frame portion. The members <NUM> and <NUM> form a portion of the top frame. Corresponding members 316b and 318b for a portion of the bottom frame. The two-part frame is option. A two-part frame as depicted in <FIG> provides an example of securing the foundation material <NUM> with the frame through a compression between the top frame and the bottom frame, as depicted in <FIG>. Alternatively, it is contemplated that the frame does not have separate top and bottom portions and the foundation material, when used, is secured my other means, such a hooks, snaps, adhesive, and/or other compression arrangements (e.g., channel and fill).

The foundation material <NUM> is depicted as being maintained in a taut configuration within the frame such that the foundation material <NUM> supports the article (i.e., upper <NUM>). The upper <NUM> has a first collection of overlays positioned on the base material <NUM>. This first collection is depicted as including the first overlay <NUM> and the second overlay <NUM>. As is easier to see in <FIG>, additional layers of bonding material, such as a thermally-activated adhesive, are positioned between the base material <NUM>, the first overlay <NUM> and the second overlay <NUM>. A bonding material may also be referred to as an adhesive material herein.

A bonding material is a material effective to bond a first material with a second material. The bonding material may be activated by heat and/or pressure in an example. Therefore, in response to heat and pressure from a hot press, the bonding material is effective to bond one or more materials together. Examples of a bonding material include, but are not limited to, a polymeric material having a deformation temperature (e.g., melting temperature) that is able to be obtained within a heat press. The deformation temperature of the bonding material is less than a deformation temperature of the materials to be bonded by the bonding material in an example. This difference in deformation temperatures between the to-be-bonded materials and the bonding material allows for the to-be-bonded materials to be bonded without unintentionally deforming.

The bonding material may be referred to as a "hot-melt adhesive. " A hot-melt adhesive is a polymeric composition that changes from a firsts ate (e.g., sheet-like configuration in a solid state) to a more viscous fluid-like state in the presence of thermal energy. Stated differently, the polymeric composition melts or otherwise changes to a more fluid state in response to a pressing operation contemplated herein. Following the pressing operation or following a portion of the pressing operation (e.g., removal of excess thermal energy), the polymeric composition solidifies and captures or adheres to portions of the to-be-bonded material.

In an example, the bonding material is elevated to a temperature of <NUM>-<NUM> degrees C for at least <NUM> seconds to achieve a suitable bond for the upper <NUM> to be effective as an article of footwear. This temperature of the bonding material may be in contrast to a deformation temperature of the base material <NUM> that deforms at around <NUM> degrees C. Therefore, it is desirable in an example, to keep the material contacting surfaces of the platens below the deformation temperature of the base material, but above the target temperature for the bonding material (e.g., above <NUM> degrees C).

<FIG> illustrates a thickness difference across the upper <NUM> resulting from the various overlay stacks. For example, the first overlay stack comprised of the first overlay <NUM> and the second overlay <NUM> shows a stepped thickness difference created by the different shape/size/orientations of the stacked overlays. As previously discussed with respect to the conformability of the top contacting material <NUM> from <FIG>, the conformance allows the press to conform to the stepped thickness to uniformly apply pressure to the article as a whole even with a greater thickness caused by the overlay s tack in a specific location of the article. But for the conformance, the pressure applied by the press would be concentrated at the greatest thickness location of the article and would therefore potentially overly compress that portion of the article without sufficiently compressing other portions of the article having less thickness. Similarly, the conformance allows for effective conduction of thermal energy from the platen through contact between the conforming material and the less thick portions of the article. Therefore, the conforming quality of the material of the platen can aid in apply a more uniform pressure and temperature, which can limit bleeding and other defects when pressing an article having variable thicknesses.

<FIG> depicts a magnified portion of <FIG>, in accordance with aspects hereof. Specifically, the second overlay <NUM>, a bonding material <NUM>, the first overlay <NUM>, a bonding material <NUM>, the base material <NUM>, and the foundation material <NUM>. The bonding material <NUM> and <NUM> may be the same bonding material or it may be a different bonding material. For example, the bonding material may be different based on the material to be bonded (e.g., compatibility of materials to be bonded). Additionally, the bonding material may be different such that they activate in response to different conditions, such as different deformation temperatures. For example, the bonding material <NUM> may have a higher melting temperature of the bonding material <NUM> as a result of a bottom platen operating at a higher temperature than the top platen and therefore different temperatures are achieved throughout the thickness of the article. The bonding material may be the same for the bonding material <NUM> and the bonding material <NUM>, such that a uniform temperature or narrow temperature range is targeted through a thickness of the article.

<FIG> illustrates an absence of a bonding material between the base material <NUM> and the foundation material <NUM>. In this example, the article is not secured to the foundation material. However, alternative examples contemplate the article being adhered or otherwise bonded with the foundation material to ensure a consistent position of the article during conveyance and pressing. It is contemplated that any combination of materials (e.g., overlays, bonding materials) may be used at any location in any number.

<FIG> depicts the hot press <NUM> from <FIG> in a first configuration, in accordance with exemplary aspects hereof. The first configuration includes the conveyor lowered by the actuators <NUM> from a first position <NUM> to a second position <NUM>. The lowering of the conveyor <NUM> allows the frame assembly <NUM> to be positioned relative to the bottom platen <NUM>. The positioning of the frame assembly <NUM> may include supporting the frame assembly <NUM> by the bottom platen <NUM>, as is depicted in <FIG>. In this example, the foundation material or article are resting on and supported directly by the contacting surface of the bottom platen <NUM> such that during a pressing operation the frame assembly does not interfere with a positioning change of one or more of the platens. In an alternative example, the conveyor <NUM> lowers to a position such that the bottom platen <NUM> may contact the article or the foundation material of the frame assembly <NUM>, but the frame is still in contact with the conveyor <NUM>. In this example, the conveyor <NUM> supports the weight of the frame (e.g., frame members <NUM>, <NUM>, <NUM>, and <NUM> of <FIG>), while the article may be supported or contacting the bottom platen <NUM>.

Also depicted in <FIG> is the generation of thermal energy by the platens. As will be seen in <FIG>, this thermal energy in connection with a compression allows for a bonding to occur between materials forming the article being pressed.

<FIG> depicts the hot press <NUM> of <FIG> in a second configuration, in accordance with aspects hereof. Specifically, a position of the top platen <NUM> is adjusted to create a compression of the article between the bottom platen <NUM> and the top platen <NUM>. The position of the top platen <NUM> is changed by the actuator <NUM> causing an extension of the pistons <NUM> that moves the top platen into a pressure-generating positions to compress the article associated with the frame assembly <NUM>. The amount of positional change created by the actuator <NUM> is adjusted, in part, by the force measured by the load cell <NUM>. As previously discussed, the force created by the actuator may be determined from a recipe or program for the given article. Measuring of the force generated by the load cell <NUM> as part of a closed-loop feedback system allows for the relative position of the top platen <NUM> to be adjusted to achieve a desired force. An amount of time that the hot press <NUM> maintains this configuration may vary. In an example aspect, the hot press <NUM> maintains this configuration for <NUM> to <NUM> second when pressing a shoe upper. As will be discussed in connection with <FIG>, variations in pressure may occur during this configuration to have an initial accelerated heating through higher pressure and then a reduced pressure portion as the materials approach a target temperature.

<FIG> depicts the hot press <NUM> of <FIG> in a third configuration, in accordance with aspects hereof. Specifically, the conveyor <NUM> returns to the first position <NUM> from the second position <NUM>, which elevates the frame assembly <NUM> from the bottom platen <NUM> such that the frame assembly <NUM> may be conveyed out of the hot press <NUM> by the conveyor <NUM>. Additionally, the top platen <NUM> is raised in position by the actuator <NUM> retracting the pistons (e.g., screws in an actuator or members extending from a screw). The retraction of the top platen <NUM> further clears a pathway for the conveyance of the frame assembly <NUM> out of the hot press <NUM>.

While <FIG> depict an example series of steps, it is contemplated that additional steps could be depicted. For example, variations in pressure applied during a pressing operation could be depicted with slight, if not noticeable by human perception, position changes of the top platen <NUM>. Additionally, the conveyor <NUM> may be positioned at different locations, depending on the amount of support the conveyor <NUM> is to provide the frame or frame assembly <NUM> during various stages of the pressing operation.

<FIG> depicts a process chart <NUM> for an example pressing operation, in accordance with aspects hereof. The chart includes a vertical axis <NUM> on a left side representing an amount of pressure applied. The chart includes a vertical axis on a right side representing a temperature variable. The chart includes a horizontal axis on a bottom representing a time variable. The pressure axis <NUM> has a higher pressure <NUM> at the top and a lower pressure <NUM> at the bottom. The temperature axis <NUM> has a higher temperature <NUM> at the top and a lower temperature <NUM> at the bottom. The time axis has an earlier point <NUM> and a later point <NUM>. Further a line <NUM> represents a temperature of a bottom platen over time. A line <NUM> represents a temperature of a top platen over time. A line <NUM> represent a pressure experienced between the top platen and the bottom platen over time. A line <NUM> represent a temperature over time of a bottom material (e.g., base material <NUM> of <FIG>) forming the article being pressed. A line <NUM> represent a temperature over time of a top material (e.g., second overlay <NUM> of <FIG>) forming the article being pressed. A line <NUM> represent a point in time associated with a position change of a top platen that causes a reduction in pressure experienced by the pressed article.

Looking at the lines <NUM> and <NUM>, in the example recipe or process of <FIG>, the bottom platen is maintained at a temperature slightly above that of the top platen through the duration of the pressing operation. This temperature differential, as previously discussed, is effective to reduce bleeding of bonding materials and protecting of the top materials from excessive heat. As a reminder, some aspects contemplate the top material of the article to have a lower deformation temperature or to be more responsive to thermal energy such that an unintentional deformation may occur at higher temperatures. For these reasons, the top platen is contemplated as having a conforming material (e.g., silicon foam) forming the contacting surface. The conforming material may aid in producing the temperature differential through a relative increase in thermal insulation capabilities as compared to a material forming the contacting surface of the bottom platen. The temperature differential may also be accomplished through a varied output of heating elements in the top platen relative to the bottom platen. The temperature for the bottom platen and the top platen are depicted as staying consistent through the pressing operation, this is done due to thermal mass and efficiency of heating. However, other examples contemplate adjusting the temperature of one or more of the platens during different stages of the pressing operation.

The line <NUM> demonstrates a multi-phased pressured application during the pressing operation. For example, a pressure experienced by an article at the beginning of the operation is at a level represented by number <NUM>. At the time represented by the line <NUM>, the pressure is reduced to a level represented by a number <NUM>. This second pressure may be accomplished through a movement of one or more platens. The movement may not be measurable, but a position change of an actuator causes a position change as measured by a change in pressure experienced by the article. The pressure may be reduced to a third pressure <NUM> at a future time in the pressing operation. Any number of pressure variations may occur over a pressing operation. In an example for an article of footwear, the pressure is changed <NUM>-<NUM> times during a pressing operation. The change in pressure, as previously described herein and as shown in the lines <NUM> and <NUM>, allows for an accelerated temperature increase with higher pressures. This accelerated temperature increase can reduce a pressing time. For example, variable pressures allows the press time for an article to reduce from <NUM> second down to <NUM> seconds. As the material increase in temperature they may become more susceptible deformation and bleeding; therefore, as the material temperature increase, a reduction in pressure reduces the potential for bleeding and/or unintended deformation.

Looking at the line <NUM> representing the temperature of the bottom material and the line <NUM> representing the temperature of the top material, a difference in temperature acceleration is depicted. This difference is in part a result of the proximity of each material to platens having different temperatures. For example, the bottom material is closer to the bottom platen and the top material is closer to the top platen. The bottom plate, in this example, is hotter than the top platen. Therefore, the bottom material accelerates greater toward a target temperature than the top material. However, over time in this example, the top material and the bottom material converge on a uniform temperature represented by the number <NUM>. This temperature may be maintained for at least <NUM> seconds, in an example, to ensure sufficient state change of a bonding material occur, to ensure sufficient bonding occurs, and/or to ensure a uniform temperature is achieved. It is contemplated that the bottom material and the top material may not converge on a common temperature in an example. It is contemplated that the top material and the bottom material may follow a similar temperature line throughout the pressing operation in another example.

<FIG> depicts a method as a diagram <NUM> for pressing an article, in accordance with aspects hereof. The method includes a block <NUM> representing a compression of an article at a first force or pressure. The term force is used in an example as the amount of force applied by the actuator to the top platen may be measured as a force by the load cell as opposed to as a pressure. However, the top platen has a set size in an example and therefore the pressure resulting from the force is able to be calculated. Therefore, for purposes of the present application, the term force when describing amount of compression applied is synonymous with an amount of pressure.

During this compression of the article between a top platen and a bottom platen in the block <NUM>, the top platen and or the bottom platen may have a temperature that is above ambient conditions. However, in examples the platen or platens are not heated. In an example where both platens are heated relative to ambient conditions, the material contacting surface of each platen may have a temperature differential relative to the other platen. The temperature differential may be a result of different thermal characteristics of the platens, such as a thermal insulation or thermal conduction different between the contacting materials of each platen. The top plate includes a silicon foam material as a contacting material that is less thermally conductive of heat generated by the top platen as compared to a contacting material associated with the bottom platen. It is also contemplated that the top platen may generate less thermal energy than the top platen (e.g., set to achieve a lower elevated temperature from ambient as compared to the top platen). Combinations of the characteristics of the contacting material and the setting of the thermal energy generation may be used to achieve a temperature differential between the top platen material contacting surface and the bottom platen material contacting surface. The temperature differential between the two surfaces may be <NUM>-<NUM> degrees C, <NUM>-<NUM> degrees C, and/or <NUM>-<NUM> degrees C, in examples.

At a block <NUM> the method of <FIG> provides for maintaining the article in compression at the force established at the block <NUM> for a first period of time. This compression force is measured during the first period of time continuously, in an example, by a load cell. The force is maintained by adjusting a position of the actuator and as a result one or more platens to ensure the force is consistently applied during the first period. An example as to why the force may change during the first period of time is because of a state change of one or more material of the article under compression. A bonding material that is intended to have a state change (e.g., deform, melt, viscosity change) under pressure and/or heat may undergo that state change during the first time period. As the material changes state, the thickness of the article may diminish as the bonding material is deformed and absorbed, transferred, or integrated into the other materials of the article. This deformation redistributes the volume of material previously consumed by the bonding material such that a thickness of the article may change. As the thickness changes between the top platen and the bottom platen during the first time, a distance between the top platen and the bottom platen may need to be adjusted to maintain a consistent force.

The force that is maintained for the first period of time may be expressed as a pressure for a specific top platen and a bottom platen. The force therefore may be in a range of <NUM>-<NUM> psi (<NUM> - <NUM> bar) for a given platen size, such as a <NUM> inch by <NUM> inch (<NUM>,<NUM> by <NUM>) platen. The force may also be in a range of <NUM>-<NUM> psi (<NUM> - <NUM> bar) as measured between the top platen and the bottom platen with a non-compressible (e.g., nickel plated steel that may for plates of the platens) surface. The force may also be in a range of <NUM>,<NUM> pounds to <NUM>,<NUM> pounds (<NUM>,<NUM> to <NUM>,<NUM> kN) as measured at the load cell from the actuator, in an example. The force is maintained within the prescribed force by a range of plus/minus <NUM> psi (<NUM>,<NUM> mbar) through a continuous or frequent automated monitoring of the force/pressure and then adjustment by the actuator to maintain the prescribed pressure.

At a block <NUM> the force applied to the platens producing the compressive force is reduced after the first time period. The first time period may be any length of time, such as <NUM> second, <NUM> seconds, <NUM> seconds, <NUM> second, <NUM> seconds, or anything therebetween. As previously discussed, the first timer period at the first force allows for an accelerated heating of the article to bring the article closer to an activation temperature for one or more bonding materials. The reduction in compression after this first time period limits bleeding of the bonding material from the article edges (e.g., prevents the bonding material from extending beyond a perimeter of an overlay onto an underlying material, such as a base material). Additionally, the reduction in pressure can reduce or prevent a deformation of a material forming the article, such as a cosmetic material forming an exposed surface of the article.

At a block <NUM>, the second force is maintained for a second period of time. This second period of time may be any length of time, such as <NUM> second, <NUM> seconds, <NUM> seconds, <NUM> second, <NUM> seconds, or anything therebetween. The second force is less than the first force. The second force may be <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, or anything therebetween reduction in force from the first compressive force. The system continuously or frequently measures the force applied during the second time period and adjusts the actuator to maintain the force in an automated manner during the second period.

While the method of <FIG> only provide two distinct time periods at two different pressures, it is contemplated that any number of phases (e.g., time periods and pressures) may be implemented in connection with aspects hereof. As more layers are combined to form the article to be pressed, the more phases may be implemented. For example, if there are two material layers with one bonding layer therebetween, <NUM>-<NUM> phases may be leveraged. If there are three layers with a different bonding layer between each, <NUM>-<NUM> phases may be leveraged. If there are four layer or more, some aspects contemplated <NUM> phases may be leveraged. Additional variables include a thickness of each material, a composition of each material, a bonding material composition, a deformation or critical temperature for each of the materials to be bonded, and any combination thereof are all contemplated.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

As used in the specification and the appended claims, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a foam particle," "a midsole," or "an adhesive," including, but not limited to, two or more such foam particles, midsoles, or adhesives, and the like.

As used herein, in substance or substantially means at least <NUM> percent, <NUM> percent, <NUM> percent, <NUM> percent, or more, as determined based on weight, volume, or unit.

The terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and/or sections. These terms can be only used to distinguish one element, component, region, layer or section from another region, layer or section.

As used herein, the modifiers "upper," "lower," "top," "bottom," "upward," "downward," "vertical," "horizontal," "longitudinal," "transverse," "front," "back" etc., unless otherwise defined or made clear from the disclosure, are relative terms meant to place the various structures or orientations of the structures of the article of footwear in the context of an article of footwear worn by a user standing on a flat, horizontal surface.

The term "receiving", such as for "receiving an upper for an article of footwear", when recited in the claims, is not intended to require any particular delivery or receipt of the received item. Rather, the term "receiving" is merely used to recite items that will be referred to in subsequent elements of the claim(s), for purposes of clarity and ease of readability.

The terms "at least one" and "one or more of" an element are used interchangeably, and have the same meaning that includes a single element and a plurality of the elements, and can also be represented by the suffix "(s)" at the end of the element. For example, "at least one polyamide", "one or more polyamides", and "polyamide(s)" can be used interchangeably and have the same meaning.

It should be noted that ratios, concentrations, amounts, and other numerical data can be expressed herein in a range format. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure, e.g. the phrase "x to y" includes the range from 'x' to 'y' as well as the range greater than 'x' and less than 'y'. The range can also be expressed as an upper limit, e.g. 'about x, y, z, or less' and should be interpreted to include the specific ranges of 'about x', 'about y', and 'about z' as well as the ranges of 'less than x', less than y', and 'less than z'. Likewise, the phrase 'about x, y, z, or greater' should be interpreted to include the specific ranges of 'about x', 'about y', and 'about z' as well as the ranges of 'greater than x', greater than y', and 'greater than z'. In addition, the phrase "about `x' to 'y'", where 'x' and 'y' are numerical values, includes "about `x' to about 'y'". It is to be understood that such a range format is used for convenience and brevity, and thus, should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. To illustrate, a numerical range of "about <NUM>% to <NUM>%" should be interpreted to include not only the explicitly recited values of about <NUM>. 1percent to about <NUM> percent, but also include individual values (e.g., <NUM> percent, <NUM> percent, <NUM> percent, and <NUM> percent) and the sub-ranges (e.g., <NUM> percent, <NUM> percent, <NUM> percent, <NUM> percent, and <NUM> percent) within the indicated range.

The terms "about" and "substantially" are used herein with respect to measurable values and ranges due to expected variations known to those skilled in the art (e.g., limitations and variabilities in measurements).

As used herein, the terms "optional" or "optionally" means that the subsequently described component, event or circumstance can or cannot occur, and that the description includes instances where said component, event or circumstance occurs and instances where it does not.

Unless otherwise specified, temperatures referred to herein are based on atmospheric pressure (i.e. one atmosphere).

Before proceeding to the Examples, it is to be understood that this disclosure is not limited to particular aspects described, and as such may, of course, vary. Other systems, methods, features, and advantages of foam compositions and components thereof will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to be limiting. The skilled artisan will recognize many variants and adaptations of the aspects described herein.

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.

Claim 1:
A method of pressing an article (<NUM>), the method comprising:
compressing an article (<NUM>) between a top platen (<NUM>) having a top platen contacting surface (<NUM>) and a bottom platen (<NUM>) having a bottom platen contacting surface (<NUM>), the article (<NUM>) compressed at a first pressure, wherein a temperature of the top platen contacting surface (<NUM>) is less than a temperature of the bottom platen contacting surface (<NUM>);
maintaining the article (<NUM>) in compression at the first pressure between the top platen (<NUM>) and the bottom platen (<NUM>) for a first time period, wherein the first pressure is determined a plurality of times during the first time period and at least one of the top platen (<NUM>) or the bottom platen (<NUM>) are positionally adjusted to maintain the first pressure in response to the plurality of determinations of the first pressure;
reducing the compression of the article (<NUM>) between the top platen (<NUM>) and the bottom platen (<NUM>) to a second pressure after the first time period; and
maintaining the article (<NUM>) in compression at the second pressure between the top platen (<NUM>) and the bottom platen (<NUM>) for a second time period, wherein the second pressure is measured during the second time period and at least one of the top platen (<NUM>) or the bottom platen (<NUM>) are positionally adjusted to maintain the second pressure during the second time period,
wherein the top platen contacting surface is formed from a silicon-based composition,
wherein the silicon-based composition has an uncompressed thickness from <NUM> to <NUM>, and
wherein the silicon-based composition has a compressed thickness during the first time period that is <NUM>% to <NUM>% an uncompressed thickness of the silicon-based composition.