Patent Description:
Such sole structures typically include a layered arrangement extending between a ground surface and the upper. The layered arrangement may include a midsole that provides the sole structure with a degree of cushioning and an outsole that provides the sole structure with abrasion-resistance and traction with the ground surface. The midsole and/or outsole may additionally include a plate formed of a rigid or semi-rigid material that provides rigidity and energy distribution across the sole structure.

In some instances, the plate is formed of a composite material including one or more strands of fibers (including loose strands of fibers, bunched strands of fibers or tows, fibers present in the form of a textile, and strands affixed to a textile) surrounded and consolidated by a solid polymeric material. During manufacturing of the plate, strands may be inserted into a mold cavity and combined with a solid polymeric material (e.g., by injecting a liquid material into the mold cavity or by melting a thermoplastic material present in the mold cavity) to surround, consolidate, and bond the strands together, thereby forming a rigid or semi-rigid plate. In some instances, the strands inserted into the mold cavity are of a larger dimension than the finished composite article. Thus, after the molding process, the excess strands and solid polymeric material must be trimmed to form the peripheral profile of the finished composite article.

Document <CIT> describes a stitched article including a substrate and a first strand portion formed from a bundle of fibers. The substrate has a first region and a second region. The first strand portion is attached to the substrate in the first region and in the second region via a series of stitches formed with a thread and forms a first layer on the substrate. The article has a first concentration of the stitches in the first region along a first length of the strand portion and a second concentration of the stitches different than the first concentration in the second region along a second length of the first strand portion.

The invention relates to a method of forming a composite article as defined by independent claim <NUM>. Preferred embodiments are further disclosed in the dependent claims <NUM>-<NUM>. some examples, composite articles made using the methods and/or molds are provided in an intermediate state, and include a trim flange. In other examples, the composite articles made using the methods and/or molds are provided in a finished state, where the trim flange has been removed. When molding composite articles, ensuring even pressure distribution across the entire article is desired to achieve optimum part quality. In some methods of making composite articles, preforms are initially formed by winding one or more tows or strands upon a substrate. The substrate can be rigid or flexible. As the strands are wound back and forth upon the substrate, it is necessary to turn or loop the strands at the edges of the substrate. Because tows of strands tend to be flat, there is a tendency of the tow to bunch or twist in these turns. Additionally, in some methods it is necessary to utilize additional stitching to secure the tows in these turns. As a result of either or both of these phenomena, a thickness of the article preform tends to be higher at the peripheral edges than in the center of the preform, both before and after the preform is consolidated with solid polymeric material. Traditionally, this variable thickness has been addressed by trimming off the peripheral edges. While trimming does result in a uniform thickness preform and/or composite article, there are several challenges involved with this approach. For example, when the peripheral edges are trimmed prior to consolidation, the strands tend to move and/or get pulled out of the preform, leading to an inferior part after consolidation. Additionally, trimming of unconsolidated preforms as well as consolidated articles can generate undesirable fiber dust, such as carbon fiber dust when using carbon fiber strands. The proposed tooling-based approach of the present disclosure eliminates these concerns.

In one example of the present disclosure, a mold is provided and includes a first mold plate and a second mold plate, which cooperate to define a mold cavity including an article forming region, a trim region surrounding the article forming region, and a relief region surrounding the trim region. In use, a preform including one or more strands, such as one or more strands stacked upon a substrate, is placed within the mold cavity so that a peripheral portion of the strand extends into the relief region. Additionally, a peripheral portion of the substrate can extend into the relief region, or can extend into the trim region. The strands stacked upon the substrate can be in the form of plies. Each of the plies may be formed by winding one or more strands upon the substrate such that the peripheral region of each ply includes loops or ends formed where each strand is turned or terminates. When placed within the mold cavity, the ends and the loops of the strands will be disposed within the relief region of the mold cavity. An interior void formed by the relief region can be sized such that the ends and the loops of the strands can loosely bunch within the relief region without forming pinch points or frustrating the arrangement of the strands within the molding region. The mold is then closed, and a liquid material is used to form a composite preform. As molded, the composite preform includes a trim flange associated with the trim region, and flashing associated with the relief region. Particularly, the trim region forms a trim flange surrounding the periphery of an article. The trim region allows excess material, including the loops and ends of the strands present in the relief region, to be easily removed to define a smooth outer perimeter of the composite article.

One aspect of the disclosure provides a mold for forming a composite article. The mold includes a first mold plate and a second mold plate. The first mold plate has a first mold surface defining a first portion of a mold cavity. The second mold plate has a second mold surface opposing the first mold surface of the first mold plate and defining a second portion of the mold cavity. The mold cavity includes (i) an article-forming region configured to impart a profile of the composite article, (ii) a trim region surrounding the article-forming region, and (iii) a relief region surrounding the trim region.

Another aspect of the disclosure provides a method for forming a composite article. The method includes inserting a preform into a mold cavity of a mold, wherein the preform has an interior portion and a peripheral portion surrounding the interior portion. Inserting the preform includes receiving the interior portion of the preform in a molding region of the mold cavity and receiving the peripheral portion of the preform in a relief region of the mold cavity. The method further includes closing the mold after the preform is inserted into the mold cavity. When the mold is closed, the interior portion of the preform is compressed within the molding region of the mold cavity. During compression, the peripheral portion of the preform is maintained in a loose state within the relief region.

In yet another aspect of the disclosure, a composite article is formed using the aforementioned mold and/or method. Particularly, the composite article is formed by inserting a preform into a mold cavity of a mold, wherein the preform has an interior portion and a peripheral portion surrounding the interior portion. Inserting the preform includes receiving the interior portion of the preform in a molding region of the mold cavity and receiving the peripheral portion of the preform in a relief region of the mold cavity. The method further includes closing the mold after the preform is inserted into the mold cavity. When the mold is closed, the interior portion of the preform is compressed within the molding region of the mold cavity. During compression, the peripheral portion of the preform is maintained in a loose state within the relief region.

Another aspect of the disclosure provides a composite preform. The composite preform includes one or more strands forming a plurality of strand segments traversing an interior portion of the composite preform, and one or more loops disposed in a peripheral portion of the preform and connecting the plurality of strand segments. A solid polymeric material is infused within and consolidates the strand layer. When the composite article is a composite component for a footbed for an article of footwear, the composite preform may include a footbed, a trim region surrounding an outer perimeter of the footbed, and a relief region surrounding an outer perimeter of the trim region.

Another aspect of the disclosure provides a composite article including one or more strands forming a plurality of strand segments, and a solid polymeric material infused within and consolidating the strand layer. The composite article may be formed with a continuous peripheral edge, where the plurality of the strand segments are trimmed along the continuous peripheral edge.

In one configuration, a method of forming a composite article is provided and includes inserting a preform into a mold cavity of a mold, the preform having a strand layer including an interior portion and a peripheral portion surrounding the interior portion. Inserting the preform includes inserting the interior portion of the preform into a molding region of the mold cavity and inserting the peripheral portion of the preform into a relief region of the mold cavity. The method further includes closing the mold following insertion of the preform into the mold cavity, compressing the interior portion of the preform within the molding region in the closed mold, and maintaining the peripheral portion loose within the relief region during compression of the interior portion.

The method may include one or more of the following optional steps. For example, the method may include (i) providing a liquid material to the preform and (ii) infusing at least the strand layer of the preform with the liquid material. In this configuration, providing the liquid material may comprise injecting the liquid material into the molding region of the mold cavity in the closed mold. The method may further include inserting a component comprising a thermoplastic material into the mold cavity prior to closing the mold. Additionally or alternatively, providing the liquid material may comprise, before or after closing the mold, increasing a temperature of the component to a temperature at or above a melting temperature of the thermoplastic material.

In one configuration, the method may further comprise curing the liquid material to a solid polymeric material in the closed mold to form a rigid composite preform including the preform infused with the solid polymeric material, opening the mold after the liquid material is cured, and removing the composite preform from the mold cavity. In this configuration, the method may further include removing the peripheral portion of the composite preform and/or forming the interior portion of the composite preform into a footbed and a trim flange. The footbed and the trim flange may be formed with the same thickness.

The method may further include biasing the preform partially into a recess of the mold cavity. Additionally or alternatively, the preform may comprise the strand layer attached to a substrate.

In another configuration, a method of forming a composite article is provided and includes constructing a preform having a strand layer including an interior portion and a peripheral portion surrounding the interior portion, the strand layer including a plurality of strand segments traversing the interior portion and defining a first strand segment population density in a first area of the interior portion and a second strand segment population density in a second area of the interior portion. The method further includes inserting the preform into a molding region of a mold cavity of a mold including inserting the first area of the interior portion in a first portion of the molding region having a first thickness corresponding to the first strand segment population density and inserting the second area of the interior portion in a second portion of the molding region having a second thickness corresponding to the second strand segment population density. The mold is closed following insertion of the preform into the molding region and the interior portion of the preform is compressed within the molding region in the closed mold.

The method may include one or more of the following optional steps. For example, the method may additionally include (i) providing a liquid material to the preform and (ii) infusing at least the strand layer of the preform with the liquid material. In this configuration, providing the liquid material may comprise injecting the liquid material into the molding region of the mold cavity in the closed mold. The method may further include attaching the strand layer to a substrate comprising a thermoplastic material. Additionally or alternatively, providing the liquid material may comprise, before or after closing the mold, increasing a temperature of the substrate to a temperature at or above a melting temperature of the thermoplastic material.

In one configuration, the method may further include curing the liquid material to a solid polymeric material in the closed mold to form a rigid composite preform including the preform infused with the solid polymeric material, opening the mold after the liquid material is cured, and removing the composite preform from the mold cavity. In this configuration, the method may further include forming the interior portion of the composite preform into a footbed and a trim flange. The footbed and the trim flange may be formed with the same thickness. The method may additionally include removing the peripheral portion of the preform.

The preform may be partially biased into a recess of the mold cavity to form a traction element including the preform. Additionally or alternatively, inserting the preform into the mold cavity may include inserting a peripheral portion of the preform in a relief region of the mold cavity.

Referring to <FIG>, a mold <NUM> for forming a composite plate <NUM> according to the present disclosure is shown. The mold <NUM> includes an upper mold plate <NUM> and a lower mold plate <NUM>, which cooperate with each other to define one or more mold cavities <NUM> when the mold <NUM> is in a closed position, as shown in <FIG>. As shown in <FIG>, the mold <NUM> is configured to form a pair of mold cavities <NUM> for forming corresponding medial and lateral plates <NUM>. Thus, the cavities <NUM> are mirror images of each other, and are otherwise identical in their configurations. Accordingly, only a single one of the mold cavities <NUM> will be described and shown throughout the application.

In the illustrated example, the upper mold plate <NUM> includes a first, upper mold surface <NUM>. Similarly, the lower mold plate <NUM> includes a second, lower mold surface <NUM>, which opposes the upper mold surface <NUM> of the upper mold plate <NUM> when the mold <NUM> is assembled. Each of the upper mold surface <NUM> and the lower mold surface <NUM> may be described as including a mold portion 112a, 112b and a parting portion 114a, 114b, whereby the mold portions 112a, 112b cooperate with each other to define the one or more mold cavities <NUM>, while the parting portions 114a, 114b may interface with each other to maintain alignment of the mold plates <NUM>, <NUM> when the mold <NUM> is moved between an opened position and the closed position.

In the illustrated example, the mold portion 112a of the upper mold plate <NUM> is a positive mold portion 112a, while the mold portion 112b of the lower mold plate <NUM> is a negative mold portion 112b configured to receive the positive mold portion 112a to define the mold cavity <NUM>. Accordingly, thicknesses of each mold cavity <NUM> are defined by the distance between the opposing mold portions 112a, 112b measured normal to the upper mold surface <NUM> and the lower mold surface <NUM>, as illustrated in <FIG>. Conversely, widths of the mold cavities <NUM> are measured in a substantially horizontal direction, irrespective of the profile of the mold surfaces <NUM>, <NUM>.

With reference to <FIG>, the mold cavity <NUM> is described as including a molding region <NUM> and a relief region <NUM>. Generally, the molding region <NUM> of the mold cavity <NUM> defines a profile of the plate <NUM> when the mold <NUM> is closed, while the relief region <NUM> provides a space or void around a perimeter of the molding region <NUM> for accommodating excess material and liquid material. The molding region <NUM> of the mold cavity <NUM> is further described as including a plate-forming region <NUM> and a trim region <NUM> surrounding the plate-forming region <NUM>. As discussed in greater detail below, the relief region <NUM> surrounds the trim region <NUM> and includes one or more portions <NUM>, <NUM> having thicknesses T<NUM>, T<NUM> configured to accommodate bunching of the peripheral region of a preform <NUM> when the mold <NUM> is in the closed position.

Generally, the plate-forming region <NUM> is configured for imparting the profile of the molded plate <NUM>, while the trim region <NUM> is configured to form an outer trim flange <NUM> circumscribing a periphery of the plate <NUM>. The trim flange <NUM> can be trimmed or removed from the plate <NUM> in a post-molding process to provide an exposed, uniform, and clean outer peripheral edge <NUM> to the plate <NUM>, as discussed below. The plate-forming region <NUM> may include a central channel region <NUM>, a support region <NUM> surrounding the central channel region <NUM>, and a peripheral lip region <NUM> surrounding the support region <NUM>. The central channel region <NUM> extends longitudinally along the center of the plate-forming region <NUM> and is configured to form a rib or shank <NUM> in the molded plate <NUM>. The support region <NUM> surrounds the central channel region <NUM>, and is configured to form a cupped portion of the plate <NUM> for receiving and supporting a plantar surface of the foot. The peripheral lip region <NUM> extends radially outwardly and upwardly from the outer periphery of the support region <NUM>, and is configured to form a lip or rim around the outer periphery of the plate <NUM>, which receives the foot therein to maintain the plate <NUM> in a constant position relative to the plantar surface of the foot.

Optionally, the plate-forming region <NUM> may include one or more projection elements <NUM> configured for forming traction elements <NUM> in the plate <NUM>. As shown in <FIG> and 3A, the projection elements <NUM> include upper projection features 134a and corresponding lower projection features 134b that cooperate with each other to form the traction elements <NUM>. Here, the upper projection feature 134a includes a protuberance 134a and the lower projection feature 134b includes a recess 134b configured to receive the protuberance 134a, whereby a portion of the mold cavity <NUM> formed between the upper and lower projection features 134a, 134b defines a shape or profile of the traction element <NUM>.

Generally, a height of the upper projection features 134a is less than a depth of the corresponding lower projection features 134b such that the upper projection features 134a extend only partially into the lower projection features 134b. Further, a thickness of the mold cavity <NUM> is greater in a central portion of each of the projection elements <NUM>. For example, a ratio of the thickness T<NUM> of the projection element <NUM> to the thickness T<NUM> of the support region <NUM> may be less than or equal to <NUM>:<NUM>. In the illustrated example, the upper projection features 134a are each blunted or rounded and form a hemispherical protuberance while the lower projection features 134b are each pointed and form a conical recess for receiving one of the upper projection features 134a. In other examples, the upper projection features 134a may be a truncated shape, such as a truncated cone or pyramid, while the lower projection features 134b are conical or pyramidal shaped recesses. As discussed in greater detail below, the difference in the height of the upper projection features 134a and the depth of the lower projection features 134b allows the upper projection feature 134b to partially bias a preform <NUM> into the recess of the lower projection feature 134b during a plate molding process. Accordingly, when resin <NUM> is injected into the mold cavity <NUM>, the resin <NUM> encapsulates the preform <NUM> within the projection feature <NUM> to form a traction element <NUM> including the preform <NUM> and the resin <NUM>.

As best shown in <FIG>, <FIG>, and <FIG>, the mold cavity <NUM> may include a plurality of sockets <NUM> configured for forming bosses <NUM> on a bottom side of the plate <NUM>. Here, each of the sockets <NUM> includes a frustoconical recess in the lower surface <NUM> of the support region <NUM>. The sockets <NUM> may be configured to receive a cleat component, such as a threaded bushing or a spike. Thus, during the molding process, the cleat component can be integrally molded within the plate <NUM> by injecting the liquid material <NUM> around the cleat component within each socket <NUM>. Alternatively, the bosses <NUM> may be processed (i.e., drilled, cut) after the plate <NUM> is formed to attach the cleat component to the plate <NUM>. Optionally, the mold cavity <NUM> may include one or more vents <NUM> connecting the sockets <NUM> or other features having an increased thickness to an exterior of the plate-forming region <NUM>. The vents <NUM> allow air to be evacuated from the mold cavity plate-forming region <NUM> in areas where the liquid material <NUM> has a greater thickness (e.g., the sockets <NUM>).

As discussed above, thicknesses of the mold cavity <NUM> are measured normal to the mold surfaces <NUM>, <NUM>, and are defined by distances between the mold portions 112a, 112b of the upper mold surface <NUM> and the lower mold surface <NUM>. As shown in <FIG>, the plate-forming region <NUM> of the mold cavity <NUM> has a variable thickness defined by a normal distance between the upper mold portion 112a and the lower mold portion 112b in the plate-forming region <NUM> when the mold <NUM> is in the closed position. The thicknesses of the plate-forming region <NUM> correspond to desired thicknesses of the finished plate <NUM>, and may depend on a population density of strand segments <NUM> in a particular region of the mold cavity <NUM>.

With reference to <FIG>, cross-sectional views are taken along the length (<FIG>) and widths (<FIG>) of the mold <NUM> to illustrate an example of a mold cavity <NUM> having a plate-forming region <NUM> with variable thicknesses based on a population density of strand segments <NUM> within a finished plate <NUM> (described below). Thicknesses of the plate-forming region <NUM> may be defined by thicknesses T<NUM> of the channel region <NUM>, thicknesses T<NUM> of the support region <NUM>, and/or thicknesses T<NUM> of the peripheral lip region <NUM>. The thicknesses are dependent on a population density of the strand segments <NUM> within a particular portion of the mold cavity <NUM> such that thicknesses are calculated to ensure complete saturation of the strand segments <NUM> with the resin <NUM>. In some examples, the mold cavity <NUM> is designed to ensure a weight content of the strand segments <NUM> does not exceed <NUM>% of the total weight content of any portion of the plate <NUM>. In other words, the thicknesses T<NUM>, T<NUM>, T<NUM> are selected to ensure a resin content by weight of at least <NUM>%. Thus, thicknesses of the plate-forming region <NUM> will be greater in areas of the plate-forming region <NUM> associated with a higher population density of the strand segments <NUM> than in areas associated with a lower population density of the strand segments <NUM>.

The mold cavity <NUM> of the present example is configured for forming the composite preform <NUM> and plate shown in <FIG> and <FIG>, which include a fiber strand <NUM> with strand segments <NUM> that extend along a lengthwise direction (i.e., from an anterior end to a posterior end) of the plate <NUM>. The strand segments <NUM> of the fiber strand <NUM> have a first population density associated with a forefoot region <NUM>, a second population density associated with a midfoot region <NUM>, and a third population density associated with a heel region <NUM>. Here, the first population density in the forefoot region <NUM> is less than the second population density in the midfoot region <NUM> and greater than the third population density in the heel region <NUM>.

With reference to <FIG>, the support region <NUM> of the mold cavity <NUM> has thicknesses T<NUM>-<NUM>, T<NUM>-<NUM>, T<NUM>-<NUM> that correspond to the population densities of the fiber strand segments <NUM> in each region <NUM>, <NUM>, <NUM> of the plate <NUM>. Thus, the support region <NUM> includes a first support region thickness T<NUM>-<NUM> in the forefoot region <NUM> corresponding to the first population density, a second support region thickness T<NUM>-<NUM> in the midfoot region <NUM> corresponding to the second population density, and a third support region thickness T<NUM>-<NUM> in the heel region <NUM> corresponding to the third population density. Here, the first support region thickness T<NUM>-<NUM> is less than the second support region thickness T<NUM>-<NUM> and greater than the third support region thickness T<NUM>-<NUM>. As shown, the thickness T<NUM> of the support region <NUM> includes gradients or tapers between the thicknesses T<NUM>-<NUM>, T<NUM>-<NUM>, T<NUM>-<NUM> that correspond to changes in the population densities. Thus, the mold cavity <NUM> transitions from one of the thicknesses T<NUM>-<NUM>, T<NUM>-<NUM>, T<NUM>-<NUM> to the other of the thicknesses T<NUM>-<NUM>, T<NUM>-<NUM>, T<NUM>-<NUM> according to the pattern of the strand segments <NUM>.

Referring to <FIG>, thicknesses of the mold cavity may also vary across a widthwise direction of the mold cavity <NUM> in one or more of the regions <NUM>, <NUM>, <NUM>. For example, in the forefoot region <NUM> (<FIG>), the mold cavity <NUM> may have the first support region thickness T<NUM>-<NUM> in the central portion and a first peripheral lip thickness T<NUM>-<NUM> in the peripheral lip region <NUM>. The first peripheral lip thickness T<NUM>-<NUM> may be the same as or different from the first support region thickness T<NUM>-<NUM> depending on the population density of the strand segments <NUM> of the plate <NUM> across the width of the plate <NUM>. Thus, where the strand segments <NUM> are evenly spaced across the width of the plate <NUM>, the mold cavity <NUM> will have a first support region thickness T<NUM>-<NUM> that is the same as the first peripheral lip thickness T<NUM>-<NUM>.

In the midfoot region <NUM> (<FIG>), the plate forming region <NUM> includes the second support region thickness T<NUM>-<NUM> along with a second peripheral lip thickness T<NUM>-<NUM> and a channel thickness T<NUM>-<NUM>. Similarly, the heel region <NUM> (<FIG>) of the plate forming region <NUM> includes the third support region thickness T<NUM>-<NUM> along with a third peripheral lip thickness T<NUM>-<NUM> and a second channel thickness T<NUM>-<NUM>. As with the forefoot region <NUM>, the support region thicknesses T<NUM>-<NUM>, T<NUM>-<NUM> and the corresponding peripheral lip thicknesses T<NUM>-<NUM>, T<NUM>-<NUM> may be the same or variable depending on the population density of the strand segments <NUM> in a particular area of the plate <NUM>. The channel thicknesses T<NUM>-<NUM>, T<NUM>-<NUM> may be greater than the support region and peripheral lip thicknesses T<NUM>-<NUM>, T<NUM>-<NUM>,T<NUM>-<NUM>, T<NUM>-<NUM> for forming the rib or shank <NUM> on the bottom side of the plate <NUM>.

Referring to <FIG>, the mold cavity <NUM> may further include an increased thickness T<NUM> at each of the projection elements <NUM>. As discussed above, the upper projection features 134a include a rounded or hemispherical shape while the lower projection features 134b have a pointed or conical shape such that a thickness T<NUM> of the mold cavity <NUM> associated with the projection elements <NUM> increases in a direction from the outer periphery of the projection element <NUM> to a central point of the projection element <NUM>. The thickness T<NUM> of the projection element <NUM> at the central point is greater than a thickness of the mold cavity <NUM> immediately adjacent to and surrounding the projection element <NUM>. For example, the thickness T<NUM> of the projection element <NUM> may be as much as three times greater than the thickness T<NUM> of the immediately adjacent portion of the support region <NUM>.

Referring to <FIG>, the trim region <NUM> of the mold cavity <NUM> has a thickness T<NUM> defined by a normal distance between the upper mold surface <NUM> and the lower mold surface <NUM> in the trim region <NUM> when the mold <NUM> is in the closed position. In the illustrated example, the thickness T<NUM> of the trim region <NUM> is the same as the first thickness T<NUM> of the peripheral lip region <NUM>. In some examples, the trim region <NUM> has a width W<NUM> of at least <NUM> to provide a sufficient width of material for a trimming process, as described in greater detail below. The trim region <NUM> may be formed as a horizontal structure or may be tangent (i.e., continuous) to the peripheral lip region <NUM> of the mold cavity <NUM>.

With continued reference to <FIG>, the relief region <NUM> of the mold cavity <NUM> may include a lateral portion <NUM> disposed adjacent to and surrounding the trim region <NUM>, and a vertical portion <NUM> surrounding the lateral portion <NUM>. Generally, the lateral portion <NUM> has a third thickness T<NUM>, and a width W<NUM> that is greater than its thickness T<NUM>. The vertical portion includes a fourth thickness T<NUM> that is greater than its width W<NUM>, as shown in <FIG>. However, in other examples, the relief region <NUM> may have a constant thickness T<NUM> that is greater than the thicknesses T<NUM>, T<NUM> of the plate-forming region <NUM>.

The upper mold surface <NUM> and the lower mold surface <NUM> are spaced apart from each other by a greater distance in the lateral portion <NUM> of the relief region <NUM> than in the molding region <NUM>. As such, the lateral portion <NUM> of the relief region <NUM> has a thickness T<NUM> that is greater than the thicknesses T<NUM> of the peripheral lip region <NUM> of the plate-forming region <NUM> and the thickness T<NUM> of the trim region <NUM>. Particularly, the lateral portion <NUM> of the relief region has a thickness T<NUM> that is at least <NUM> greater than the thickness T<NUM> of the trim region <NUM> and a width W<NUM> of at least <NUM>, thereby providing sufficient volume for accommodating the excess structure and liquid material/solid polymeric material used in forming the plate <NUM>. Accordingly, the lateral portion <NUM> of the relief region <NUM> defines a peripheral void or space <NUM> surrounding the molding region <NUM>, whereby subcomponents of the preform <NUM> of the plate <NUM> disposed within the relief region <NUM> will remain loose and uncompressed when the mold <NUM> is moved into the closed position. Optionally, the vertical portion <NUM> may have a fourth thickness T<NUM> that is greater than the third thickness T<NUM> of the lateral portion <NUM>. Thus, the relief region <NUM> may form an L-shaped stack connecting the trim region <NUM> and the parting portion 114a, 114b.

As shown, the portion of the lower mold surface <NUM> defining lateral portion <NUM> of the relief region <NUM> may be continuous and flush with the portion of the lower mold surface <NUM> defining the trim region <NUM>. Conversely, the portion of the upper mold surface <NUM> defining the lateral portion <NUM> of the relief region <NUM> may be vertically offset from the portion of the upper mold surface <NUM> defining the trim region <NUM>, thereby providing the lateral portion <NUM> of the mold cavity <NUM> with the greater thickness T<NUM> than the trim region <NUM>.

Generally, the thicknesses, T<NUM>, T<NUM>, T<NUM>, T<NUM>, T<NUM> of the mold cavity <NUM> are selected to ensure that sufficient pressure is maintained within the plate-forming region <NUM>, while ensuring that the mold <NUM> is capable of fully closing. The thickness T<NUM> of the trim region <NUM> can range from the thickness T<NUM> of the peripheral lip region <NUM> to the thickness T<NUM> of the lateral portion <NUM> of the relief region. For example, as illustrated, the second thickness T<NUM> of the trim region <NUM> may be the same as the thickness T<NUM> of the peripheral lip region <NUM>. Here, the plate <NUM> will also be compressed by the opposing mold portions 112a, 112b within the trim region <NUM> of the mold cavity <NUM> when the mold <NUM> is moved to the closed position. However, in other examples, the thickness T<NUM> of the trim region <NUM> may be different from the thickness T<NUM> of the peripheral lip region <NUM> of the plate-forming region <NUM>. For example, the thickness T<NUM> of the trim region <NUM> may be greater than the thickness T<NUM> of the peripheral lip region <NUM> and, more particularly, the thickness T<NUM> of the trim region <NUM> may be the same as the thickness T<NUM> of the lateral portion <NUM>. In this implementation, the trim region <NUM> and the relief region <NUM> will have a substantially constant thickness T<NUM>. Thicknesses for the trim region <NUM> and the relief region <NUM> may be selected to accommodate complexities of a particular configuration of the preform <NUM>.

In some examples, the portions of the upper and lower mold surfaces <NUM>, <NUM> forming the mold cavity <NUM> may be formed at a constant angle α relative to a horizontal datum of the mold <NUM>. In some examples, the angle α may be an oblique angle relative to the horizontal datum. For example, the upper and lower mold surfaces <NUM>, <NUM> may be formed at a decline in the trim region <NUM> and the lateral portion <NUM> of the relief region <NUM>. Particularly, the upper and lower mold surfaces <NUM>, <NUM> may decline along the direction from the center of the mold cavity <NUM> to the outer periphery of the mold cavity <NUM>, as illustrated in <FIG>. In other examples, the mold surfaces <NUM>, <NUM> may be formed parallel to the horizontal datum in the trim region <NUM> and the lateral portion <NUM> of the relief region <NUM>, such that the angle α is <NUM>°. Alternatively, the portions of the upper and lower mold surfaces <NUM>, <NUM> defining the trim region <NUM> may be tangent or continuous with the portions of the upper and lower mold surfaces <NUM>, <NUM> forming the outer peripheral lip region <NUM>.

Referring still to <FIG>, the upper mold surface <NUM> is configured to be spaced apart from the lower mold surface <NUM> in the parting portion 114a, 114b when the mold <NUM> is in the closed position to define a parting thickness T<NUM>. In some examples, the parting thickness is approximately <NUM>. The parting portion 114a, 114b may include one or more guide features 142a, 142b configured to maintain alignment between the upper mold plate <NUM> and the lower mold plate <NUM>, as shown in <FIG>.

The upper mold plate <NUM> and the lower mold plate <NUM> are at least partially formed of materials suitable for use in injection molding processes. In some examples, the mold plates <NUM>, <NUM> are formed entirely of a first material. In other examples, the upper mold plate <NUM> and/or the lower mold plate <NUM> may be formed as composite plates, wherein a first portion is formed of a first material and a second portion is formed of a second material. For example, the portion of the mold plate <NUM>, <NUM> defining mold cavity <NUM> may be formed of the first material, while an outer shell of the mold plate <NUM>, <NUM> may be formed of a different material. Materials used for forming the mold plates <NUM>, <NUM>, and particularly, the mold cavity <NUM>, will exhibit favorable properties related to hardness, polishing ability, corrosion resistance, and thermal stability/conductivity. For example, metallic materials may be used for forming the mold plates <NUM>, <NUM>. In some examples, tool steel or aluminum may be used in forming the mold.

With reference to <FIG>, the plate <NUM> is formed of a preform <NUM> having one or more layers <NUM> bonded by a solid polymeric material <NUM>. As explained in greater detail below, each of the layers <NUM> includes at least one ply <NUM> having one or more strands <NUM> of fibers arranged on a substrate <NUM> in selected patterns to impart stiffness and gradient load paths throughout the plate <NUM>. Only a single ply <NUM> is shown in the example of <FIG>. However, each layer <NUM> may be formed with various quantities and arrangements of the plies <NUM> to impart desired torsional properties to the finished plate <NUM>.

Each strand <NUM> may refer to a tow of a plurality of fibers, a monofilament, yarn, or polymer pre-impregnated tows. As used herein, the term "tow" or "strand" refers to a bundle (i.e., plurality of filaments (e.g., fiber) that may be twisted or untwisted and each tow may be designated a size associated with a number of fibers the corresponding tow contains. For instance, a single strand <NUM> may range in size from about <NUM>,<NUM> fibers per bundle to about <NUM>,<NUM> fibers per bundle.

In some configurations, the fibers associated with each strand <NUM> include at least one of carbon fibers, boron fibers, glass fibers, and polymeric or thermoplastic fibers. Fibers such as carbon fibers, aramid fibers, and boron fibers may provide a high Young's modulus while glass fibers (e.g., fiberglass) and polymer fibers (e.g., synthetic fibers) provide a medium modulus. Additionally or alternatively, each strand <NUM> may be provided with first fibers comingled with second fibers, whereby the second fibers have one or more of a different length, thickness, melting temperature, and/or Young's modulus than the first fibers. For example, the strand <NUM> may include a plurality of carbon fibers and a plurality of thermoplastic fibers that, when heated above their melting point, form a liquid material that infuses the carbon fibers, and solidifies into a solid polymeric material which consolidates and holds the carbon fibers in a desired shape and position relative to one another.

As used herein, the substrate <NUM> refers to any one of a veil, carrier, or backer to which at least one strand <NUM> of fibers is attached. The substrate <NUM> may be formed from a thermoset polymeric material or a thermoplastic polymeric material and can be a textile (e.g., knit, woven, or non-woven), an injection molded article, a fabric-reinforced thermoplastic article (organo sheet), or a thermoformed article.

The strands <NUM> of fibers forming the plies <NUM> of each layer <NUM> may be affixed to the same or separate substrates <NUM> and embroidered in a layered configuration. When forming the layers <NUM> of the plate <NUM>, the strand or strands <NUM> of the plies <NUM> may be applied directly to the substrate <NUM>, and may be attached to the substrate <NUM> using stitching <NUM> to hold the strands <NUM> in a desired location. In some examples, the stitching <NUM> may include a continuous zig-zag stitch extending along the strand. Alternatively, the stitching <NUM> may be provided at discrete attachment points spaced along the strand <NUM>.

The stitching <NUM> may be formed from the same material as the substrate <NUM>. Alternatively, the stitching <NUM> may be formed from a different material than the material forming the substrate <NUM> such that the stitching <NUM> is associated with a higher melting point than the substrate <NUM>. Providing the stitching <NUM> with a higher melting point than the substrate <NUM> allows the stitching <NUM> to melt after the substrate <NUM> when heat is applied during formation of the plate <NUM>. In some examples, the stitching <NUM>, or at least a portion thereof, is formed from a thermoplastic material.

Referring to <FIG>, the plies <NUM> of the preform <NUM> each include at least one torsion strand <NUM> wound in a serpentine configuration, such that each strand <NUM> includes a plurality of segments <NUM> distributed throughout the ply <NUM>. Each of the segments <NUM> includes arcuate portions and is initially connected to adjacent ones of the segments <NUM> by loops <NUM> at each end. As such, a single strand <NUM> may form the entire ply <NUM>. In the example of <FIG>, the strand <NUM> includes the loops <NUM> disposed outside a peripheral edge P of the substrate for connecting adjacent segments <NUM> of the strand <NUM>. As shown, the segments <NUM> extend through an interior portion of the preform <NUM> corresponding to a location of a footbed <NUM> (<FIG>), while the loops <NUM> form a peripheral portion of the preform <NUM>.

With reference to <FIG> and <FIG>, once the preform <NUM> is constructed using the desired quantity and configurations of plies <NUM> and substrates <NUM>, the assembled preform <NUM> is positioned within the mold cavity <NUM> (<FIG>) and the mold <NUM> is moved to the closed position (<FIG>) to compress the preform <NUM> within the plate-forming region <NUM>. The preform <NUM> is aligned within the mold cavity <NUM> so that a peripheral portion of the substrate <NUM> extends at least partially into the trim region <NUM> of the mold cavity <NUM> when the mold <NUM> is moved to the closed position. Accordingly, the ends <NUM> and the loops <NUM> of the strands <NUM> will extend into the interior void <NUM> formed by the relief region <NUM> of the mold cavity <NUM>. Here, the interior void <NUM> is sized so that the ends <NUM> and loops <NUM> of the strands <NUM> can loosely bunch within the relief region <NUM> without forming pinch points or frustrating the arrangement of the strands <NUM> within the molding region. In some instances, compression of the preform <NUM> within the plate-forming region <NUM> causes a portion of the preform <NUM> to be displaced from the plate-forming region <NUM> and into the trim region <NUM> and/or the relief region <NUM>. Accordingly, the relief region <NUM> may be sized to accommodate the displaced preform materials.

With continued reference to <FIG>, when the mold <NUM> is in the closed position, the preform <NUM> is pushed or biased partially into the lower projection features 134b by the upper projection features 134a. For example, as discussed above, the upper projection features 134a are formed as blunted or rounded protuberances having a height that is less than a depth of the corresponding lower projection features 134b such that the distal ends of the upper projection features 134a are spaced apart from the bottom tips of the lower projection features 134b. Accordingly, when the mold <NUM> is closed, the preform is pushed partially into the recesses formed by the lower projection features 134b, but is spaced apart from the bottom tip of the lower projection features 134b by a gap or void.

Referring now to <FIG>, once the mold <NUM> is in the closed position, the liquid material <NUM> is injected into the mold cavity <NUM> through one or more injection ports <NUM> formed in the upper and/or lower mold plates <NUM>, <NUM>. Here, a single port <NUM> is shown in the central channel region <NUM> of the mold cavity <NUM>. However, in other examples, a plurality of ports <NUM> may be distributed along the mold cavity <NUM>. Initially, liquid material <NUM> is injected into the plate-forming region <NUM>, such that the material <NUM> is infused within or encapsulates the portions of the strands <NUM> disposed within the plate-forming region <NUM>. In these implementations, the liquid material <NUM> may include a curable material provided to the mold cavity <NUM> in a fluid state and having a viscosity ranging from <NUM> cps to <NUM> cps. The curable material can include a polymerizable composition, or a crosslinkable composition, or both. When cured, the curable material forms a solid polymeric material having a surface hardness ranging from <NUM> Shore A to <NUM> Shore D. The curable material can include one or more pre-polymers or polymers. The curable material can be a thermosettable material which, when cured, forms a solid thermoset material. The curable material may include at least one of an epoxy and a polyurethane. Moreover, one or more additional polymers, such as a rubber and/or a block copolymer, may be added to the curable material to increase its ductility when cured. The liquid material <NUM> can be a thermoplastic material provided to the mold cavity <NUM> in a molten state, which, when cooled to a temperature below its melting point, forms a solid thermoplastic material. The thermoplastic material may include at least one of a thermoplastic polyurethane, a thermoplastic polyester, a thermoplastic polyether, and a thermoplastic polyamide. Additionally or alternatively, a polymeric material (e.g., fibers or filaments comprising a thermoplastic material, or fibers or filaments comprising a second polymeric material which is soluble in the liquid material) may be incorporated into the at least one strand <NUM> and/or a substrate to assist with consolidating the at least one strand <NUM>, and, when a substrate is present, with binding/affixing the at least one strand <NUM> to the substrate <NUM>.

As the liquid material <NUM> flows into or within the mold cavity <NUM>, the liquid material <NUM> fills the plate-forming region <NUM> to define the footbed <NUM> of the plate <NUM>, which includes the traction elements <NUM> formed by the projection elements <NUM> and the shank <NUM> formed by the channel region <NUM>. As discussed previously, the preform <NUM> is only partially pushed into the lower projection feature 134b by the upper projection feature 134a such that a gap is formed between the preform <NUM> and the lower tip of the lower projection feature 134b. When the liquid material <NUM> flows into the mold cavity <NUM>, the tip of the lower projection features 134b is filled with the liquid material <NUM>. Accordingly, the traction elements <NUM> formed with the projection elements <NUM> include distal ends or tips that are entirely formed of the liquid material <NUM>, while the material of the preform <NUM> is disposed in an intermediate portion of the traction elements <NUM>. Furthermore, the upper projection features 134a form concave depressions <NUM> in a top side of the footbed <NUM>. Thus, the rounded upper projection features 134a function to force at least some of the fibers associated with the preform <NUM> into each of the lower projection features 134b, allowing enough of the liquid material <NUM> within the projection element <NUM> to prevent damage to the fibers while simultaneously minimizing areas of excess liquid material thickness by forming the depressions <NUM> on opposite sides from the traction elements <NUM>.

After the plate-forming region <NUM> is filled, excess liquid material <NUM> will flow through the trim region <NUM> and into the relief region <NUM>. Here, the liquid material may be provided until the relief region <NUM> is filled to a desired level, or until a desired threshold mold pressure is satisfied. For example, the relief region <NUM> may only be partially filled with the liquid material, such that the loops <NUM> within the relief region <NUM> are partially encapsulated by the liquid material <NUM>, and are partially encapsulated by the solid polymeric material once the liquid material has solidified. Thus, in addition to the footbed <NUM> of the plate <NUM> that is formed in the plate-forming region <NUM>, the liquid material <NUM> and the peripheral portion of the preform <NUM> may cooperate to form a trim flange <NUM> and flashing <NUM> corresponding to the trim region <NUM> and the relief region <NUM>, respectively.

With reference to <FIG>, the trim flange <NUM> surrounds the footbed <NUM> of the plate <NUM>, and provides a continuous rim around the molded plate <NUM> that can be removed to form the outer periphery <NUM> of the finished plate <NUM>. As discussed above, the trim region <NUM> of the mold cavity <NUM> has a width W<NUM> of at least <NUM>. Accordingly, the trim flange <NUM> will also have a width of at least <NUM>, which provides sufficient width for allowing a cutting tool to be maneuvered along the trim flange <NUM> in a post-molding trim step. By providing a trim flange <NUM> having a width greater than the width of the cutting tool, the flashing <NUM> (i.e., excess preform <NUM> and material <NUM>) can be easily removed from the plate <NUM> to provide the plate <NUM> with a smooth outer peripheral edge <NUM>. The inclusion of the trim flange <NUM> is particularly useful when using CNC cutting equipment, as the trim flange <NUM> is configured to provide a boundary region along which the CNC cutting equipment can be programmed to follow. In some examples, the trim flange <NUM> is formed as a substantially flat or planar region. However, in other examples, where the outer peripheral edge <NUM> of the finished plate <NUM> is contoured (i.e., not in the same horizontal plane), the trim flange <NUM> may also be contoured to correspond to the outer peripheral edge <NUM>. In some implementations, the trim flange <NUM> will extend outwardly from the peripheral edge at a constant angle corresponding to the angle α discussed above with respect to the mold surfaces <NUM>, <NUM>.

When the mold cavity <NUM> is sufficiently filled with the liquid material <NUM>, the material <NUM> is cured within the mold cavity <NUM> under the effects of heat and pressure to form a plate blank or composite preform <NUM> including the preform <NUM> and the cured material <NUM>. In a cured state, the material <NUM> is hardened or solidified such that the composite preform <NUM> is rigid. For example, the portion of the composite preform <NUM> forming the footbed <NUM> may have a density ranging from <NUM>/cm<NUM> to <NUM>/cm<NUM> and a stiffness ranging from <NUM> GPa to <NUM> GPa. The composite preform <NUM> may be described as an intermediate state of the finished plate <NUM>, where the trim flange <NUM> and the flashing <NUM> have not been removed from the footbed <NUM>. Once the material <NUM> is cured, the mold <NUM> is moved to an opened position by translating the upper mold portion <NUM> away from the lower mold portion <NUM>. With the mold <NUM> opened, the composite preform <NUM> is exposed and can be removed from the mold cavity <NUM> for finishing.

Claim 1:
A method of forming a composite article, the method comprising:
inserting a preform (<NUM>) including a strand (<NUM>) into a mold cavity (<NUM>) of a mold (<NUM>), the preform (<NUM>) having a strand layer including an interior portion and a peripheral portion surrounding the interior portion, the strand including loops (<NUM>) forming the peripheral portion, wherein the inserting includes inserting the interior portion of the preform (<NUM>) into a molding region (<NUM>) of the mold cavity (<NUM>) and inserting the peripheral portion of the preform (<NUM>) into a relief region (<NUM>) of the mold cavity (<NUM>), wherein the molding region (<NUM>) of the mold cavity (<NUM>) includes a plate-forming region (<NUM>) and a trim region (<NUM>) surrounding the plate-forming region <NUM>, the relief region (<NUM>) surrounds the trim region (<NUM>) and includes one or more portions (<NUM>, <NUM>) having thicknesses (T<NUM>, T<NUM>) configured to accommodate bunching of a peripheral region of the preform (<NUM>) when the mold (<NUM>) is in a closed position, and the loops (<NUM>) of the strand (<NUM>) extend into an interior void (<NUM>) formed by the relief region (<NUM>) of the mold cavity (<NUM>);
closing the mold (<NUM>) following insertion of the preform (<NUM>) into the mold cavity (<NUM>);
compressing the interior portion of the preform (<NUM>) within the molding region in the closed mold (<NUM>); and
maintaining the peripheral portion loose within the relief region (<NUM>) during compression of the interior portion.