US-12622484-B2 - System and method for forming a molded component with an insert

Abstract

A method for forming a molded article having an insert includes temporarily protecting features of the insert during a molding process using a malleable plugging material. In one step, the method includes disposing a plug including the plugging material within a receptacle of the insert, where each receptacle includes an engagement feature. The insert and the plugging material are placed into a mold, and a liquid molding material is applied to an exterior surface of the insert. The liquid molding material is solidified, forming the molded article including the insert embedded in the solidified molding material. The molded article is removed from the mold, and the plugging material is removed from the receptacle of the insert that is embedded in the molded article to expose the engagement feature.

Inventors

• Aaron Bartel
• Michael A. Hofmann
• Sam Lacey
• Geun Rok Park
• Manki Park

Assignees

• NIKE, INC.

Dates

Publication Date

20260512

Application Date

20231124

Claims (20)

1. 1 . A molded article comprising: an insert including a projection extending from a base, the projection defining a receptacle having a first engagement feature disposed on an inner surface thereof; a plug including a first material disposed within the receptacle of the projection and including a second engagement feature matingly receiving the first engagement feature to retain the plug within the receptacle, the plug including an alignment feature operable to receive an external structure to align the insert with the external structure; and a second material surrounding the projection and the base and being spaced apart and separated from the plug.
2. 2 . The molded article of claim 1 , wherein the external structure is a fixture of a mold.
3. 3 . The molded article of claim 2 , wherein the fixture extends from a surface within a cavity of the mold, the fixture received by the alignment feature to position the insert relative to the surface of the mold when the second material is applied to the insert.
4. 4 . The molded article of claim 3 , wherein the alignment feature is a cylindrical bore formed through the plug and the fixture is a cylindrical post, the cylindrical post being received by the cylindrical bore to align the insert relative to the surface of the mold when the second material is applied to the insert.
5. 5 . The molded article of claim 4 , wherein the cylindrical bore is elongate and extends through a first end of the plug and a second end of the plug.
6. 6 . The molded article of claim 1 , wherein the first engagement feature includes a first series of threads, the first material of the plug engaging the first series of threads to define the second engagement feature.
7. 7 . The molded article of claim 1 , wherein the first material is an elastomer.
8. 8 . The molded article of claim 1 , wherein the base extends laterally outwardly from the projection.
9. 9 . A sole structure incorporating the molded article of claim 1 .
10. 10 . An article of footwear incorporating the molded article of claim 1 .
11. 11 . A molded article comprising: an insert including a projection extending from a base, the projection and the base being embedded in a first material; and a plug including a second material disposed within a receptacle of the projection and being spaced apart and separated from the first material by a wall of the projection, the plug including an alignment feature operable to receive an external structure to align the insert with the external structure.
12. 12 . The molded article of claim 11 , wherein the external structure is a fixture of a mold.
13. 13 . The molded article of claim 12 , wherein the fixture extends from a surface within a cavity of the mold, the fixture received by the alignment feature to position the insert relative to the surface of the mold when the first material is applied to the insert.
14. 14 . The molded article of claim 13 , wherein the alignment feature is a cylindrical bore formed through the plug and the fixture is a cylindrical post, the cylindrical post being received by the cylindrical bore to align the insert relative to the surface of the mold when the first material is applied to the insert.
15. 15 . The molded article of claim 14 , wherein the cylindrical bore is elongate and extends through a first end of the plug and a second end of the plug.
16. 16 . The molded article of claim 11 , wherein the insert includes a first series of threads to define a first engagement feature, the second material of the plug engaging the first series of threads to define a second engagement feature that retains the plug within the insert.
17. 17 . The molded article of claim 11 , wherein the second material is an elastomer.
18. 18 . The molded article of claim 11 , wherein the base extends laterally outwardly from the projection.
19. 19 . A sole structure incorporating the molded article of claim 11 .
20. 20 . An article of footwear incorporating the molded article of claim 11 .

Description

CROSS REFERENCE TO RELATED APPLICATION This application is a division of U.S. patent application Ser. No. 17/111,945, filed on Dec. 4, 2020, which claims priority under 35 U.S.C. § 119(e) to Provisional U.S. Patent Application No. 62/943,975, filed on Dec. 5, 2019, the contents of which are incorporated by reference in their entirety. FIELD The present disclosure relates generally to methods and systems for forming molded components with inserts. BACKGROUND This section provides background information related to the present disclosure, which is not necessarily prior art. Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support a foot on the sole structure. Sole structures generally include a layered arrangement extending between a ground surface and the upper. One or more components of the article of footwear, and particularly, the sole structure, may be formed using various molding systems and processes, such as injection molding and compression molding systems. In some instances, the molded components may include a molded material that is initially provided to the molding system in a fluid state and then solidified to form the molded component. Here, it may be desirable to provide the molded component with one or more pre-formed inserts which become bonded to the molded component. For example, inserts configured for attaching periphery components, such as cleats or studs, may be embedded within the molded material of the molded component. DRAWINGS The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure. FIG. 1 is a bottom perspective view of an article of footwear including a sole structure formed according to the principles of the present disclosure; FIG. 2 is an exploded perspective view of an example of an insert and traction element used in forming the sole structure of FIG. 1; FIG. 3 is a partial environmental view of a system and method according to the principles of the present disclosure, showing the formation of a plugging material into a plurality of blanks; FIG. 4 is a partial environmental view of the system and molded article of the present disclosure, showing the trimming of the blanks of FIG. 3; FIG. 5 is a partial environmental view of the system and molded article of the present disclosure, showing the formation of one of the blanks of FIG. 4 into a plug; FIG. 6A is a partial environmental view of the system and molded article of the present disclosure, showing the insertion of one of the plugs of FIG. 5 into an insert; FIG. 6B is a cross-sectional view of the insert and plug of FIG. 6A; FIG. 7 is a partial environmental view of the system and molded article of the present disclosure, showing placement of the insert and plug of FIG. 6A within a mold; FIG. 8 is a partial environmental view of the system and molded article of the present disclosure, showing removal of flashing from the insert and plug; FIG. 9 is a partial environmental view of the system and molded article of the present disclosure, showing attachment of the insert and plug to a substrate; FIG. 10 is a partial environmental view of the system and molded article of the present disclosure, showing formation of a sole plate including the substrate, insert, and plug of FIG. 9; FIGS. 11A-11C are cross-sectional views of a mold according to the principles of the present disclosure, showing steps for forming the sole plate of FIG. 10; and FIG. 12 is a partial environmental view of the system and molded article of the present disclosure, showing removal of the plugging material from the sole plate. Corresponding reference numerals indicate corresponding parts throughout the drawings. DETAILED DESCRIPTION The present disclosure is directed to methods of manufacturing molded articles, systems for use in the methods, molded articles made using the methods and/or the systems, and articles of footwear incorporating the molded articles. In some examples, molded articles are formed with inserts to provide critical elements of the molded articles with more durable or precise features. For example, where molded articles are formed using composite materials, metal or polymeric inserts may be provided within the molded article to provide rigid and durable attachment points for peripheral items, such as detachable traction elements. The methods and systems of the present disclosure are directed towards providing an efficient means for molding the molded articles including the inserts in a single molding process, whereby critical features (e.g., threads) of the inserts are protected during the molding process by a removable plugging material disposed in the critical features of the inserts. Particularly, the critical features of the inserts are temporarily protected during a molding process by the presence of the removable plugging material,