Nike, Inc.

Jeongeun Bae

Bryan N Farris

Caleb W Dyer

Rory S Blanche

Minseung Kang

William Denton

Ryan Creswell

Diego Zurita

David Jung

Methods and systems are provided for forming a molded foam article. An example method may include molding a plurality of separate pieces of closed-cell foam by exposure to a temperature cycle within a sealed mold to soften the plurality of pieces sufficiently for physical bonding; and forming a molded foam article with the pieces bonded together without an adhesive, wherein, during the temperature cycle, the mold is unsealed at least once to release gases and/or pressure. In another example, a method includes exposing a filled, sealed mold filled with a plurality of pieces of foamed material to a heating cycle; at a threshold temperature, unsealing the filled, sealed mold until a pressure reduces to within a threshold of atmospheric pressure; and, following the unsealing, cooling the filled mold prior to removing a molded foam article.

Method for molding foamed material

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Beaverton, OR, United States of America

Jeongeun Bae