权利要求：
1. A method for making a decorated foamed article, the method comprising:
placing an article and carbon dioxide (CO2) in a vessel, wherein the article comprises a solid foamable material which is a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers;
after the placing, maintaining the vessel at a first pressure and first temperature, wherein the first pressure and first temperature are a pressure and temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining includes holding the article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the article;
following the maintaining and holding, optionally exposing the infused article to a second pressure and second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material;
following the maintaining and holding and the optional exposing, subjecting the article to a third pressure and third temperature at which the carbon dioxide infused in the solid foamable material phase transitions to a gas, thereby expanding the solid foamable material into a foamed material and forming the foamed article;
wherein the foamed article comprises a decorative element, and the decorative element is a printed element, an embroidered element, an embossed element, a debossed element, a coating, a painted element, a sprayed element, a film element, a yarn or cable element, a textile element, an injection molded element, or any combination thereof; optionally wherein the decorative element comprise a pigment or a dye or both a pigment and a dye.
2. The method of claim 1, further comprising following the subjecting and expanding, stabilizing the foamed article at a stabilizing pressure and stabilizing temperature at which the carbon dioxide diffuses out of the foamed material of the foamed article while maintaining the foamed material in a foam structure, forming a stabilized foamed article, wherein the stabilizing comprises holding the foamed article at the stabilizing pressure and stabilizing temperature for a duration of time sufficient to remove substantially all of the carbon dioxide from the foamed material.
3. The method of claim 1, wherein the article is a dyed article.
4. The method of claim 1, wherein the article comprises a textile, fiber, or yarn.
5. The method of claim 1, further comprising applying a color composition onto a side of the article or of the foamed article and allowing the color composition to dry in contact with the side, forming a printed layer on the side of the article or of the foamed article.
6. The method of claim 1, wherein the decorative element comprises a printed marking and wherein the printed marking comprises a printed image, a printed design, a printed logo, a printed decoration, a printed ornamentation, or any combination thereof.
7. The method of claim 1, further comprising providing a printed film and affixing the printed film to at least a portion of a surface of the article.
8. The method of claim 1, further comprising affixing a polymeric material onto the side of the article or of the foamed article, wherein the affixed polymeric material provides a topography having a greater surface area on the side of the article or of the foamed article as compared to the topography on the side prior to the printing.
9. The method of claim 8, wherein the affixed polymeric material forms a three-dimensional structure on the side of the article or of the foamed article.
10. The method of claim 1, further comprising applying embroidery to at least a portion of the foamed article.
11. The method of claim 1, further comprising stitching at least one textile to at least a portion of the article or of the foamed article with a first yarn.
12. The method of claim 11, wherein the at least one textile comprises a solid foamable material, and the method further comprises foaming the solid foamable material of the at least one textile.
13. The method of claim 1, wherein the decorative element comprises an embossed or debossed element.
14. The method of claim 1, wherein the decorative element comprises a structurally colored element.
15. The method of claim 1, wherein the article includes a layered sheet, the steps of subjecting and expanding foam at least one layer of the sheet, and following the subjecting and expanding, a thickness of the foamed layered sheet is at least 5 percent greater than a thickness of the layered sheet in its unfoamed state.
16. The method of claim 2, wherein, following the stabilizing, the stabilized foam article is greater in at least one dimension as compared to a size of the article before the placing.
17. A decorated foamed article made by the method of claim 1.
18. A decorated foamed article comprising:
a foamed material which is a physically-expanded foam formed of a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers,
wherein the article comprises a decorative element visible on or through a side of the article,
wherein the article comprises a layered structure including a series of three or more layers, including
a first face layer comprising or consisting essentially of a first face layer material, the first face layer including a first face layer outer surface defining a first outer surface of the layered structure, a first face layer inner surface opposing the first face layer outer surface, a first face layer thickness extending from the first face layer interior surface to the first face layer outer surface, wherein the first face layer outer surface defines a first exterior surface of the article;
a second face layer comprising or consisting essentially of a second face layer material, the second face layer including a second face layer outer surface defining a second outer surface of the layered structure, a second face layer inner surface opposing the second face layer outer surface, a second face layer thickness extending from the second face layer interior surface to the second face layer outer surface; and
one or more inner layers, wherein each of the one or more inner layers comprise or consist essentially of an inner layer material, each of the one or more inner layers including an inner layer first surface, an inner layer second surface, and an inner layer thickness extending from the inner layer first surface to the inner layer second surface, wherein each of the one or more inner layers is positioned between the first face layer inner surface and the second face layer inner surface;
wherein at least one of the three or more layers of the article comprises or consists essentially of a solid material, and another of the three or more layers of the article comprises or consists essentially of the foamed material.
19. The decorated foamed article of claim 18, wherein the decorative element has been applied by printing, embroidering, embossing, debossing, coating, pressing, painting, brushing, spraying, sewing, bonding, or depositing the decorative element onto the article, or dipping the article into the decorative element, or pressing the decorative element and the article together, wherein the decorative element is in the form of a solid, a liquid, or a gas when applied to the foam article.
20. The decorated foamed article of claim 18, wherein the decorated article is an article of apparel, footwear or sporting equipment, or is a component of an article of apparel, footwear or sporting equipment.
具体实施方式：
[0017]New foamed articles including a foamed thermoplastic elastomeric material and methods for making such foamed articles have been identified. In one aspect, the foamed articles comprise a decorative element. The methods described herein include a step of infusing carbon dioxide into a solid foamable material of an article, i.e., a solid article. Following the infusing, the infused solid foamable material is foamed without thermally softening the solid foamable material by expanding the infused carbon dioxide, e.g., by phase transitioning the infused carbon dioxide to carbon dioxide gas, which in turn expands the solid foamable material into a foamed material into a foam, e.g., a foam having a multi-cellular foam structure. In this way, the solid foamable material is physically foamed without being melted in the process.
[0018]In an aspect, the decorative element can be a printed element, an embroidered element, an embossed element, a debossed element, a coating, a painted element, a sprayed element, a film element, a yarn or cable element, a textile element, an injection molded element, a multi-layer optical element, or any combination thereof. In an aspect, the decorative element comprise a pigment or a dye or both a pigment and a dye.
[0019]The foamed articles described herein include one or more foamed materials which are physically foamed materials. It has been found that these physically foamed materials, which comprise a thermoplastic elastomeric material as described herein have a low density, a uniform multi-cellular foam structure, and/or other beneficial properties making the foamed materials suitable for use in many mass-produced consumer products, including articles of apparel, footwear, and sporting equipment. FIGS. 1A-1M illustrate various articles of footwear, apparel, and athletic equipment, including containers, electronic equipment, and vision wear, that are or comprise foamed articles in accordance with the present disclosure, while FIGS. 1N(a)-1Q(e) illustrate additional details regarding different types of footwear.
[0020]It has also been found that the multi-step foaming processes described herein can be easily adapted for use with conventional materials and manufacturing lines, as they use simpler, less expensive and more energy-efficient equipment and processes than other physical foaming processes. For example, maintaining the carbon dioxide as a liquid and holding the solid foamable material in the liquid carbon dioxide requires maintaining less extreme temperatures and pressures (and thus requires less expensive, more energy-efficient equipment) than using supercritical carbon dioxide to infuse the solid foamable material. In many aspects, the step of expanding the solid foamable material into the foamed material can be conducted at or near atmospheric pressure and at relatively low temperatures well below the melting temperature of the foamable material, and so can be conducted using simple, inexpensive heating methods and equipment, making the overall foaming process efficient and cost-effective. Additionally, the present disclosure can be applied to a wide range of solid foamable materials, and to articles have a number of different geometries, including but not limited to sheets of solid foamable material(s). Further, by using articles comprising two or more types of solid foamable materials, articles comprising two or more portion or regions of solid foamable material, and articles comprising a combination of one or more solid foamable material and one or more solid non-foamable material, and/or by varying the processing conditions, the processes for foaming solid articles described herein can be adapted to selectively foam portions or regions of an article without the need for additional tooling or equipment.
[0021]Using a foamed thermoplastic elastomeric material in the foamed articles disclosed herein can reduce the weight or density of the articles as compared to articles without foamed materials, i.e., articles comprising only solid materials. Additionally or alternatively, by using a foamed material in place of an unfoamed material, the total amount of material needed to provide the same volume is reduced, reducing material costs and making the foamed article more sustainable as compared to a comparable article without foamed material. Furthermore, by using a foamed thermoplastic elastomeric material, alone or in combination with one or more additional thermoplastic material, to form the foamed article, components of the foamed article or the entire foamed article can comprise recycled thermoplastic materials, and, in turn, the components or the entire foamed article can be recycled themselves. In some aspect, by controlling the foaming conditions and, optionally, controlling the optional stabilization process, the overall volume of the foamed article may be increased within a predicted or pre-determined range. The increase in volume can be relatively small, for example, an increase in volume of less than 10 percent, or less than 5 percent, as compared to the total volume of the article prior to undergoing the foaming process Alternatively, the increase in volume can be relatively large, for example, an increase in volume of greater than 20 percent, or greater than 40 percent as compared to the total volume of the article prior to undergoing the foaming process.
[0022]In some aspects, the foamed material of the foamed article is a stabilized foam material which has undergone a stabilization process. In some aspects, the foamed article includes layers or regions of foamed material adjacent to layers or regions of solid (i.e., unfoamed) material. In some aspects, the foamed article can be a cushioning element, such as a fluid-filled bladder. In some aspects, the thermoplastic elastomeric material can comprise one or more thermoplastic polyurethanes. In some aspects, in addition to the thermoplastic elastomeric material, the foamed article can further include a second material, such as a second thermoplastic material, including a second thermoplastic material which does not foam during the foaming process.
[0023]In one aspect, the present disclosure is directed to a method for making a foamed article. The foaming process as disclosed herein is a multi-step process which includes first infusing a solid foamable material with carbon dioxide, and then exposing the infused article to conditions which cause the carbon dioxide infused in the solid foamable material to undergo a phase change, which expands and foams the solid foamable material into a foamed material. Optionally, prior to the foaming step, the infused article can be exposed to and held (e.g., stored) at a pressure and temperature at which the infused carbon dioxide remains infused in the article, allowing the infused article to be foamed at a later time. Alternatively, the infused article can be exposed to and held conditions at which a portion of the infused carbon dioxide diffuses out of it, for a duration of time to allow diffusion of carbon dioxide out of a selected portion of the infused article. In this manner, infused carbon dioxide can be removed from selected regions or portions of the article prior to foaming, which results in only selected regions or portions of the article foaming when exposed to the foaming conditions. Optionally, after undergoing foaming, the foamed article can be stabilized to release residual carbon dioxide and/or to release residual stress in the article.
[0024]In another aspect, the present disclosure is directed to a foamed article comprising a decorative element, that is, a “decorated foamed article. The foamed article comprises or consists essentially of a foamed material, wherein the foamed material is a physically-expanded foam formed of a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers. The foamed material is the product of infusing carbon dioxide into a solid foamable comprising the thermoplastic elastomeric material, and producing a phase change causing the infused carbon dioxide to expand, thereby foaming the solid foamable material into the foamed material without thermally softening the solid foamable material. Optionally, the foamed article can comprise additional foamed materials, or additional unfoamed materials. Optionally, the foamed article can be a stabilized foam article, from which residual carbon dioxide has been removed, or from which residual stresses created during the foaming process have been reduced or removed.
[0025]In one aspect, disclosed herein is a method for making a foamed article, the method comprising:
[0026]placing an article and carbon dioxide in a vessel, wherein the article comprises or consists essentially of a solid foamable material which is a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers;
[0027]after the placing, maintaining the vessel at a first pressure and a first temperature, wherein the first pressure and first temperature are a pressure and temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining includes holding the article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the foamable material of the article, thereby forming an infused article;
[0028]following the maintaining and holding, optionally exposing the infused article to a second pressure and second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material;
[0029]following the maintaining and holding and the optional exposing, subjecting the article to a third pressure and third temperature at which the carbon dioxide infused in the solid foamable material phase transitions to a gas, thereby expanding the solid foamable material into a foamed material and forming the foamed article;
[0030]wherein the foamed article comprises a decorative element.
[0031]In one aspect, the method comprises placing a decorated article in the vessel, while in another aspect, the method comprises applying a decorative element to the article after the step of placing the article in the vessel. Further in this element, the step of applying the decorative element can optionally be conducted on the foamed article. In any of these aspects, the decorative element can be affixed to an outer surface of the foamed article or can be visible through an outer surface of the foamed article. In one aspect, the foamed material of the foamed article is substantially opaque.
[0032]In some aspects, following the subjecting and expanding, the method optionally comprises bringing the foamed article to a fourth temperature and a fourth pressure and holding the foamed article at or below the fourth temperature, the fourth pressure, or both, for a duration of time. In another aspect, following the subjecting and expanding or following the optional bringing, the method further comprises stabilizing the foamed article at a fifth pressure and fifth temperature at which the carbon dioxide diffuses out of the foamed material of the foamed article while maintaining the foamed material in a foam structure, forming a stabilized foamed article.
[0033]In another aspect, disclosed herein is a foamed article manufactured by the disclosed method.
[0034]In yet another aspect, disclosed herein is a foamed article comprising a foamed material which is a physically-expanded foam formed of a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers. In one aspect, the foamed article is manufactured by the disclosed method.
[0035]The present disclosure can be described in accordance with the following numbered aspects, which should not be confused with the claims.
[0036]In accordance with aspect 1, the present disclosure is directed to a method for making a decorated foamed article, the method comprising:
[0037]placing an article and carbon dioxide (CO2) in a vessel, wherein the article comprises a solid foamable material which is a thermoplastic elastomeric material comprising one or more first thermoplastic elastomers;
[0038]after the placing, maintaining the vessel at a first pressure and first temperature, wherein the first pressure and first temperature are a pressure and temperature at which the carbon dioxide is a liquid and the liquid carbon dioxide is soluble in the solid foamable material, and wherein the maintaining includes holding the article and the liquid carbon dioxide in the vessel for a duration of time sufficient for at least a portion of the liquid carbon dioxide to infuse into the solid foamable material of the article;
[0039]following the maintaining and holding, optionally exposing the infused article to a second pressure and second temperature at which the carbon dioxide remains infused within at least a portion of the solid foamable material;
[0040]following the maintaining and holding and the optional exposing, subjecting the article to a third pressure and third temperature at which the carbon dioxide infused in the solid foamable material phase transitions to a gas, thereby expanding the solid foamable material into a foamed material and forming the foamed article;
[0041]wherein the foamed article comprises a decorative element.
[0042]In accordance with aspect 2, the present disclosure is directed to the method of aspect 1, wherein the decorative element is a printed element, an embroidered element, an embossed element, a debossed element, a coating, a painted element, a sprayed element, a film element, a yarn or cable element, a textile element, an injection molded element, or any combination thereof; optionally wherein the decorative element comprise a pigment or a dye or both a pigment and a dye.
[0043]In accordance with aspect 3, the present disclosure is directed to the method of aspect 1 or 2, wherein the step of placing the article in the vessel comprises placing a decorated article in the vessel.
[0044]In accordance with aspect 4, the present disclosure is directed to the method of aspect 3, wherein the method further comprises applying a decorative element to the article prior to the step of placing the decorated article in the vessel.
[0045]In accordance with aspect 5, the present disclosure is directed to the method of aspect 1 or 2, wherein the method comprises applying a decorative element to the article after the step of placing the article in the vessel, optionally wherein the step of applying the decorative element is conducted on the foamed article.
[0046]In accordance with aspect 6, the present disclosure is directed to the method of any one of the preceding aspects, wherein, in the decorated article, the decorative element is affixed to an outer surface of the foamed article or is visible through an outer surface of the foamed article.
[0047]In accordance with aspect 7, the present disclosure is directed to the method of any one of the preceding aspects, wherein the foamed material of the foamed article is substantially opaque.
[0048]In accordance with aspect 8, the present disclosure is directed to the method of aspect 7, wherein the decorative element is affixed to or infused in the substantially opaque foamed material.
[0049]In accordance with aspect 9, the present disclosure is directed to the method of any one of aspects 5-8, wherein the applying comprises applying the decorative element by printing, embroidering, embossing, debossing, coating, pressing, painting, brushing, spraying, sewing, bonding, or depositing the decorative element, or dipping the article into the decorative element, or pressing the decorative element and the article together, wherein the decorative element is in the form of a solid, a liquid, or a gas when applied to the article, optionally wherein the decorative element comprises a pigment or a dye or both a pigment and a dye.
[0050]In accordance with aspect 10, the present disclosure is directed to the method of any one of the preceding aspects, further comprising following the subjecting and expanding, bringing the foamed article to a fourth temperature and fourth pressure, and holding the foamed article at or below the fourth temperature, the fourth pressure, or both, for a duration of time.
[0051]In accordance with aspect 11, the present disclosure is directed to the method of any one of the preceding aspects, further comprising following the subjecting and expanding or following the optional bringing, stabilizing the foamed article at a fifth pressure and fifth temperature at which the carbon dioxide diffuses out of the foamed material of the foamed article while maintaining the foamed material in a foam structure, forming a stabilized foamed article.
[0052]In accordance with aspect 12, the present disclosure is directed to the method of aspect 11, wherein the stabilizing comprises holding the foamed article at the fifth pressure and fifth temperature for a duration of time sufficient to remove substantially all of the carbon dioxide from the foamed material.
[0053]In accordance with aspect 13, the present disclosure is directed to the method of any one of the preceding aspects, wherein, at the first pressure and temperature, the liquid carbon dioxide is soluble in the solid foamable material at a concentration of from about 1 weight percent to about 30 weight percent, optionally from about 5 weight percent to about 20 weight percent.
[0054]In accordance with aspect 14, the present disclosure is directed to the method of any one of the preceding aspects, wherein the decorative element comprises a coating.
[0055]In accordance with aspect 15, the present disclosure is directed to the method of aspect 14, wherein the coating is a brushed, sprayed or deposited coating, optionally wherein the method further comprises brushing, spraying, or depositing a coating composition onto a target coating area to form the decorated element.
[0056]In accordance with aspect 16, the present disclosure is directed to the method of aspect 14, wherein applying the coating comprises immersing at least a portion of the article into a colorant composition.
[0057]In accordance with aspect 17, the present disclosure is directed to the method of aspect 16, wherein the colorant composition comprises a solid pigment, an ink, a dye, a paint, or any combination thereof.
[0058]In accordance with aspect 18, the present disclosure is directed to the method of any one of aspects 14-17, wherein the coating comprises a solidified ink, a solidified paint, a film, or any combination thereof.
[0059]In accordance with aspect 19, the present disclosure is directed to the method of any one of aspects 14-18, wherein the coating comprises a crosslinked coating including a matrix of crosslinked polymers, and optionally includes a plurality of solid pigment particles entrapped in the matrix of crosslinked polymers.
[0060]In accordance with aspect 20, the present disclosure is directed to the method of aspect 19, wherein the matrix of crosslinked polymers includes crosslinked elastomeric polymers, optionally, the crosslinked elastomeric polymers include crosslinked polyurethane homopolymers or copolymers or both, and optionally the crosslinked polyurethane copolymers include crosslinked polyester polyurethanes.
[0061]In accordance with aspect 21, the present disclosure is directed to the method of aspect 19 or 20, wherein the coating is a product of crosslinking a polymeric coating composition, the polymeric coating composition comprises a dispersion of polymers, and optionally comprises at least one of a crosslinking agent, a plurality of solid pigment particles, a dye, and an organic solvent.
[0062]In accordance with aspect 22, the present disclosure is directed to the method of any one of the preceding aspects, further comprising applying a primer layer to the article prior to applying the decorative element.
[0063]In accordance with aspect 23, the present disclosure is directed to the method of aspect 22, wherein the primer layer is a digitally printed layer, an offset printed layer, a pad printed layer, a screen printed layer, a flexographically printed layer, or a heat transfer printed layer.
[0064]In accordance with aspect 24, the present disclosure is directed to the method of aspect 22 or 23, wherein the primer layer is a coating according to any one of aspects 14-21.
[0065]In accordance with aspect 25, the present disclosure is directed to the method of any one of aspects 22-24 wherein applying the primer layer comprises applying a dispersion, emulsion or solution of uncrosslinked polymers in a carrier.
[0066]In accordance with aspect 26, the present disclosure is directed to the method of aspect 25, wherein the carrier is water or an aqueous solution.
[0067]In accordance with aspect 27, the present disclosure is directed to the method of any one of aspects 22-26, wherein the primer layer comprises a plurality of solid pigment particles entrapped in a matrix of crosslinked polymers.
[0068]In accordance with aspect 28, the present disclosure is directed to the method of aspect 27, wherein, when the solid pigment particles are present in the primer layer, the solid pigment particles are selected from the group consisting of: metal and metal oxide pigments, carbon pigments, clay earth pigments, ultramarine pigments, or any combination thereof.
[0069]In accordance with aspect 29, the present disclosure is directed to the method of any one of aspects 22-28, wherein the primer layer further comprises a dye, optionally wherein the dye is an acid dye, optionally wherein the coating further comprises a quaternary ammonium compound.
[0070]In accordance with aspect 30, the present disclosure is directed to the method of any one of aspects 22-29, wherein the primer layer has a color selected from the group consisting of: black, dark brown, dark red, dark orange, dark yellow, dark green, dark cyan, dark blue, dark violet, grey, dark magenta, dark indigo, tones thereof, tints thereof, shades thereof, or any combination thereof.
[0071]In accordance with aspect 31, the present disclosure is directed to the method of any one of the preceding aspects, wherein the decorative element is bonded to the surface of the article, optionally wherein the decorative element is an adhesively bonded element, optionally wherein the method comprises the step of bonding the decorative element to the surface of the article, optionally wherein the bonding includes forming an adhesive bond by applying an adhesive to a first side of the decorative element or to the surface of the foamed article or both, and then pressing together the first side of the decorative element and the surface of the article.
[0072]In accordance with aspect 32, the present disclosure is directed to the method of any one of aspects 14-31, wherein the decorative element is a thermally bonded element and is thermally bonded to the surface of the article, optionally wherein the method comprises the step of bonding the decorative element to the surface of the article, and the bonding includes forming a thermal bond between a thermoplastic material of a first side of the decorative element and a thermoplastic material defining the surface of the foamed article by softening or melting at least an outer portion of one or both of the thermoplastic materials, and pressing the first side of the decorative element and the surface of the article against each other while the one or both of the thermoplastic materials are softened or melted, and then re-solidifying the softened or melted outer portion.
[0073]In accordance with aspect 33, the present disclosure is directed to the method of any one of aspects 14-31, wherein the decorative element is bonded to a surface of the foamed article, optionally wherein the surface is an exterior surface, optionally wherein the bond between the decorative element and the surface of the foamed article is an adhesive bond or a thermal bond, optionally wherein the bond is a bond between the decorative element and the foamed material.
[0074]In accordance with aspect 34, the present disclosure is directed to the method of any one of aspects 14-31, wherein the decorative element is a dyed element infused into material defining a surface of the article, optionally wherein the dyed element is applied to a surface of the article, and, during the applying or during a curing or during both the applying and the curing, the decorative element infuses into a material defining the surface of the article, optionally wherein the decorative element is applied as a solution of a dye or as a sublimation dye.
[0075]In accordance with aspect 35, the present disclosure is directed to the method of any one of aspects 14-31, wherein the decorative element comprises a pigment or a dye or both a pigment and a dye.
[0076]In accordance with aspect 36, the present disclosure is directed to the method of aspect 35, wherein the step of applying the decorative element onto the article comprises curing the decorative element on the article, optionally wherein the curing comprises drying the decorative element, or crosslinking the decorative element, or infusing at least a portion of the decorative element into a polymeric material of a surface or layer of the article, or bonding the decorative element to the surface or layer of the article, or any combination thereof; optionally wherein the surface or layer of the article is an exterior surface or layer.
[0077]In accordance with aspect 37, the present disclosure is directed to the method of aspects 35 or 36, wherein the article is a dyed article, optionally wherein the dye is infused into a material defining a surface or layer of the article, optionally wherein the dye is infused into the solid foamable material or into the foamed material.
[0078]In accordance with aspect 38, the present disclosure is directed to the method of any one of aspects 35-37, wherein the article comprises a textile, fiber, or yarn; optionally wherein the textile, fiber, or yarn is a dyed textile, a dyed fiber, or a dyed yarn.
[0079]In accordance with aspect 39, the present disclosure is directed to the method any one of aspects 35-38, wherein the dyeing is a first dyeing and comprises dyeing at least a portion of the article before the step of placing, or after the step of expanding.
[0080]In accordance with aspect 40, the present disclosure is directed to the method of any one of aspects 35-39, wherein the dyeing comprises using a dye solution comprising at least one dye.
[0081]In accordance with aspect 41, the present disclosure is directed to the method of aspect 40, wherein using the dye solution comprises immersing the article in the dye solution, optionally wherein the immersing is conducted before or after the placing.
[0082]In accordance with aspect 42, the present disclosure is directed to the method of aspect 40 or 41, wherein using the dye solution comprises immersing an entire outer surface area of the article in the dye solution.
[0083]In accordance with aspect 43, the present disclosure is directed to the method of any one of aspects 35-40, wherein using the dye solution comprises spraying the article with the dye solution.
[0084]In accordance with aspect 44, the present disclosure is directed to the method of aspect 43, wherein using the dye solution comprises spraying an entire outer surface area of the article with the dye solution, or. spraying the dye solution onto at least a portion of the outer surface area of the component, or spraying the dye solution onto a target dye area.
[0085]In accordance with aspect 45, the present disclosure is directed to the method of any one of aspects 35-44, wherein the dye solution is an aqueous dye solution
[0086]In accordance with aspect 46, the present disclosure is directed to the method of any one of aspects 35-45, wherein the at least one dye is an acid dye.
[0087]In accordance with aspect 47, the present disclosure is directed to the method of any one of aspects 35-46, wherein the dye solution includes an infrared absorbing dye.
[0088]In accordance with aspect 48, the present disclosure is directed to the method of any one of aspects 35-47, wherein dye solution comprises a quaternary ammonium compound, optionally wherein the quaternary ammonium compound is a soluble tetrabutylammonium compound, optionally wherein the soluble tetrabutylammonium compound includes tetrabutylammonium bromide or tetrabutylammonium chloride or both.
[0089]In accordance with aspect 49, the present disclosure is directed to the method of aspect 48, wherein the dye solution includes from about 0.1 to about 5 equivalents of the quaternary ammonium compound per equivalent of the dye.
[0090]In accordance with aspect 50, the present disclosure is directed to the method of any one of the preceding aspects, further comprising applying a color composition onto a side of the foamed article and allowing the color composition to dry in contact with the side, forming a printed layer on the side of the article, optionally wherein the side is an exterior side, and optionally wherein the applying the color composition is conducted following the step of expanding.
[0091]In accordance with aspect 51, the present disclosure is directed to the method of aspect 50, wherein the step of applying the color composition onto the side of the article comprises applying the color composition to at least a portion of material exposed on the side of the article, and, following the step of applying the color composition but prior to the step of allowing the color composition to dry, the method further comprises allowing the color composition to penetrate into the material.
[0092]In accordance with aspect 52, the present disclosure is directed to the method of aspect 51, wherein the printed layer extends from a surface of the side of the article into a polymeric material, optionally wherein the polymeric material is the solid foamable material or optionally wherein the polymeric material is the foamed material.
[0093]In accordance with aspect 53, the present disclosure is directed to the method of aspect 51 or 52, wherein the step of allowing the color composition to penetrate into the polymeric material comprises allowing the color composition to penetrate into an outer portion of the foamed material, but not into a layer of a barrier material adjacent to the foamed material.
[0094]In accordance with aspect 54, the present disclosure is directed to the method of any one of aspects 51-53, wherein the method further comprises: applying a primer layer on the side of the article prior to applying the color composition to the side of the foamed article, wherein the primer layer is a primer layer according to any one of aspects 198-206, the step of applying the color composition to the side of the foamed article comprises applying the color composition to the primer layer while the primer layer remains wet, and the step of allowing the color composition to dry comprises allowing the color composition and the primer layer to dry on the side of the article.
[0095]In accordance with aspect 55, the present disclosure is directed to the method of any one of aspects 51-54, wherein the color composition comprises a solvent.
[0096]In accordance with aspect 56, the present disclosure is directed to the method of any one of aspects 51-55, wherein the printed layer includes a matrix of crosslinked polymers.
[0097]In accordance with aspect 57, the present disclosure is directed to the method of aspect 56, wherein the matrix of crosslinked polymers includes crosslinked polyurethane homopolymers or copolymers or both, and optionally includes crosslinked polyester polyurethanes.
[0098]In accordance with aspect 58, the present disclosure is directed to the method of any one of aspects 51-57, wherein the printed layer is elastomeric and is the product of crosslinking the primer layer in the presence of the color composition.
[0099]In accordance with aspect 59, the present disclosure is directed to the method of any one of aspects 51-58, wherein the primer layer, the color composition, or both comprise a crosslinking agent.
[0100]In accordance with aspect 60, the present disclosure is directed to the method of any one of aspects 51-59, wherein applying the color composition comprises printing the color composition on the side of the article.
[0101]In accordance with aspect 61, the present disclosure is directed to the method of aspect 60