Injection molded article

Abstract

An injection molded article has at least a first portion with a first cross sectional thickness and an integral second portion having a second cross sectional thickness. A plurality of hollow projections extend into the second portion, thereby allowing the second portion to have an overall cross sectional thickness substantially greater than the first portion thickness.

What is claimed is:  
     
         1 . An injection molded article comprising: 
 a first portion having a first thickness;    a second portion integral with said first portion and having a second thickness, said second portion further comprising at least a first surface and a plurality of projections extending into said second portion from said first surface;    wherein a ratio of said second portion thickness to said first portion thickness is at least about 1 to 0.75.    
     
     
         2 . An injection molded article as in  claim 1  wherein said ratio of said second thickness to said first thickness is at least about 1 to 0.5.  
     
     
         3 . An injection molded article as in  claim 1  wherein said ratio of said second thickness to said first thickness is at least about 1 to 0.25.  
     
     
         4 . An injection molded article as in  claim 1  wherein said ratio of said second thickness to said first thickness is at least about 6 to 1.  
     
     
         5 . An injection molded article as in  claim 1  wherein said second thickness is at least about 5 mm greater than said first thickness.  
     
     
         6 . An injection molded article as in  claim 1  wherein said projections comprise channels.  
     
     
         7 . An injection molded article as in  claim 1  wherein said second portion has a second surface opposite said first surface, wherein said second portion thickness between said first and second surfaces varies, and wherein each of said plurality of projections has a distal end a substantially equal distance from said second surface.  
     
     
         8 . An injection molded article as in  claim 7  wherein said projections are separated from one another by a substantially equal distance.  
     
     
         9 . An injection molded article as in  claim 8  wherein said distance separating said projections from one another is substantially equal to said distance separating said distal ends from said second surface.  
     
     
         10 . An injection molded thermoplastic component comprising: 
 a first portion having a first thickness;    a second portion integral with said first portion, said second portion having a first and a second surface and a varying thickness defined between said first and second surfaces, said thickness having a maximum;    a plurality of projections extending into said second portion from said first surface, each of said projections having a distal end terminating at a substantially equal distance from said second surface, said projections separated from one another by a substantially equal distance; and    wherein said maximum thickness of said second portion is at least about twice as large as said first portion thickness.    
     
     
         11 . An injection molded footwear component comprising: 
 a substantially vertical interior surface and a substantially vertical exterior surface;    an upper portion and a lower portion defined between said interior and exterior surfaces, said upper portion having a minimum thickness, said lower portion having a varying thickness;    a plurality of projections in said lower portion extending from said interior surface towards said exterior surface, said projections extending from said interior surface by varying distances whereby each of said projections has a distal end separated from said exterior surface by a substantially equal distance; and    wherein a ratio of said lower portion thickness at its maximum value to said upper portion minimum thickness is at least about 2 to 1.    
     
     
         12 . An injection molded component as in  claim 11  wherein said projections comprise channels.  
     
     
         13 . An injection molded component as in  claim 12  wherein said channels are separated from one another by a substantially equal distance.  
     
     
         14 . An injection molded component as in  claim 13  wherein said distance separating said channels from one another is substantially equal to said distance separating said channel distal end from said exterior surface.  
     
     
         15 . An injection molded component as in  claim 14  wherein said upper portion thickness goes to zero at a top edge of said upper portion where said interior and exterior surfaces converge, and wherein said upper portion minimum thickness is measured below an edge zone of said upper portion, said edge zone having a length substantially equal to said distance separating said channel distal ends from said exterior surface.  
     
     
         16 . An injection molded component as in  claim 11  wherein said ratio of said lower portion maximum thickness to said upper portion minimum thickness is at least about 4 to 1.  
     
     
         17 . An injection molded component as in  claim 11  wherein said lower portion thickness at its maximum value is at least about 5 mm greater than said upper portion minimum thickness.  
     
     
         18 . An injection molded component as in  claim 11  wherein said upper portion thickness is less than or equal to about 3 mm, and said lower portion thickness is greater than or equal to about 7 mm.