Selectively applied particulate on nonmetallic substrates

Abstract

The manufacturing of articles relies on the bonding of two or more components to form some forms of the articles, such as a shoe sole bonded with a shoe upper. The bonding may be achieved with a particulate that is applied to a surface of a substrate. The particulate is selectively fused to the substrate with a controlled energy source having multiple energy emitters individually controllable, such as a laser array. The selective application of laser energy allows for specific geometric structures of particulate to be formed on the substrate. The substrate having the fused particulate is mated with another component allowing the fused particulate to bond the first substrate and the second component.

What is claimed is: 
     
         1 . A method of applying a particulate to a nonmetallic substrate, the method comprising:
 applying a particulate to a portion of the substrate;   selectively applying laser energy from a laser source having multiple independently controllable emitters of laser energy selectively activated, the selective application of laser energy is applied to the particulate and the substrate to fuse the particulate and the substrate selectively, forming a fused particulate portion; and   after selectively applying the laser energy, removing an unfused portion of the applied particulate from the substrate.   
     
     
         2 . The method of  claim 1 , further comprising:
 subsequent to removing the unfused portion of the applied particulate, applying thermal energy to the fused particulate for bonding the substrate with a second substrate.   
     
     
         3 . The method of  claim 1 , wherein applying the particulate uses an electrostatic applicator that electrostatically charges the particulate. 
     
     
         4 . The method of  claim 3 , wherein the particulate is electrostatically applied to the substrate without the use of a conducting agent. 
     
     
         5 . The method of  claim 1 , wherein the particulate is comprised of a powdered adhesive comprised of at least one selected from the following:
 a thermoplastic polyurethane (“TPU”);   ethylene vinyl acetate (“EVA”); and   polyolefins.   
     
     
         6 . The method of  claim 1 , wherein a melting point of the particulate is within the range of 50 degrees Celsius to 130 degrees Celsius. 
     
     
         7 . The method of  claim 1 , wherein the particulate is comprised of an infrared doping agent. 
     
     
         8 . The method of  claim 1 , wherein selectively applying the laser energy comprises applying the laser energy to a first portion of the particulate in a location relative to the substrate where fusion is desired and not applying the laser energy to a second portion of the particulate in a location relative to the substrate where fusion is not desired. 
     
     
         9 . The method of  claim 1 , wherein selectively applying the laser energy comprises varying a level of energy applied from a laser at a first location of the substrate relative to a second location of the substrate. 
     
     
         10 . The method of  claim 1 , wherein selectively applying the laser energy comprises directing the laser energy at a first location of the substrate and intentionally avoiding application of laser energy at a second location of the substrate. 
     
     
         11 . The method of  claim 1 , wherein selectively applying laser energy produces a fused particulate perimeter enclosing a non-fused particulate area. 
     
     
         12 . The method of  claim 1 , wherein the laser energy is produced by a diode laser in at least the near infrared spectrum range. 
     
     
         13 . The method of  claim 2 , wherein subsequent to removing the unfused particulate, applying a crosslinking material comprising an encapsulated isocyanate hardener to the fused particulate. 
     
     
         14 . The method of  claim 2 , wherein the application of thermal energy is, at least in part:
 produced from an infrared energy source; or   conducted through the substrate to the fused particulate.   
     
     
         15 . The method of  claim 2 , wherein subsequent to applying thermal energy to the fused particulate, bonding an article of footwear component with the second substrate. 
     
     
         16 . The method of  claim 15 , wherein the second substrate is comprised of a fused particulate portion. 
     
     
         17 . The method of  claim 1 , wherein the laser source having multiple emitters of laser energy selectively activated is comprised of:
 a first laser emitter activated at a first location relative to the substrate and a second laser emitter deactivated at the first location; and   the first laser emitter deactivated at a second location relative to the substrate and the second laser emitter activated at the second location.   
     
     
         18 . The method of  claim 1 , wherein each of the multiple emitters of laser energy are selectively activated and deactivated based on a relative location to the substrate. 
     
     
         19 . The method of  claim 1  further comprising moving the substrate relative to the laser source, wherein the laser source is statically positioned while the substrate moves. 
     
     
         20 . The method of  claim 1  further comprising moving the laser source relative to the substrate, wherein the substrate is statically positioned while the laser source moves.