Laminate and method for making laminate
A method of insert molding comprises placing in a first mold a curable rubber composition comprising a reactive species; placing on a surface of the rubber composition a first thermoplastic material in a film or layer comprising a group reactive with the reactive species of the rubber composition; curing the rubber composition in the mold to form a first molded article of cured rubber having a first thermoplastic material layer covalently bonded through reactive of the reactive species and the group; placing the first molded article as an insert into a second mold, the cured rubber contacting an inside surface of the second mold and the thermoplastic layer facing into the second mold cavity; closing the second mold and injecting into the second mold a second thermoplastic material that to form a second molded article comprising the first molded article thermally welded and/or covalently bonded to the second thermoplastic material.
1. An article made according to a method comprising:
placing in a first mold a curable rubber composition;
placing on a surface of the rubber composition a layer comprising a first thermoplastic material with unsaturated carbon-carbon bonds;
curing the rubber composition in the first mold to form a first molded portion with the first thermoplastic material covalently bonded to the cured rubber composition;
placing the first molded portion into a second mold, the layer facing an inside cavity of the second mold and the rubber composition facing a surface of the mold cavity;
closing the second mold and injecting into the second mold a second thermoplastic material to form a second molded portion with the first thermoplastic material thermally bonded to the second thermoplastic material wherein the second thermoplastic material comprises a groove in which at least one rubber insert is set, having the first thermoplastic material located around a perimeter portion of the rubber insert set into the groove,
wherein the second molded portion is the article.
2. An article according to claim 1 , wherein the article is an article of footwear.
3. An article according to claim 2 , wherein the footwear comprises an outsole, wherein said outsole comprises the second thermoplastic material and the at least one rubber insert formed of the curable rubber composition joined to the second thermoplastic material through a layer of the first thermoplastic material.
4. An article according to claim 3 , wherein the rubber insert is a traction element of the outsole.
5. An article according to claim 3 , wherein the rubber insert increases flexibility of the outsole.
6. An article according to claim 3 , wherein the rubber insert is wedge-shaped.