Methods for manufacturing cushioning elements for sports apparel

• US 11,135,797 B2
• Filed: 03/14/2019
• Issued: 10/05/2021
• Est. Priority Date: 02/13/2013
• Status: Active Grant

• Current Assignee: Adidas AG
• Original Assignee: Adidas AG
• Inventors: Wardlaw, Angus, Manz, Gerd Rainer, Le, Tru Huu Minh, Freeman, Warren
• Primary Examiner(s): Theisen, Mary Lynn F
• Application Number:
  US16/353,374
• Publication Number:
  US 20190291371A1
• Time in Patent Office: 936 Days
• CPC Class Codes: A43B 13/187 Resiliency achieved by the features of the material, e.g. foam, non liquid materials
• CPC Class Codes: A43D 29/00 Machines for making soles from strips of material
• CPC Class Codes: B29C 2043/3455 for particles, powder, fibres, e.g. fluidized or sprayed
• CPC Class Codes: B29C 43/003 characterised by the choice of material
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 43/34 Feeding the material to the mould or the compression means B29C43/085 takes precedence
• CPC Class Codes: B29C 44/3426 Heating by introducing steam in the mould
• CPC Class Codes: B29C 67/205 comprising surface fusion, and bonding of particles to form voids, e.g. sintering
• CPC Class Codes: B29D 35/0054 by compression moulding, vulcanising or the like; Apparatus therefor
• CPC Class Codes: B29D 35/0063 Moulds
• CPC Class Codes: B29D 35/128 Moulds or apparatus therefor
• CPC Class Codes: B29D 35/142 Soles
• CPC Class Codes: B29D 35/148 Moulds or apparatus therefor
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2675/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, for preformed parts, e.g. for inserts
• CPC Class Codes: B29K 2905/00 Use of metals, their alloys or their compounds, as mould material
• CPC Class Codes: B29L 2031/504 Soles
• CPC Class Codes: C08J 9/228 Forming foamed products
• CPC Class Codes: C08J 9/236 using binding agents

Abstract

Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.

Claims

1. A method for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material, comprising

(a) loading a mold with the particles of an expanded material,

(b) wherein the particles are treated with steam within the mold.

2. The method according to claim 1, wherein the particles of an expanded material are coated with a liquid matrix material prior to being treated with pressure and/or heat and/or steam.

3. The method according to claim 2, wherein the liquid matrix material is liquid polyurethane.

4. The method according to claim 2, wherein the liquid matrix material solidifies and enters a bond with the particles of an expanded material.

5. The method according to claim 1, wherein the particles of an expanded material are exposed to a pressure and/or heat and/or further steam treatment within the mold.

6. The method according to claim 1, wherein a functional element is positioned in the mold prior to step (b).

7. A method for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material, comprising

(a) loading a mold with the particles of an expanded material,

(b) wherein the particles are loaded into the mold under pressure;

and

(c) treating the particles with steam within the mold.

8. The method according to claim 7, wherein the particles of an expanded material are mixed with a transport liquid and/or steam and then loaded into the mold.

9. The method according to claim 7, wherein the particles of an expanded material are mixed with a powder that behaves like a liquid and then loaded into the mold.

10. The method according to claim 8, wherein the transport liquid and/or steam is at least partially removed from the mold after the particles of an expanded material are loaded into the mold.

11. The method according to claim 10, wherein the mold contains a series of openings from which the transport liquid and/or steam is at least partially removed.

12. The method according to claim 11, wherein the series of openings are connected to a vacuum system.

13. A method for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material, comprising

(a) loading a mold with the particles of an expanded material, and

(b) heating at least a part of the wall of the mold to a temperature to cause the particles of the expanded material adjacent to the at least a part of the wall of the mold to melt either partially or entirely.

14. The method according to claim 13, wherein the at least partially melted particles selectively stiffen the cushioning element.

15. The method according to claim 13, wherein the at least partially melted particles selectively increase the density of the cushioning element.

16. The method according to claim 13, wherein the at least a part of the wall of the mold comprises a structured surface.

17. The method according to claim 16, wherein the structured surface is grid-shaped.

18. The method according to claim 16, wherein the structured surface is honeycomb shaped.

19. The method according to claim 16, wherein the structured surface is rib shaped.

20. The method according to claim 16, wherein the structured surface increases the stiffness of the cushioning element selectively in one or more directions.