Cushioning Elements For Apparel And Other Products And Methods Of Manufacturing The Cushioning Elements

• US 20120052249A1
• Filed: 02/25/2011
• Published: 03/01/2012
• Est. Priority Date: 04/07/2010
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Turner, David
• Granted Patent: US 8,702,895 B2
• Time in Patent Office: Days
• US Class Current: 428/172
• CPC Class Codes: A41D 13/0156 having projecting patterns
• CPC Class Codes: A41D 13/05 protecting only a particular body part ear protectors A61F11/06
• CPC Class Codes: A41D 13/0581 with permanent fastening means
• CPC Class Codes: A41D 31/285 using layered materials
• CPC Class Codes: A43B 13/187 Resiliency achieved by the features of the material, e.g. foam, non liquid materials
• CPC Class Codes: A43D 8/06 Dies therefor
• CPC Class Codes: A43D 8/08 Combined stamping-out and bonding, e.g. high frequency electric current being applied between cutting edge and work support
• CPC Class Codes: A45F 2003/122 Back cushioning parts or details of backpacks, e.g. with ventilation
• CPC Class Codes: A45F 2003/125 with ventilation
• CPC Class Codes: A45F 3/08 Carrying-frames; Frames combined with sacks
• CPC Class Codes: A45F 3/12 Shoulder-pads
• CPC Class Codes: A47C 7/021 Detachable or loose seat cushions
• CPC Class Codes: A63B 2071/1233 for the hip
• CPC Class Codes: A63B 2071/1241 for the thigh
• CPC Class Codes: A63B 2071/125 for the knee
• CPC Class Codes: A63B 2071/1266 for the calf
• CPC Class Codes: A63B 71/08 Body-protectors for players or sportsmen , i.e. body-protecting accessories affording protection of body parts against blows or collisions protective clothing or garments for sporting purposes A41D13/00
• CPC Class Codes: A63B 71/12 for the body or the legs , e.g. for the shoulders A63B71/081 takes precedence
• CPC Class Codes: B26D 7/1836 by pulling out
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/26 : Hot fluid
• CPC Class Codes: B29C 65/30 : Electrical means B29C65/38 takes precedence
• CPC Class Codes: B29C 65/48 : using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/4815 : Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/62 : Stitching
• CPC Class Codes: B29C 65/7841 : Holding or clamping means for handling purposes clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04
• CPC Class Codes: B29C 65/7847 : using vacuum to hold at least one of the parts to be joined vacuum work holders in general B25B11/005
• CPC Class Codes: B29C 66/1122 : Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/133 : Fin-type joints, the parts to be joined being flexible the parts to be joined being rigid B29C66/1312
• CPC Class Codes: B29C 66/24223 : being oval
• CPC Class Codes: B29C 66/24241 : forming a triangle
• CPC Class Codes: B29C 66/24244 : forming a rectangle
• CPC Class Codes: B29C 66/24249 : forming a specific polygon not provided for in B29C66/24241 - B29C66/24243
• CPC Class Codes: B29C 66/30326 : in the form of porosity
• CPC Class Codes: B29C 66/433 : Casing-in, i.e. enclosing an element between two sheets by an outlined seam for bookbinding B42C11/06; for packaging B65B; by laminating B32B37/00; enclosing tubular articles between substantially flat elements B29C66/53261
• CPC Class Codes: B29C 66/472 : said single elements being substantially flat
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/727 : being porous, e.g. foam
• CPC Class Codes: B29C 66/729 : Textile or other fibrous material made from plastics
• CPC Class Codes: B29C 66/7392 : characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/7484 : Leather
• CPC Class Codes: B29C 66/8122 : characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
• CPC Class Codes: B29C 66/81457 : comprising a block or layer of deformable material, e.g. sponge, foam, rubber pressing elements supported or backed-up by resilient material B29C66/8161
• CPC Class Codes: B29C 66/8322 : Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/836 : Moving relative to and tangentially to the parts to be joined, e.g. transversely to the displacement of the parts to be joined, e.g. using a X-Y table B29C66/65 takes precedence
• CPC Class Codes: B29C 66/845 : C-clamp type or sewing machine type
• CPC Class Codes: B29C 69/005 : cutting-off or cutting-out a part of a strip-like or sheet-like material, transferring that part and fixing it to an article if labeling see B65C, in combination with box-making B31B50/81; labelling in general B65C
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/083 : EVA, i.e. ethylene vinyl acetate copolymer
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2821/00 : Use of unspecified rubbers as mould material
• CPC Class Codes: B29K 2883/00 : Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as mould material
• CPC Class Codes: B29K 2905/02 : Aluminium
• CPC Class Codes: B29K 2905/12 : Iron
• CPC Class Codes: B29L 2031/443 : Chairs
• CPC Class Codes: B29L 2031/48 : Wearing apparel
• CPC Class Codes: B29L 2031/4821 : Helmets
• CPC Class Codes: B29L 2031/4864 : Gloves
• CPC Class Codes: B29L 2031/507 : Insoles
• CPC Class Codes: B29L 2031/71 : Eyelets
• CPC Class Codes: B29L 2031/7128 : Bags, sacks, sachets tea bags B29L2031/7122; medical bags B29L2031/7148
• CPC Class Codes: B32B 2038/042 : Punching
• CPC Class Codes: B32B 2571/00 : Protective equipment
• CPC Class Codes: B32B 38/04 : Punching, slitting or perforating
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B68G 13/04 : with indented pattern formed by bonding
• CPC Class Codes: B68G 5/02 : of cellular material, e.g. sponge rubber
• CPC Class Codes: B68G 7/00 : Making upholstery manufacturing upholstered panels B68G13/00 ; from plastics B29D99/0092; sewing-machines D05B
• CPC Class Codes: Y10T 156/1062 : Prior to assembly
• CPC Class Codes: Y10T 156/1089 : of discrete laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/1092 : All laminae planar and face to face
• CPC Class Codes: Y10T 156/1093 : with covering of discrete laminae with additional lamina
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet

Abstract

A method for manufacturing the cushioning elements may include utilizing a die with a plurality of die elements positioned in a particular arrangement. A polymer material, which may be a polymer foam material, is located between the die and an extractor. The polymer material is compressed between the die and the extractor, and the die elements cut the polymer material to form a plurality of pad components, which are arranged like the die elements. The die and the extractor are separated, and the pad components are secured to the extractor in the arrangement of the die elements. Additionally, the pad components are bonded to at least one material layer such that the pad components remain in the arrangement of the die elements.

Claims

1. A method of manufacturing a cushioning element, the method comprising:

providing a die and an extractor, the die having a plurality of die elements, and the extractor including a plurality of pins and an extractor sheet, the pins extending through apertures in the extractor sheet;

locating a polymer material between the die and the extractor;

compressing the polymer material between the die and the extractor, the die elements cutting the polymer material to form a plurality of pad components, and the pins extending into the pad components;

separating the die and the extractor, the pad components being secured to the pins;

compressing the pad components against a first material layer with the extractor to bond the pad components to the first material layer;

separating the extractor sheet from the pins to push the pad components from the extractor; and

compressing the pad components against a second material layer to bond the pad components to the second material layer.

2. The method recited in claim 1, wherein the step of providing further includes locating the pins opposite the die elements.

3. The method recited in claim 1, wherein the step of providing includes positioning the die elements and the pins in offset rows.

4. The method recited in claim 1, wherein the step of compressing the pad components against the first material layer includes forming a thermalbond between the pad components and the first material layer.

5. A method of manufacturing a cushioning element, the method comprising:

locating a plurality of pad components between a first material layer and a second material layer;

joining the pad components to the first material layer and the second material layer; and

securing the first material layer to the second material layer around a perimeter of the pad components with a bonding element.

6. The method recited in claim 5, further including a step of bonding the bonding element to the first material layer prior to the step of locating.

7. The method recited in claim 6, wherein the step of bonding includes locating the bonding element at an edge of the first material layer.

8. The method recited in claim 6, wherein the step of bonding includes configuring the bonding element to have an aperture that exposes a central area of the first material layer.

9. The method recited in claim 8, wherein the step of joining includes securing the pad components to the central area of the first material layer.

10. The method recited in claim 5, further including a step of selecting the bonding element to include a thermoplastic polymer material.

11. The method recited in claim 10, further including a step of applying the thermoplastic polymer material to surfaces of the pad components.

12. A method of manufacturing a cushioning element, the method comprising:

providing a die and an extractor, the die having a plurality of die elements positioned in an arrangement;

locating a polymer material between the die and the extractor;

compressing the polymer material between the die and the extractor, the die elements cutting the polymer material to form a plurality of pad components;

separating the die and the extractor, the pad components being secured to the extractor, and the pad components having the arrangement of the die elements;

securing a bonding element formed from a thermoplastic polymer material to a first material layer, the bonding element being positioned adjacent to an edge of the first material layer, and the bonding element being absent from a central area of the first material layer;

compressing the pad components against the central area of the first material layer with the extractor to bond the pad components to the first material layer in the arrangement of the die elements;

compressing the pad components against a second material layer to bond the pad components to the second material layer; and

compressing the first material layer against the second material layer to bond the first material layer and the second material layer together with the bonding element.

13. The method recited in claim 12, wherein the step of providing includes forming the extractor to include a plurality of outwardly-extending pins.

14. The method recited in claim 13, wherein the step of providing further includes locating the pins in the arrangement of the die elements.

15. The method recited in claim 12, wherein the step of compressing the pad components against the central area of the first material layer includes forming a thermalbond between the pad components and the first material layer.

16. A cushioning element comprising:

a first material layer and a second material layer;

a plurality of pad components located between the first material layer and the second material layer, the pad components being thermalbonded to the first material layer and the second material layer,

the first material layer being thermalbonded to the second material layer around a periphery of the pad components.

17. The cushioning element recited in claim 16, wherein a thermoplastic polymer element is located between the first material layer and the second material layer.

18. The cushioning element recited in claim 16, wherein a frame component is located between the first material layer and the second material layer, the frame component defining a plurality of apertures that receive at least a portion of the pad components, and the frame component being unsecured to the first material layer, the second material layer, and the pad components.

19. The cushioning element recited in claim 18, wherein thicknesses of the pad components are greater than a thickness of the frame component.

20. The cushioning element recited in claim 16, wherein the pad components are formed from a polymer foam material and the first material layer and the second material layer are textiles.