Method of manufacturing cushioning elements for apparel and other products
AssigneeNIKE, Inc.
InventorDavid Turner
Life of this patent
Estimating the term…
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.
Claims18
A method of manufacturing a cushioning element, the method comprising:
- providing a die and an extractor, the die having a plurality of the 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;
- bonding the pad components to a first material layer in the arrangement of the die elements by using the extractor to compress the pad components against the first material layer;
- separating the extractor from the pad components;
- and
- compressing the pad components against a second material layer to bond the pad components to the second material layer.
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;
- compressing the pad components against a 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;
- wherein the step of providing includes forming the extractor to include a plurality of outwardly-extending pins.
A method of manufacturing a cushioning element, the method comprising:
- providing a die and an extractor, the having a plurality of the die elements positioned in offset rows;
- locating a polymer foam material between the die and the extractor;
- compressing the polymer foam 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 in offset rows;
- providing a first material layer and a second material layer;
- and
- bonding the pad components to (a) the first material layer with the extractor and separating the extractor from the pad components and (b) to the second material layer.
A method of manufacturing a cushioning element, the method comprising:
- cutting a polymer foam material to simultaneously form a plurality of pad components arranged in rows;
- securing the pad components to an extractor, the pad components being arranged in the rows;
- bonding the pad components to a first material layer using the extractor separating the extractor from the pad components;
- and
- bonding the pad components to a second material layer.
A method of manufacturing a cushioning element, the method comprising:
- cutting a polymer foam material to simultaneously form a plurality of pad components arranged in rows;
- securing the pad components to an extractor, the pad components being arranged in the rows;
- bonding the pad components to at least one material layer with the extractor;
- wherein the step of securing includes piercing the pad components with a plurality of pins from the extractor.
Dependencies are inferred from the claim text.