Cushioning elements for apparel and other products and methods of manufacturing the cushioning elements

摘要

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.

主权项

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.