Cushioning Elements For Apparel And Other Products
Cushioning elements may include a first material layer, a second material layer, a plurality of components (e.g., polymer foam components) that are located between the first material layer and the second material layer. Some of the components are secured to the first material layer and the second material layer, and other components are unsecured to the first material layer and the second material layer. In some configurations, the various components have different thicknesses. In further configurations, at least one of the component defines a plurality of apertures that receive other components.
1 . 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 secured to the first material layer and the second material layer; and
a frame component 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.
2 . The cushioning element recited in claim 1 , wherein all of the pad components are positioned within the apertures.
3 . The cushioning element recited in claim 1 , wherein only a portion of the pad components are positioned within the apertures.
4 . The cushioning element recited in claim 1 , wherein the frame component is located in a central area of the cushioning element and absent from a peripheral area of the cushioning element.
5 . The cushioning element recited in claim 1 , wherein thicknesses of the pad components are greater than a thickness of the frame component.
6 . The cushioning element recited in claim 1 , wherein the pad components and the frame component are formed from polymer foam materials.
7 . The cushioning element recited in claim 1 , wherein the first material layer and the second material layer are textile materials.
8 . The cushioning element recited in claim 1 , wherein the first material layer is joined to the second material layer around a periphery of the pad components.
9 . An article of apparel comprising:
a first material layer and a second material layer; and
a plurality of foam components located between the first material layer and the second material layer, a majority of the foam components being secured to both of the first material layer and the second material layer, and at least one of the foam components being unsecured to both of the first material layer and the second material layer, the foam components having corresponding shapes that mate with each other to form a foam layer within the apparel.
10 . The article of apparel recited in claim 9 , wherein the foam components include a frame that defines a plurality of apertures, and the foam components include a plurality of pads located within the apertures.
11 . The article of apparel recited in claim 10 , wherein all of the pads are positioned within the apertures.
12 . The article of apparel recited in claim 10 , wherein only a portion of the pads components are positioned within the apertures.
13 . The article of apparel recited in claim 10 , wherein thicknesses of the pads are greater than a thickness of the frame.
14 . The article of apparel recited in claim 10 , wherein the pads are unsecured to the frame.
15 . An article of apparel comprising:
a first textile layer that defines at least a portion of an interior surface of the apparel and at least a portion of an opposite exterior surface of the apparel; and
at least two second textile layers, each of the second textile layers being joined to different areas of the first textile layer, and each of the second textile layers forming pockets with the first textile layer, each of the pockets including (a) a plurality of pad components joined to at least the first textile layer and (b) a frame component defining a plurality of apertures that receive the pad components.
16 . The article of apparel recited in claim 15 , wherein the frame component is unsecured to the textile layers and the pad components.
17 . The article of apparel recited in claim 15 , wherein the pad components and the frame component are formed from polymer foam materials.
18 . The article of apparel recited in claim 15 , wherein thicknesses of the pad components are greater than a thickness of the frame component in at least one of the pockets.
19 . A cushioning element comprising:
a first material layer and a second material layer;
a plurality of first strips located between the first material layer and the second material layer, the first strips being secured to the first material layer and the second material layer, and the first strips being spaced from each other; and
a plurality of second strips located between the first material layer and the second material layer, the second strips being unsecured to the first material layer and the second material layer, and the first strips being positioned between the first strips,
wherein (a) at least one of the first strips and the second strips are molded to impart a non-planar configuration to the cushioning element, (b) each of the first strips and the second strips have edges with an undulating configuration that mate with each other, and (c) a thickness of the first strips is greater than a thickness of the second strips.
20 . The cushioning element recited in claim 19 , wherein the first strips are formed from a polymer foam material, and the second strips are formed from a material with greater density than the polymer foam material.