Method of manufacturing cushioning elements for apparel and other products

1. 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.

2. The method recited in claim 1 , wherein the step of providing includes positioning the elements in offset rows.

3. The method recited in claim 1 , wherein the step of bonding the pad components to the first material layer includes forming a thermalbond between the pad components and the first material layer.

4. The method recited in claim 1 , wherein the step of providing includes locating an ejection member within each of the die elements.

5. The method recited in claim 4 , wherein the step of providing further includes forming the ejection member from a polymer foam material with lesser compressibility than the polymer material of the pad components.

6. 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.

7. The method recited in claim 6 , wherein the step of providing further includes locating the pins in the arrangement of the die elements.

8. 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.

9. The method recited in claim 8 , wherein the step of providing the die and the extractor includes forming the extractor to include a plurality of outwardly-extending pins.

10. The method recited in claim 9 , wherein the step of providing the die and the extractor further includes positioning the pins in offset rows.

11. The method recited in claim 8 , wherein the step of bonding includes forming a thermalbond between the pad components and the first material layer.

12. 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.

13. The method recited in claim 12 , wherein the step of cutting includes utilizing a die with a plurality of die elements arranged in rows.

14. The method recited in claim 13 , wherein the step of cutting further includes compressing the polymer foam material between the extractor and the die elements.

15. The method recited in claim 12 , wherein the step of cutting includes utilizing a die with a plurality of die elements arranged in offset rows.

16. The method recited in claim 12 , wherein the step of bonding includes forming a thermalbond between the pad components and the material layer.

17. 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.

18. The method recited in claim 17 , wherein the step of securing further includes arranging the pins in rows.