ATHLETIC GEAR OR OTHER DEVICES COMPRISING POST-MOLDED EXPANDABLE COMPONENTS
A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).
1 .- 228 . (canceled)
229 . A component comprising expandable material formed into an initial three-dimensional configuration and subsequently expanded to an expanded three-dimensional configuration that is a scaled-up version of the initial three-dimensional configuration, wherein an elongation at break of the expandable material is at least 100%.
230 . The component of claim 229 , wherein the elongation at break of the expandable material is at least 150%.
231 . The component of claim 229 , wherein a resilience of the expandable material is at least 60% according to ASTM D2632-01.
232 . The component of claim 229 , wherein a resilience of the expandable material is at least 80% according to ASTM D2632-01.
233 . The component of claim 229 , wherein a tensile strength of the expandable material is at least 1 MPa.
234 . The component of claim 229 , wherein a tensile strength of the expandable material is at least 2 MPa.
235 . The component of claim 229 , wherein the expandable material is subsequently expanded to the expanded three-dimensional configuration in response to heat.
236 . The component of claim 229 , wherein an expansion temperature of the expandable material is at least 150° C.
237 . The component of claim 229 , wherein the expandable material is formed into the initial three-dimensional configuration using 3D printing.
238 . The component of claim 237 , wherein the 3D printing comprises selective laser sintering (SLS).
239 . The component of claim 237 , wherein the 3D printing comprises stereolithography (SLA).
240 . The component of claim 237 , wherein the expandable material is molded into the initial three-dimensional configuration in a 3D-printed mold.
241 . The component of claim 240 , wherein the expandable material molded into the initial three-dimensional configuration in the 3D-printed mold is injection molded into the initial three-dimensional configuration in the 3D-printed mold.
242 . The component of claim 229 , wherein the expandable material comprises a polymeric substance and an expansion agent mixed with the polymeric substance.
243 . The component of claim 242 , wherein the expansion agent constitutes at least 40% of the expandable material by weight.
244 . The component of claim 242 , wherein the expansion agent constitutes a majority of the expandable material by weight.
245 . The component of claim 242 , wherein the expansion agent comprises expandable microspheres.
246 . The component of claim 242 , wherein the polymeric substance is elastomeric.
247 . The component of claim 242 , wherein the elongation at break of the expandable material is greater than an elongation at break of the expansion agent.
248 . The component of claim 247 , wherein the elongation at break of the expandable material is at least 200% of the elongation at break of the expansion agent.
249 . The component of claim 247 , wherein the elongation at break of the expandable material is at least 400% of the elongation at break of the expansion agent.
250 . The component of claim 242 , wherein a resilience of the expandable material is greater than a resilience of the expansion agent according to ASTM D2632-01.
251 . The component of claim 242 , wherein a tensile strength of the expandable material is greater than a tensile strength of the expansion agent.
252 . The component of claim 229 , wherein an expansion ratio of the expandable material is at least three.
253 . The component of claim 229 , wherein an expansion ratio of the expandable material is at least five.
254 . The component of claim 229 , wherein the component comprises a plurality of regions that differ in stiffness and are made of the expandable material.
255 . The component of claim 254 , wherein: a first one of the regions of the component is configured to be disposed closer to a user during use of the component than a second one of the regions of the component; and the second one of the regions of the component is stiffer than the first one of the regions of the component.
256 . The component of claim 229 , wherein the component comprises a plurality of portions that are at least one of curved and angular and are present in the initial three-dimensional configuration and in the expanded three-dimensional configuration.
257 . The component of claim 229 , wherein the component comprises a predetermined arrangement of shaped elements that are made of the expandable material, intersect one another, and are present in the initial three-dimensional configuration and in the expanded three-dimensional configuration.
258 . The component of claim 257 , wherein the shaped elements are relief elements of a texture of the component.
259 . The component of claim 229 , wherein the component is configured to be part of an article wearable by a user.
260 . The component of claim 259 , wherein: the article is a protective article configured to protect the user; the protective article comprises a pad; and the pad comprises the component.
261 . The component of claim 260 , wherein: the protective article is a helmet configured to protect a head of the user; the helmet comprises an outer shell and a liner disposed within the outer shell; and the liner comprises the pad comprising the component.
262 . The component of claim 229 , wherein the component is a pad.
263 . The component of claim 229 , wherein the component is a cushion.
264 . A method of making a component, the method comprising:
forming expandable material into an initial three-dimensional configuration; and
causing expansion of the expandable material from the initial three-dimensional configuration to an expanded three-dimensional configuration that is a scaled-up version of the initial three-dimensional configuration;
wherein an elongation at break of the expandable material is at least 100%.
265 . A method of making a component, the method comprising:
forming expandable material into an initial three-dimensional configuration using 3D printing; and
causing expansion of the expandable material from the initial three-dimensional configuration to an expanded three-dimensional configuration that is a scaled-up version of the initial three-dimensional configuration;
wherein an elongation at break of the expandable material is at least 100%.