Method of manufacturing cushioning elements for apparel and other products
A method for manufacturing a cushioning element may include securing a plurality of pad components to pins that extend outward from a base, each of the pins having a non-circular short-axis cross-sectional shape. The pad components are then compressed between the base and a material layer to bond the pad components to the material layer. In some configurations, the pins may have an elongate short-axis cross-sectional shape. In some configurations, the pins may have an elliptical short-axis cross-sectional shape. Additionally, in some configurations, the pins may have a short-axis cross-sectional shape selected from triangular, square, rectangular, hexagonal, and semi-circular.
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 with a non-circular short-axis cross-sectional shape;
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, and the pins extending into the pad components;
separating the die and the extractor, the pad components being secured to the pins; and
bonding the pad components to (a) a first material layer with the extractor and (b) a second material layer.
2. The method recited in claim 1 , wherein the step of providing the die and the extractor further includes positioning the die elements and the pins in offset rows.
3. The method recited in claim 1 , wherein the step of providing the die and the extractor further includes shaping the pins to have an elongate short-axis cross-sectional shape.
4. The method recited in claim 1 , wherein the step of providing the die and the extractor further includes shaping the pins to have a short-axis cross-sectional shape with rounded sides and pointed end areas.
5. The method recited in claim 1 , wherein the step of providing the die and the extractor further includes shaping the pins to have a short-axis cross-sectional shape selected from a group consisting of triangular, square, rectangular, hexagonal, and semi-circular.
6. The method recited in claim 1 , wherein the step of bonding includes forming a thermalbond between the pad components and the first material layer.
7. 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 pins of an extractor, the pad components being arranged in the rows, and the pins having a non-circular short-axis cross-sectional shape; and
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.
8. The method recited in claim 7 , wherein the step of cutting includes utilizing a die with a plurality of die elements arranged in rows.
9. The method recited in claim 8 , wherein the step of cutting further includes compressing the polymer foam material between the extractor and the die elements.
10. The method recited in claim 7 , wherein the step of securing further includes arranging the pins in rows.
11. The method recited in claim 7 wherein the step of bonding includes forming a thermalbond between the pad components and the material layer.
12. The method recited in claim 7 , further including a step of selecting the pins to have a short-axis cross-sectional shape selected from a group consisting of triangular, square, rectangular, hexagonal, and semi-circular.