Methods for manufacturing cushioning elements for sports apparel
Methods for manufacturing cushioning elements for sports apparel are described. A method is provided for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material. The method includes positioning a functional element within a mold and loading the mold with the particles of the expanded material, wherein the loading occurs through at least two openings within the mold and/or wherein the loading occurs between different movable parts of the mold.
1. A method for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material, comprising:
(a) positioning of a functional element within a mold; and
(b) loading the mold with the particles of the expanded material.
2. The method according to claim 1 , wherein the method further comprises heating at least a part of a wall of the mold to a temperature that will cause the particles of the expanded material adjacent to the part of the wall to melt either partially or entirely.
3. The method according to claim 1 , wherein the particles of the expanded material are treated with pressure, heat, and/or steam within the mold.
4. The method according to claim 1 , wherein at least part of a wall of the mold has a structured surface.
5. The method according to claim 4 , wherein the structured surface is designed as a profile for a sole of the sports apparel.
6. The method of claim 4 , wherein the structured surface is grid-shaped.
7. The method of claim 4 , wherein the structured surface is honeycomb shaped.
8. The method of claim 4 , wherein the structured surface is rib shaped.
9. The method of claim 4 , wherein the structured surface increases the stiffness of the cushioning element selectively in one or more directions.
10. The method of claim 1 , further comprising fixing the functional element within the cushioning element without an adhesive bond.
11. The method of claim 1 , wherein the functional element has a flat design.
12. The method of claim 1 , wherein the cushioning element is part of a shoe sole.
13. The method of claim 1 , wherein the particles are loaded into the mold through a stream of a transport liquid or a stream of steam.
14. The method of claim 13 , wherein the transport liquid is a powder that behaves like a liquid.
15. The method of claim 13 , wherein the transport liquid is water.
16. A method for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material, comprising:
(a) positioning of a functional element within a mold; and
(b) loading particles of the expanded material into the mold via at least one inlet pipe.
17. The method of claim 16 , wherein the particles are loaded under pressure.
18. The method of claim 16 , wherein the particles fill the mold substantially evenly.
19. The method of claim 16 , further comprising treating the particles to a pressure and/or heat and/or steam treatment in the mold.
20. The method of claim 19 , wherein the treatment causes chemical bonding between the particles.