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) loading a mold with the particles of an expanded material,
(b) wherein the particles are treated with steam within the mold.
2. The method according to claim 1 , wherein the particles of an expanded material are coated with a liquid matrix material prior to being treated with pressure and/or heat and/or steam.
3. The method according to claim 2 , wherein the liquid matrix material is liquid polyurethane.
4. The method according to claim 2 , wherein the liquid matrix material solidifies and enters a bond with the particles of an expanded material.
5. The method according to claim 1 , wherein the particles of an expanded material are exposed to a pressure and/or heat and/or further steam treatment within the mold.
6. The method according to claim 1 , wherein a functional element is positioned in the mold prior to step (b).
7. A method for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material, comprising
(a) loading a mold with the particles of an expanded material,
(b) wherein the particles are loaded into the mold under pressure; and
(c) treating the particles with steam within the mold.
8. The method according to claim 7 , wherein the particles of an expanded material are mixed with a transport liquid and/or steam and then loaded into the mold.
9. The method according to claim 7 , wherein the particles of an expanded material are mixed with a powder that behaves like a liquid and then loaded into the mold.
10. The method according to claim 8 , wherein the transport liquid and/or steam is at least partially removed from the mold after the particles of an expanded material are loaded into the mold.
11. The method according to claim 10 , wherein the mold contains a series of openings from which the transport liquid and/or steam is at least partially removed.
12. The method according to claim 11 , wherein the series of openings are connected to a vacuum system.
13. A method for manufacturing a cushioning element for sports apparel from randomly arranged particles of an expanded material, comprising
(a) loading a mold with the particles of an expanded material, and
(b) heating at least a part of the wall of the mold to a temperature to cause the particles of the expanded material adjacent to the at least a part of the wall of the mold to melt either partially or entirely.
14. The method according to claim 13 , wherein the at least partially melted particles selectively stiffen the cushioning element.
15. The method according to claim 13 , wherein the at least partially melted particles selectively increase the density of the cushioning element.
16. The method according to claim 13 , wherein the at least a part of the wall of the mold comprises a structured surface.
17. The method according to claim 16 , wherein the structured surface is grid-shaped.
18. The method according to claim 16 , wherein the structured surface is honeycomb shaped.
19. The method according to claim 16 , wherein the structured surface is rib shaped.
20. The method according to claim 16 , wherein the structured surface increases the stiffness of the cushioning element selectively in one or more directions.