CN102892571B - 制造用于服装及其它产品的缓冲元件的方法 - Google Patents

制造用于服装及其它产品的缓冲元件的方法 Download PDF

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Publication number
CN102892571B
CN102892571B CN201180017350.3A CN201180017350A CN102892571B CN 102892571 B CN102892571 B CN 102892571B CN 201180017350 A CN201180017350 A CN 201180017350A CN 102892571 B CN102892571 B CN 102892571B
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Prior art keywords
spacer assembly
mould
stripper
material layer
buffer element
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CN201180017350.3A
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CN102892571A (zh
Inventor
大卫·特纳
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Nike Innovation LP
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Nike Innovation LP
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B68—SADDLERY; UPHOLSTERY
    • B68G—METHODS, EQUIPMENT, OR MACHINES FOR USE IN UPHOLSTERING; UPHOLSTERY NOT OTHERWISE PROVIDED FOR
    • B68G13/00—Upholstered panels
    • B68G13/04—Upholstered panels with indented pattern formed by bonding
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/28—Shock absorbing
    • A41D31/285—Shock absorbing using layered materials
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/18—Resilient soles
    • A43B13/187—Resiliency achieved by the features of the material, e.g. foam, non liquid materials
    • A—HUMAN NECESSITIES
    • A45—HAND OR TRAVELLING ARTICLES
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    • A45F3/12—Shoulder-pads
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    • A63B71/12—Body-protectors for players or sportsmen, i.e. body-protecting accessories affording protection of body parts against blows or collisions for the body or the legs, e.g. for the shoulders
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    • B26D7/18—Means for removing cut-out material or waste
    • B26D7/1836—Means for removing cut-out material or waste by pulling out
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
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    • B26F1/38—Cutting-out; Stamping-out
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    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/472—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially flat
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    • B29C69/005—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore cutting-off or cutting-out a part of a strip-like or sheet-like material, transferring that part and fixing it to an article
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    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
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    • B32B38/04—Punching, slitting or perforating
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    • B26F—PERFORATING; PUNCHING; CUTTING-OUT; STAMPING-OUT; SEVERING BY MEANS OTHER THAN CUTTING
    • B26F1/00—Perforating; Punching; Cutting-out; Stamping-out; Apparatus therefor
    • B26F1/38—Cutting-out; Stamping-out
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    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0009—Cutting out
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
    • B29C65/26—Hot fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B29C65/24—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools characterised by the means for heating the tool
    • B29C65/30—Electrical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/62—Stitching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7841—Holding or clamping means for handling purposes
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2422—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical
    • B29C66/24223—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being circular, oval or elliptical being oval
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2424—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain
    • B29C66/24241—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a triangle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2424—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain
    • B29C66/24243—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral
    • B29C66/24244—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a quadrilateral forming a rectangle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/24—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight
    • B29C66/242—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours
    • B29C66/2424—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain
    • B29C66/24249—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being closed or non-straight said joint lines being closed, i.e. forming closed contours being a closed polygonal chain forming a specific polygon not provided for in B29C66/24241 - B29C66/24243
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/303—Particular design of joint configurations the joint involving an anchoring effect
    • B29C66/3032—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined
    • B29C66/30325—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined
    • B29C66/30326—Particular design of joint configurations the joint involving an anchoring effect making use of protrusions or cavities belonging to at least one of the parts to be joined making use of cavities belonging to at least one of the parts to be joined in the form of porosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/748—Joining plastics material to non-plastics material to natural products or their composites, not provided for in groups B29C66/742 - B29C66/746
    • B29C66/7484—Leather
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/812—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B29C66/8122—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the composition, by the structure, by the intensive physical properties or by the optical properties of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

用于制造缓冲元件（200）的方法可包括使用具有放置在特殊布置中的多个模具元件（312）的模具（310）。聚合物材料，其可以是聚合物泡沫材料，位于模具（310）和脱模器（320）之间。聚合物材料在模具（310）和脱模器（320）之间被压缩，且模具元件（312）切割聚合物材料以形成多个衬垫组件（230），其与模具元件（312）相同地布置。模具（310）和脱模器（320）被分离，且衬垫组件（230）在模具元件（312）的布置中被固定到脱模器（320）。此外，衬垫组件（230）被结合到至少一个材料层（210,220），使得衬垫组件保持在模具元件的布置中。

Description

制造用于服装及其它产品的缓冲元件的方法
技术领域
本发明涉及一种制造用于服装及各种其它产品的缓冲元件的方法。
背景
给予衬垫、缓冲或以其它方式衰减冲击力的材料或元件通常被并入各种产品。例如，运动服装通常并入保护穿戴者免于接触其它运动员、器械或地面的缓冲元件。更具体地，用在美国足球和曲棍球中的垫并入了为穿戴者的各个部分提供冲击保护的缓冲元件。用在美式足球、曲棍球、自行车、滑雪、滑板滑雪及滑板运动中的头盔并入了在跌倒或碰撞期间提供头部保护的缓冲元件。同样，用在足球(例如通过守门员)和曲棍球中的手套并入了为穿戴者的手提供保护的缓冲元件。除服装之外，例如，席子(例如用于瑜伽或露营)、椅垫及背包，全部并入了缓冲元件以提高舒适感。
发明概述
下面公开了可在服装和各种其它产品中使用的各种缓冲元件。通常，缓冲元件包括第一材料层、第二材料层以及位于第一材料层和第二材料层之间并固定到第一材料层和第二材料层的多个衬垫组件。
下面还公开了用于制造缓冲元件的方法。该方法可包括使用具有放置在特殊的布置中的多个模具元件的模具。聚合物材料，其可以是聚合物泡沫材料，位于模具和脱模器之间。聚合物材料在模具和脱模器之间被压缩，且模具元件(die element)切割聚合物材料以形成多个衬垫组件，衬垫组件与模具元件一样地被布置。模具和脱模器被分离，且衬垫组件在模具元件的布置中被固定到脱模器。此外，衬垫组件被结合到至少一个材料层，使得衬垫组件保持在模具元件的布置中。
为获得以本发明的方面为特征的新颖性的优点和特征的更好的理解，可以参考描述和示出与本发明相关的各种配置和概念的如下描述性的主题和附图。
附图描述
结合附图理解时，上述发明概述和如下的详述将被更好地理解。
图1是穿着服装物品的个体的正视图。
图2是服装物品的正视图。
图3和图4是服装物品的侧视图。
图5是服装物品的后视图。
图6是缓冲元件的透视图。
图7是缓冲元件的分解透视图。
图8是缓冲元件的俯视图。
图9A和图9B是正如由图8中的剖面线9A和9B限定的缓冲元件的横截面视图。
图10是在用于缓冲元件的制造过程中使用的制造装置的部分的透视图。
图11A-11J是制造过程的示意性透视图。
图12A-12J是如分别由图11A-11J中的剖面线12A-12J限定的制造过程的示意性横截面视图。
图13是对应于图7且描绘了缓冲元件的另外的配置的分解透视图。
图14A-14P是对应于图8且描绘了缓冲元件的另外的配置的俯视图。
图15A-15D是对应于图9A且描绘了缓冲元件的另外的配置的横截面视图。
图16A-16H是并入了缓冲元件的服装物品的正面图。
图17A-17C是并入了缓冲元件的另外的产品的透视图。
详述
如下讨论和附图公开了各种缓冲元件，其可被并入多种产品，包括例如服装物品(例如短裤、长裤、衬衫、护带、手套、头盔和鞋袜)、席子、座垫和背包。此外，如下讨论和附图公开了与制造该缓冲元件相关联的各种过程。
服装配置
参照图1，个体10被描绘为穿着具有短裤型服装的一般配置的服装物品100。虽然服装100可以穿在其它服装物品下，但是服装100可以单独穿着、可以显露或可以穿在其它服装物品之上。服装100还可以结合其它器械(例如运动或保护器械)的部件穿着。因此，服装100的配置和服装100被个体10穿着的方式可显著变化。
在图2-5中，服装100被单独描绘为包括骨盆区域101和从骨盆区域101向外延伸的一对腿部区域102。骨盆区域101对应于个体10的骨盆区且当被穿着时覆盖骨盆区的至少一部分。当服装100被穿着时，骨盆区域101的上部区域定义了围绕个体10的腰部延伸的腰部开口103。腿部区域102对应于个体10的右腿和左腿，且当被穿着时覆盖右腿和左腿的至少一部分。当服装100被穿着时，腿部区域102的下部区域各自定义了围绕个体10的大腿延伸的大腿开口104。此外，当服装100被穿着时，服装100包括背向个体10的外表面105，而且当服装100被穿着时，服装100包括朝向个体10且可接触个体10的相对的内表面106。
多个缓冲元件200被并入服装100的各个区域以给予衬垫、缓冲或以其它方式衰减冲击力。例如，当服装100在体育活动期间被穿着时，缓冲元件200可保护个体10免于接触其它运动员、器械或地面。就服装100而言，缓冲元件200位于骨盆区域101和腿部区域102二者中，且更具体地，被放置以保护个体10的臀部、大腿和尾骨。如下面更详细地描述的，缓冲元件200可以并入各种不同的服装物品，且缓冲元件200可放置在该服装物品的各个区域中以保护个体10的特定部分(例如肌肉、骨、关节、碰撞区域)。此外，缓冲元件200的形状、尺寸和其它性能，以及缓冲元件200中使用的材料和组件，可以显著变化以对个体10的特定部分提供特殊水平的保护。
缓冲元件配置
在图6-9B中，用于缓冲元件200的实例配置被描绘为包括第一材料层210、第二材料层220和多个衬垫组件230。第一材料层210和第二材料层220协作地形成用于缓冲元件200的外表面或覆盖层。也就是说，第一材料层210和第二材料层220协作形成一个袋子或空隙，衬垫组件230位于其中。而第二材料层220被描绘为具有一般的平面结构，第一材料层210在衬垫组件230上且还沿衬垫组件230的侧面延伸，以接合第二材料层220(例如通过缝合、粘合剂或热结合)。虽然缓冲元件200可以以各种方式并入服装100，但是第一材料层210可被放置在第二材料元件220的外部，使得缓冲元件200从服装100向外突出。也就是说，第一材料层210可形成外表面105的一部分，而第二材料层220可形成外表面105和内表面106两者的一部分。可替换地，第二材料层220可放置在第一材料元件210的外部，使得缓冲元件200向内突出。
各种材料可用于第一材料层210和第二材料层220，包括例如各种纺织品、聚合物片材、皮革或合成皮革。这些材料的组合(例如结合到纺织品的聚合物片材)也可用于材料层210和220。尽管材料层210和220可由相同的材料形成，但是材料层210和220的每一个也可由不同的材料形成。就纺织品而言，材料层210和220可以由例如针织物、纺布、无纺布、隔片或包括人造丝、尼龙、涤纶、聚丙烯酸物、弹性纤维、棉纱、毛线或丝绸的网状纺织品组分形成。此外，纺织品可以是无伸缩性的、可表现一个方向的伸缩或可以显示多个方向的伸缩。因此，各种材料适合用于第一材料层210和第二材料层220。
衬垫组件230位于材料层210和220之间并被固定到材料层210和220中的每一个。衬垫组件230中的每一个具有固定到第一材料层210的第一表面231、固定到第二材料层220的相对的第二表面232以及在表面231和232之间延伸的侧表面233。虽然衬垫组件230的形状可显著变化，但是表面231和232中的每一个被描绘为具有带有圆形的端部区域的椭圆的或大致细长的形状，且侧表面233以大致笔直的方式在表面231和232之间延伸。衬垫组件230还被描绘为相互均匀地隔开且成数行地布置，特别是平移的行，但也可以按各种布置隔开或定位。成平移的行地布置衬垫组件230的优点是衬垫组件230之间的区域被有效地最小化，同时保持了相邻的衬垫组件230之间的规则的间隔。
各种材料可被用于衬垫组件230，包括被压缩后恢复到原始形状的各种聚合物泡沫材料。用于衬垫组件230的合适的聚合物泡沫材料的例子包括聚氨酯、乙烯基乙酸乙酯、聚酯、聚丙烯和聚乙烯泡沫。此外，热塑性和热固性聚合物泡沫材料都可被使用。在缓冲元件200的一些配置中，衬垫组件230可由具有不同密度的聚合物泡沫材料形成，或者可以使用固体聚合物或橡胶材料。充满液体的腔室也可以用作衬垫组件230。此外，不同的衬垫组件230可由不同的材料形成，或可由具有不同密度的类似的材料形成。如下面更详细地讨论的，形成衬垫组件230的聚合物泡沫材料衰减冲击力以提供缓冲或保护。通过选择用于各种衬垫组件230中的每一个的厚度、材料和密度，遍及缓冲元件200，冲击力衰减的程度可被改变，以给予所需程度的缓冲或保护。
形成衬垫组件230的可压缩的聚合物泡沫材料衰减了压缩或以其它方式接触缓冲元件200的冲击力。例如，当被并入服装100或另一服装物品时，衬垫组件230的聚合物泡沫材料可以压缩以保护穿戴者免于接触其它运动员、器械或地面。因此，缓冲元件200可用来为被缓冲元件200覆盖的个体10或其他穿戴者的区域提供缓冲或保护。
除衰减冲击力之外，缓冲元件200具有同时提供透气性、柔韧性、相对低的总质量和可洗涤性中的一种或多种的优点。当被并入服装物品如服装100时，穿戴者可以出汗及产生过多的热量。通过使用用于材料层210和220的渗透性的纺织品且还在相邻的衬垫组件230之间形成间隙，用于空气进入服装100及用于水分排出服装100的区域通过缓冲元件200被形成。更特别地，空气和水分可以穿过材料层210和220及衬垫组件230之间通过，以给予具有缓冲元件200的服装100的区域透气性。此外，上面讨论的用于缓冲元件200的材料和结构给予了缓冲元件200柔韧性和低的总质量。此外，上面讨论的用于缓冲元件200的材料和结构允许洗涤缓冲元件200而没有显著缩水或变形，即使当使用与商业洗涤过程相关联的温度时也是如此。因此，缓冲元件200可同时为服装物品提供冲击力衰减、透气性、柔韧性、相对低的总质量和可洗涤性。
制造过程
各种技术可被用来制造缓冲元件200。参照图10，制造装置300被公开为包括模具310、脱模器320、加热板330和压板340。图10中所描绘的及下面讨论的用于制造装置300的配置旨在提供可以在缓冲元件200的制造中使用的制造装置的例子。还可使用以类似的方式操作的各种其它制造装置。
模具310包括基板311、多个模具元件312、多个推顶构件313和一对对准栓314。基板311由耐用的和刚性的材料例如钢或铝制成，以提供用于模具310的底座。模具元件312从基板311向外(例如向上)延伸，并表现出衬垫组件230的一般形状。更特别地，每个模具元件312的内部区域具有单独的衬垫组件230的一般形状。如下面更详细地讨论的，模具元件312的边缘315(例如上部边缘)被用来切断形成衬垫组件230的材料，从而成形和形成衬垫组件230的每一个。边缘315通常可具有协助切断形成衬垫组件230的材料的削尖的结构。推顶构件313位于每个模具元件312的内部区域，并且与边缘315隔开(例如向下隔开)。作为例子，推顶构件313可由具有比形成衬垫组件230的聚合物泡沫材料更小的压缩率的聚合物泡沫材料形成。此外，对准栓314从基板311向外延伸(例如向上)。
除具有衬垫组件230的一般形状外，模具元件312以和衬垫组件230相同的方式相对于彼此被布置或另外被设置。如上面提到的，衬垫组件230被描绘为相互均匀地隔开且成平移的行地布置。同样，模具元件312相互均匀地隔开且成平移的行地布置。也就是说，模具元件312被布置在对应于缓冲元件200中的衬垫组件230的位置的布置中。然而，如果不同的布置需要用于衬垫组件230，那么模具元件312可被移动或以其它方式重新放置以对应于不同的布置。
脱模器320包括基板321、多个脱模器元件322和一对对准孔323。基板321由耐用的和刚性的材料如钢或铝形成，来提供用于脱模器320的底板。脱模器元件322具有从基板321向外(例如向下)延伸的且具有削尖的且尖锐的端部区域的引脚的配置。如下面更详细地讨论的，当从模具310取出时，协助保持衬垫组件230的位置。作为引脚的替代，例如，脱模器元件322(a)可具有针、钉子、长钉或尖头物的结构，或(b)可以是当从模具310取出时保持衬垫组件230的位置的真空系统。因此，脱模器元件322是可用于将衬垫组件230固定到脱模器320且当从模具310取出时协助保持衬垫组件230的位置的任何设备或系统。此外，对准孔323在基板321中形成了被放置以对应于对准栓314并安放对准栓314的孔。
脱模器元件322的位置对应于模具元件312的位置。此外，脱模器元件322以和模具元件312相同的方式相对于彼此被布置或另外设置，且模具元件313以和衬垫组件230相同的方式相对于彼此被布置或另外设置。也就是说，脱模器元件322被布置在对应于缓冲元件200中的衬垫组件230的位置的配置中。然而，如果不同的布置需要用于衬垫组件230，那么脱模器元件322和模具元件312可被移动或以其它方式重新放置以对应于不同的布置。
加热板330包括基板331和一对对准栓332。基板331也可由耐用的且刚性的材料如钢或铝制成，且并入加热元件。更具体地，电子线圈可延伸穿过基板331以将基板331加热到将衬垫组件230结合到材料层210和220的温度。作为替代，基板331可包含流体通道，加热后的流体穿过该通道通过，或者可以使用辐射加热器、无线电频率发射器或其它设备。此外，对准栓332从基板331向外(例如向上)延伸。在加热板330的一些配置中，基板331的在制造过程期间接触缓冲元件200的部分的表面可包含橡胶或硅树脂材料。
压板340由定义了一对对准孔342的基板341形成。与基板311、321和331一样，基板341可由耐用的且刚性的材料制成，如钢或铝。对准孔342形成了基板341中的被放置以对应于对准栓332且安放对准栓332的孔。
参照图11A-11J和图12A-12J，使用制造装置300的合适的制造过程的例子被公开。最初，模具元件312被布置在对应于缓冲元件200中的衬垫组件230的位置的配置中，且脱模器元件322被布置在对应于模具元件312和缓冲元件200中的衬垫组件230的位置的配置中。然后坯料301被放在模具310和脱模器320之间，如图11A和图12A中所描绘的。坯料301由与衬垫组件230相同的材料形成且具有衬垫组件230的厚度，衬垫组件230从坯料301处被切割。一旦坯料301就位，模具310和脱模器320靠近、压缩并切割坯料301，如图11B和图12B中所描绘的。更具体地，(a)坯料301抵着模具元件312被压缩，使得边缘315穿透并切断坯料301，且(b)脱模器元件322穿透并进入坯料301。注意，脱模器元件322被放置以对应于模具元件312中的每一个且进入模具元件312中的每一个的内部区域，其是推顶构件313被设置的位置。根据脱模器元件322的长度，在操作期间，脱模器元件322的端部区域可通过坯料301且刺入推顶构件313。为确保模具元件312与脱模器元件322适当地对准，对准栓314与对准孔323对准且进入对准孔323。
在过程的该阶段中，模具元件312已有效地切断坯料301。参照图12B，模具元件312的边缘315穿过坯料301完全地通过以靠在基板321的表面。如上面提到的，每个模具元件312的内部区域具有一个单独的衬垫组件230的一般形状。因此，单独的衬垫组件230被设置在模具元件312内，且在基板321的表面和推顶构件313之间被压缩。如图11C和图12C所描绘的，模具310和脱模器320然后分离以将衬垫组件230从模具元件312内取出，而且衬垫组件230被各个脱模器元件322固定到脱模器320。再次参照图12B，模具元件312内的坯料301的部分(即形成衬垫组件230的部分)被压缩的程度多于模具元件312的外部的坯料301的部分。也就是说，模具元件312内的坯料301的部分抵着推顶构件313被压缩。当模具310和脱模器320分离时，衬垫组件230的压缩导致衬垫组件230从模具元件312向外扩展，且保持适当地放置在脱模器元件322上。因此，当模具310和脱模器320分离时，衬垫组件230保持固定到脱模器元件322。此外，注意，在该阶段，坯料301可以保持在模具310内(即在各个模具元件312周围)或者可从模具310分离，而且注意坯料301在衬垫组件230被取出的地方定义了各个孔。
作为到现在为止的制造过程的总结，衬垫组件230已有效地从坯料301中取出。更具体地，(a)模具元件312被用于切断坯料301，以形成衬垫组件230，而且(b)衬垫组件230从模具元件312中取出且由于脱模器元件322的存在保持固定到脱模器320，脱模器元件322延伸进入到各个衬垫组件230。此外，衬垫组件230以和模具元件312相同的方式被放置和定向，而且因此与在缓冲元件200内一样地被放置和定向。因此，衬垫组件230已从坯料301中取出，并被放置和定向以并入缓冲元件200。
然后，脱模器320和衬垫组件230的组合与加热板330相邻地放置，如图11D和图12D所描绘的。此外，第一材料层210被放在衬垫组件230和加热板330之间。接着，脱模器320和加热板330靠近并压缩第一材料层210和衬垫组件230，如图11E和图12E所描绘的。如上面讨论的，加热板330的基板331并入了加热元件。因此，基板331的温度可以升高到一点，在该点处第一材料层210和衬垫组件230之间发生结合。为确保衬垫组件230相对于第一材料层210适当地放置，对准栓332与对准孔323对准并进入对准孔323。
当在脱模器320和加热板330之间被压缩时，来自加热板330的能量可用于将第一材料层210和衬垫组件230相互结合。热塑性聚合物当加热时材料熔化，且充分冷却时恢复到固体状态。基于热塑性聚合物材料的这种性质，热结合工艺可用来形成连接第一材料层210和衬垫组件230的热结合部。如本文中使用的，术语“热结合”或其变体被定义为两个元件之间的固定技术，该技术涉及该元件中的至少一个内的热塑性聚合物材料的软化或熔化，使得当冷却时，该元件的材料被相互固定。类似地，术语“热结合部”或其变体被定义为通过工艺接合两个元件的结合部、连接部或构造，该工艺涉及该元件中的至少一个内的热塑性聚合物材料的软化或熔化，使得当冷却时，该元件的材料被相互固定。作为例子，热结合可涉及，例如(a)第一材料层210和衬垫组件230中的任何一个内的热塑性材料的熔化或软化，其将这些元件接合在一起，(b)衬垫组件230内的热塑性材料的熔化或软化，使得热塑性聚合物材料延伸进入到或渗透入用于第一材料层210的纺织品的结构，或(c)第一材料层210内的热塑性材料的熔化或软化，使得热塑性聚合物材料延伸进入到或渗透入衬垫组件230的结构。当只有一个元件包括热塑性聚合物材料或当两个元件包括热塑性聚合物材料时，可发生热结合。另外，热结合一般不涉及缝合或粘合剂的使用，但涉及用加热直接将元件相互结合。然而，在一些情况中，缝合或粘合剂可用来补充热结合部或通过热结合的元件的接合。作为热结合的替代，粘合剂、热活化的粘合剂或其它固定结构可用来接合第一材料层210和衬垫组件230。
如上面讨论的，在制造过程期间基板331接触缓冲元件200的部分的表面可并入橡胶或有机硅材料。参照图12E，脱模器元件322与基板331隔开且不接触基板331。在第一材料层210和衬垫组件230的压缩引起脱模器元件322接触基板331的情况中，橡胶或有机硅材料可被呈现以接纳脱模器元件322的端部区域。也就是说，在第一材料层210和衬垫组件230的压缩期间，脱模器元件322的端部区域可刺破并进入橡胶或有机硅材料。
压缩和结合之后，脱模器320和加热板330分离以显露结合后的第一材料层210和衬垫组件230，如图11F和图12F所描绘的。然后第二材料层220与加热板330相邻地放置，第一材料层210和衬垫组件230的组合被翻转或以其它方式定向，使得衬垫组件230在材料层210和220之间，且压板340与第一材料层210相邻地设置，如图11G和图12G所描绘的。然后压板340和加热板330靠近并压缩第一材料层210、第二材料层220和衬垫组件230，如图11H和图12H所描绘的。考虑到基板331的升高后的温度，结合(例如热结合)发生在第二材料层220和衬垫组件230之间。为确保衬垫组件230相对于第二材料层220适当地放置，对准栓332与对准孔342对准并进入对准孔342。
一旦压缩和结合完成，加热板330和压板340分离以显露结合的第一材料层210、第二材料层220和衬垫组件230，如图11I和图12I所描绘的。在制造过程的该阶段，第一材料层210未固定到第二材料层220。现在，另外的缝合、粘合剂或或热结合步骤可用来接合衬垫组件230的外周周围的材料层210和220。作为例子，参照图11J和图12J，一个缝纫或缝合机350可用来相互固定材料层210和220，从而基本上完成了缓冲元件200的制造。
图11A-11J和图12A-12J的上述讨论提供了用于缓冲元件200的合适的制造过程的例子。总体上，制造过程的优点是，模具元件312的布置确定了缓冲元件200中的衬垫组件230的由此产生的布置。也就是说，模具310被最初设定，以便模具元件312被放置在特定的布置中，并且衬垫组件230的由此产生的位置实际上反映了模具元件312的布置。因此，衬垫组件320的位置可以通过模具元件312的布置被预先选择。
还可使用各种其它制造过程或上面讨论的制造过程的变化。例如，脱模器元件322可以缩回，使得脱模器320也可用作压板340。在其它配置中，推顶材料313可以是不存在的，或者在模具元件312内可使用机械化的推顶器。另外，脱模器元件322可以是可移动的或放置在不同的位置，以允许衬垫组件230的不同的配置。此外，可形成专门的机器以使上面讨论的总体制造过程自动化。
可以利用各种技术以将缓冲元件200并入服装100或其它服装物品。作为例子，缓冲元件200可以被缝合或以其它方式结合到形成服装100的其它材料。在一些配置中，缓冲元件200可具有图6中所描绘的配置，其中(a)第二材料层220向外延伸超出第一材料层210的外周。在该配置中，第二材料层220可以是形成服装100的部分的更大的材料元件。也就是说，第二材料层220可形成服装100的内表面106以及缓冲元件200不存在的区域中的外表面105。在其它配置中，缓冲元件200可被定向，使得第一材料层210形成内表面106的一部分。因此，缓冲元件200被并入服装100的方式可以改变。
另外的缓冲元件配置
缓冲元件200的方面可以改变，其取决于用于缓冲元件200和缓冲元件200被并入其中的产品的预期用途。此外，缓冲元件200内使用的尺寸、形状和材料的变化可以改变缓冲元件200的总体性能。也就是说，通过改变缓冲元件200内使用的尺寸、形状和材料，缓冲元件200的压缩率、冲击力衰减、透气性、柔韧性和总质量可适合于特定的目的或产品。对于缓冲元件200的多个变化将在下面讨论。这些变化中的任何一个以及这些变化的组合可用于使缓冲元件200的性能适合预期的用途或特定的产品。此外，这些变化中的任何一个可通过上面讨论的过程或过程的变化来制造。
缓冲元件200的另外的配置在图13中描绘，其中框架组件240被放置成围绕各个衬垫组件230且在各个衬垫组件230之间延伸。虽然衬垫组件230被固定到材料层210和220，但是框架组件240可以不固定到层210和220，而且框架组件240的厚度可小于衬垫组件230的厚度。框架组件240的优点涉及在对象接触缓冲元件200且在衬垫组件230之间突出时提供的额外的保护。
如上面所讨论的，衬垫组件230具有带有圆形的端部区域的椭圆的或大致细长的形状。但是，衬垫组件230可具有各种其它形状，包括圆形、三角形和六角形，分别如图14A-14C所描绘的。衬垫组件230可具有不规则的形状，如图14D所描绘的，或者可以是不同形状的混合，如图14E所描绘的。虽然衬垫组件230中的每一个可具有相同的形状和尺寸，但是衬垫组件230也可具有带有各种不同尺寸的大致相似的形状，如图14F所描绘的。
除了可以显著改变的衬垫组件230的方面之外，缓冲元件200的整体形状可以改变。参照图14G，缓冲元件200表现了大致圆的或圆形的形状。在另外的配置中，缓冲元件200可具有三角形、六角形或H形的结构，分别如图14H-14J所描绘的。用于缓冲元件200的各种形状还被描绘出与图1-5中的服装100相关联。作为这些的例子，来自服装100的具有适合用于臀垫的形状的缓冲元件200中的一个在图14K中被描绘，来自服装100的具有适合用于大腿垫的形状的缓冲元件200中的一个在图14L中被描绘，以及来自服装100的具有适合用于尾骨垫的形状的缓冲元件200中的一个在图14M中被描绘。具有适合用于手肘垫(例如用于衬衫、外套或袖套)的形状的用于缓冲元件200的配置在图14N中被描绘。
关于第一材料层210和第二材料层220的各个方面也可以显著变化。如上面讨论的，材料层210和220可由例如各种纺织品、聚合物片材、皮革、合成革或材料的组合形成。参照图14O，第一材料层210被描绘为具有网状材料的配置，其定义了多个孔，通过这些孔，衬垫组件230和框架组件240是可见的。除了给予允许空气和水分的转移的更大的透气性之外，网状材料可允许用于各种审美属性。更特别地，衬垫组件230可具有通过第一材料层210是可见的不同的颜色。除了网状材料，其它至少半透明的纺织品或聚合物片材材料也可允许衬垫组件230具有可见的不同的颜色。在另外的配置中，第一材料层210可以完全不存在于缓冲元件200中，如图14P所描绘的。
虽然衬垫组件230的厚度(即结合到材料层210和220的表面之间的距离)可以是恒定的，但是衬垫组件230也可具有变化的厚度，如图15A所描绘的。在缓冲元件200的一些配置中，位于中央区域的衬垫组件230可具有比位于周围区域中的衬垫组件230更小的厚度，如图15B所描绘的。衬垫组件230的厚度还可以在缓冲元件200的宽度上减小，如图15C所描绘的，或者可以在缓冲元件200的宽度上逐渐变小，如图15D所描绘的。
另外的服装和产品配置
服装100在图1-5中被描绘为具有短裤型服装的一般结构。参照图16A，服装100的腿部区域102在更大的程度上向下延伸，从而给予包括用于个体10的膝盖的另外的缓冲元件200的长裤型服装的配置。类似的配置描绘在图16B中，其中服装100包括用于个体10的脚踝或小腿的另外的缓冲元件200。
除了短裤型服装和长裤型服装，各种其它类型的服装也可以并入上面讨论的配置的任何一个中的缓冲元件200。参照图16C，具有衬衫型服装的配置的服装物品110被描绘为在对应于穿戴者的手肘的位置包括两个缓冲元件200。当被穿着时，缓冲元件200可对手肘提供保护。也就是说，缓冲元件200可以衰减手肘上的冲击力。除了衰减冲击力，缓冲元件200同时还可以提供透气性、柔韧性、相对低的总质量和可洗涤性的一种或多种。虽然服装110被描绘为长袖衬衫，但是服装110可具有其它衬衫型服装的配置，包括例如短袖衬衫、背心、汗衫、夹克和大衣。参照图16D，服装110被描绘为在对应于穿戴者的手肘、肩膀和肋部的位置包括六个缓冲元件200。
缓冲元件200还可以被并入覆盖穿戴者的其它区域的服装中，例如诸如帽子、头盔、护带、鞋、袜子及手套。作为例子，具有一个缓冲元件200的护带120在图16E中被描绘。护带120具有可放在穿着者的手臂或腿部的大致圆柱形的结构。例如，当手肘疼痛或受伤时，在体育活动期间，护带120的缓冲元件200可以位于手肘上方以帮助保护手肘。作为另一个例子，并入了缓冲元件200的鞋垫130在图16F中被描绘。鞋垫130可位于一种鞋子内，以缓冲脚的下表面(即足底)。此外，如图16G所描绘的，一个或多个缓冲元件200可并入手套140中以给予对穿戴者的手的保护。如图16H所描绘的，一个或多个缓冲元件200还可包含在并入头盔150中以给予对穿戴者的头部的保护。除了衰减冲击力，在这些配置中，缓冲元件200还可同时提供透气性、柔韧性、相对低的总质量和可洗涤性中的一种或多种。
缓冲元件200还可用在服装以外的产品中。参照图17A，席子160被描绘为主要由一个缓冲元件200形成。席子160可用在例如瑜伽期间或用作露营垫，以提供用于坐或躺在地上的舒服的表面。如图17B中所描绘的，缓冲元件200还可并入到椅子170中以提供坐的舒服的地方。同样，缓冲元件200可并入垫子中，其可放在例如椅子上或体育赛事处的看台上。此外，如图17C所描绘的，缓冲元件200可并入背包180中，以靠着穿戴者的背部提供缓冲。因此，缓冲元件200的各种配置可并入多种产品。
本发明在上面和在参照各种配置的附图中被公开。但是，本公开所达到的目的是提供关于本发明的各种特征和概念的例子，而不是限制本发明的范围。相关领域中的技术人员将认识到，在不脱离由所附的权利要求书限定的本发明的范围的情况下，可以对上面描述的配置做出许多变化和修改。

Claims (16)

1.一种制造缓冲元件的方法，所述方法包括：
提供模具和脱模器，所述模具具有放置在一种布置中的多个模具元件；
将聚合物材料设置在所述模具和所述脱模器之间；
压缩所述模具和所述脱模器之间的所述聚合物材料，所述模具元件切割所述聚合物材料以形成多个衬垫组件；
分离所述模具和所述脱模器，所述衬垫组件被固定到所述脱模器，且所述衬垫组件具有所述模具元件的所述布置；
将附有所述脱模器的所述衬垫组件靠着第一材料层压缩以将所述衬垫组件在所述模具元件的所述布置中结合到所述第一材料层；以及
靠着第二材料层压缩所述衬垫组件以将所述衬垫组件结合到所述第二材料层，
其中所述提供的步骤包括将所述脱模器形成为包括多个向外延伸的引脚。
2.如权利要求1所述的方法，其中所述提供的步骤还包括将所述引脚设置在所述模具元件的所述布置中。
3.如权利要求1所述的方法，其中所述提供的步骤包括将所述模具元件放置成平移的行。
4.如权利要求1所述的方法，其中靠着所述第一材料层压缩所述衬垫组件的步骤包括在所述衬垫组件和所述第一材料层之间形成热结合部。
5.如权利要求1所述的方法，其中所述提供的步骤包括将推顶构件设置在所述模具元件中的每一个内。
6.如权利要求5所述的方法，其中所述提供的步骤还包括由具有比所述衬垫组件的聚合物材料更小的压缩率的聚合物泡沫材料形成所述推顶构件。
7.一种制造缓冲元件的方法，所述方法包括：
提供模具和脱模器，所述模具具有成平移的行地放置的多个模具元件；
将聚合物泡沫材料设置在所述模具和所述脱模器之间；
在所述模具和所述脱模器之间压缩所述聚合物泡沫材料，所述模具元件切割所述聚合物泡沫材料以形成多个衬垫组件；
分离所述模具和所述脱模器，所述衬垫组件成平移的行地固定到所述脱模器；以及
将附有所述脱模器的所述衬垫组件结合到(a)第一材料层，并将所述衬垫组件结合到(b)第二材料层，
其中所述提供的步骤包括将所述脱模器形成为包括多个向外延伸的引脚。
8.如权利要求7所述的方法，其中所述提供的步骤还包括将所述引脚放置成平移的行。
9.如权利要求7所述的方法，其中结合的步骤包括在所述衬垫组件和所述第一材料层之间形成热结合部。
10.一种制造缓冲元件的方法，所述方法包括：
切割聚合物泡沫材料以同时形成成行地布置的多个衬垫组件；
将所述衬垫组件固定到脱模器，所述衬垫组件成所述行地布置，其中所述脱模器包括在其上的多个向外延伸的引脚；以及
将附有所述脱模器的所述衬垫组件结合到至少一个材料层。
11.如权利要求10所述的方法，其中所述切割的步骤包括使用具有成行地布置的多个模具元件的模具。
12.如权利要求11所述的方法，其中所述切割的步骤还包括在所述脱模器和所述模具元件之间压缩所述聚合物泡沫材料。
13.如权利要求10所述的方法，其中所述切割的步骤包括使用具有成平移的行地布置的多个模具元件的模具。
14.如权利要求10所述的方法，其中所述固定的步骤包括用来自所述脱模器的多个引脚刺入所述衬垫组件。
15.如权利要求14所述的方法，其中所述固定的步骤还包括成行地布置所述引脚。
16.如权利要求10所述的方法，其中所述结合的步骤包括在所述衬垫组件和所述材料层之间形成热结合部。
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