Method of manufacturing dye-sublimation printed elements

A method for manufacturing printed elements may include receiving an order including data representing indicia. The indicia may be printed by dye-sublimation on a surface of a first material. The first material may be positioned adjacent to and between a second material and a dye retention layer. The first material, the second material, and the dye retention layer may be compressed and heated, such as in a thermalbonding process, to secure the first material to the second material. Custom-ordered indicia of a comparatively high quality may thereby be imparted to printed elements, including textile elements, cushioning elements, and a variety of other products.

BACKGROUND

Textile materials that provide shelter or serve as barriers between environments are commonly incorporated into a variety of products. Textile materials may serve as wrappings or covers. Textile materials may also serve as screens separating one area from another, as when employed in tents or windbreaks. Textile materials may additionally serve ornamental or informative purposes, as when employed in labels, banners, or flags. For example, apparel based upon or otherwise incorporating textile materials may cover the body of a wearer, protecting it from environmental factors such as temperature and precipitation. Apparel may also serve to protect a wearer from wind. In addition, apparel may serve to identify a wearer. Such apparel may be formed for a variety of uses. For example, apparel may be formed for use in athletic training and athletic competition in a variety of different sports, such as baseball, basketball, American football, soccer, hockey, cricket, tennis, golf, track and field events, running, swimming, bicycling, skiing, snowboarding, surfing, windsurfing, and many others. Additionally, printed elements may be incorporated into other products, such as sports balls and other equipment used in athletics.

Materials or elements that impart padding, cushioning, or otherwise attenuate impact forces are also commonly incorporated into a variety of products. Athletic apparel, for example, often incorporates cushioning elements that protect the wearer from contact with other athletes, equipment, or the ground. More specifically, pads used in American football and hockey incorporate cushioning elements that provide impact protection to various parts of a wearer. Helmets used in American football, hockey, bicycling, skiing, snowboarding, and skateboarding incorporate cushioning elements that provide head protection during falls or crashes. Similarly, gloves used in soccer (e.g., by goalies) and hockey incorporate cushioning elements that provide protection to the hands of a wearer.

Indicia such as numbers, letters, words, symbols, marks, graphics, pictures, and illustrations may be imparted to surfaces of a variety of products. Indicia may serve to communicate information, to facilitate identification, or to provide decorative ornamentation, for example. Indicia may be imparted to a surface through any of a variety of techniques, including printing techniques. In some printing processes, which may be referred to as dye-sublimation printing, dyes used in the printing process may begin in a solid state, then sublimate from the solid state to a gas state upon application of heat. Subsequently, the dyes in the gas state, in the course of cooling back to the solid state, may adhere to a surface, may be absorbed by a material of the surface, or may be otherwise transferred to the surface.

Some printed elements to which indicia have been transferred may be textile elements, which may be incorporated into articles of apparel. Other printed elements may be cushioning elements, which may also be incorporated into articles of apparel. Accordingly, apparel (such as athletic apparel) may incorporate printed textile elements, printed cushioning elements, or both. In addition to apparel, printed textile elements and printed cushioning elements may also be incorporated into various other articles or as part of various other articles. For example, wrappings, covers, screens, labels, tents, banners, and flags may all incorporate printed textile elements. In addition, mats (e.g., for yoga or camping), chair cushions, and backpacks may all incorporate printed cushioning elements.

SUMMARY

Various methods of manufacturing printed elements incorporating indicia, which may themselves be incorporated into articles of apparel and other products, are disclosed below. In one step of an exemplary method of manufacturing a printed element, indicia is printed by dye-sublimation on a first material. In another step, a dye retention layer is positioned adjacent to the first material and the indicia. In another step, a second material layer is positioned adjacent to the first material. In another step, the first material, the second material, and the dye retention layer are compressed and heated to secure the first material to the second material.

In one step of an exemplary method of manufacturing a cushioning component, indicia is printed by dye-sublimation at a first temperature on a textile material. In another step, a non-absorbent material is positioned adjacent to the textile material and the indicia. In another step, the cushioning component is formed by (a) pressing the non-absorbent material against the textile material and (b) pressing the textile material against a polymer foam material at a second temperature, the first temperature being greater than the second temperature.

In one step of an exemplary method of manufacturing an article of apparel, an order including data representing indicia is received. In another step, the indicia is printed by dye-sublimation on a surface of a first textile structure according to the data representing the indicia. In another step, a plurality of polymer foam elements is located between the first textile structure and a second textile structure. In another step, a non-absorbent material is positioned adjacent to the first textile structure and the indicia. In another step, the first textile structure, the second textile structure, the polymer foam elements, and the non-absorbent material are compressed and heated to secure the first textile structure to at least one of the second textile structure and the polymer foam elements. In another step, the non-absorbent material is removed. In another step, the first textile structure, the second textile structure, and the polymer foam elements are incorporated into the article of apparel.

DETAILED DESCRIPTION

A computer or software file may include custom indicia data, which may be a digital or binary representation of one or more numbers, letters, words, symbols, marks, graphics, pictures, illustrations, or other indicia. That is, a computer or software file may include data representing custom-ordered indicia. A customer may be willing to purchase one or more products onto which custom-ordered indicia has been imparted. In turn, according to a variety of manufacturing processes, upon receiving an order from a customer including indicia data, dye-sublimation printing may be employed to impart the custom-ordered indicia onto a variety of printed elements, such as textile elements and cushioning elements. When used to impart indicia to various printed elements, dye-sublimation printing may impart indicia of a comparatively higher quality than other processes that may be used to impart indicia to printed elements, such as other printing processes.

In some manufacturing processes, steps subsequent to dye-sublimation printing may subject or expose a printed element, or one or more printed surfaces of the printed element, to relatively high temperatures. For example, a dye-sublimation printing step may be performed at a temperature of approximately 425° F. (i.e., approximately 218° C.). Subsequent to the dye-sublimation printing step, a printed element may undergo a step in which some portion of the printed element is heat-bonded, or thermalbonded, to another element. Such a thermalbonding step may subject or expose a printed element, or one or more printed surfaces of the printed element, to a temperature of approximately 325° F. (i.e., approximately 163° C.). In other manufacturing processes, higher or lower temperatures may be utilized for both printing and bonding. In some such processes, the temperature at which the dye-sublimation printing step is performed may be lower than the temperature at which the subsequent bonding step is performed.

In manufacturing processes that incorporate both a dye-sublimation printing step and one or more subsequent high-temperature steps (e.g., bonding), dye retention layers may be used in the subsequent high-temperature steps. Dye retention layers may be sheets of material incorporating one or more layers of dye-resistant material. That is, dyes used in dye-sublimation printing processes may not adhere to a surface of a dye retention layer, or may not be absorbed by a material of a surface of the dye retention layer, or may not be otherwise transferred to a surface of the dye retention layer. When incorporated into high-temperature steps subsequent to dye-sublimation printing steps, dye retention layers may advantageously improve the final quality of indicia imparted onto surfaces of various printed elements.

The following discussion and accompanying Figures disclose various printed elements, such as textile elements and cushioning elements. Additionally, the following discussion and accompanying Figures disclose various processes associated with manufacturing the printed elements. The printed elements may be incorporated into a variety of products, including articles of apparel (e.g., shorts, pants, shirts, wraps, gloves, helmets, and footwear), sports balls and athletic equipment, mats, seat cushions, and backpacks, for example. The printed elements may also be incorporated into a variety of other consumer or industrial products.

Printed Element Configuration

An example configuration for printed element100is depicted inFIGS. 1-2as a textile element including a first material layer110, a second material layer120, a bonding element140, and indicia150. First material layer110and second material layer120cooperatively form printed element100. Bonding element140is located between material layers110and120to join material layers110and120together. A surface of first material layer110includes indicia150, thereby incorporating indicia150into printed element100.

A variety of materials may be utilized for first material layer110and second material layer120, including various textiles, polymer sheets, leather, or synthetic leather, for example. Combinations of these materials (e.g., a polymer sheet bonded to a textile) may also be utilized for material layers110and120. Although material layers110and120may be formed from the same material, each of material layers110and120may also be formed from different materials. With regard to textiles, material layers110and120may be formed from knitted, woven, non-woven, spacer, or mesh textile components that include rayon, nylon, polyester, polyacrylic, elastane, cotton, wool, or silk, for example. Moreover, the textiles may be non-stretch, may exhibit one-directional stretch, or may exhibit multi-directional stretch. Accordingly, a variety of materials are suitable for first material layer110and second material layer120.

Bonding element140joins material layers110and120. Referring toFIG. 2, for example, bonding element140is located at an edge of first material layer110and extends entirely around first material layer110. Although bonding element140is located at a perimeter of first material layer110, bonding element140is absent from a central area of first material layer110. In effect, therefore, bonding element140is absent from a portion of first material layer110. In other configurations, however, bonding element140may be located in the central area of first material layer110, or may correspond in location to any part or parts of first material layer110, including substantially all of first material layer110.

A variety of materials may be utilized for bonding element140, including thermoplastic polymer materials (e.g., polyurethane), various adhesives, or heat-activated adhesives, for example. When formed from a thermoplastic polymer material, for example, the application of heat and pressure may be utilized to bond material layers110and120to each other with bonding element140. A thermoplastic polymer material melts when heated and returns to a solid state when cooled sufficiently. Based upon this property of thermoplastic polymer materials, heat-bonding or thermalbonding processes may be utilized to form a thermalbond that joins material layer110and120.

As utilized herein, the term “thermalbonding” or variants thereof is defined as a securing technique between two elements that involves a softening or melting of a thermoplastic polymer material within at least one of the elements such that the materials of the elements are secured to each other when cooled. Similarly, the term “thermalbond” or variants thereof is defined as the bond, link, or structure that joins two elements through a process that involves a softening or melting of a thermoplastic polymer material within at least one of the elements such that the materials of the elements are secured to each other when cooled.

With regard to bonding element140, thermalbonding may involve, for example, the melting or softening of thermoplastic materials within bonding element140to join material layers110and120together. Additionally, thermalbonding does not generally involve the use of stitching or adhesives, but involves directly bonding elements to each other with heat. In some situations, however, stitching or adhesives may be utilized to supplement the thermalbond or the joining of elements through thermalbonding. As an alternative to thermalbonding, or in addition to thermalbonding, an adhesive, a thermally-activated adhesive, or other securing structure may be utilized to join material layers110and120.

First material layer110also includes indicia150, which faces outward and is visible from an exterior of printed element100. Indicia150may be one or more numbers, letters, words, symbols, marks, graphics, pictures, or illustrations, or any combination thereof. For example, indicia150may communicate information, facilitate identification, or provide decorative ornamentation.

Cushioning Element Configuration

An example configuration for a cushioning element200is depicted inFIGS. 3-5Bas including a first material layer210, a second material layer220, a plurality of pad components230, a bonding element240, and indicia250. First material layer210and second material layer220cooperatively form an outer surface or covering for cushioning element200. That is, first material layer210and second material layer220cooperatively form a pocket or void in which pad components230are located. Whereas second material layer220is depicted as having a generally planar configuration, first material layer210extends over pad components230and also along sides of pad components230. Bonding element240is located between material layers210and220to join material layers210and220together. A surface of first material layer210includes indicia250, thereby incorporating indicia250into printed element200.

A variety of materials may be utilized for first material layer210and second material layer220, including various textiles, polymer sheets, leather, or synthetic leather, for example. Combinations of these materials (e.g., a polymer sheet bonded to a textile) may also be utilized for material layers210and220. Although material layers210and220may be formed from the same material, each of material layers210and220may also be formed from different materials. With regard to textiles, material layers210and220may be formed from knitted, woven, non-woven, spacer, or mesh textile components that include rayon, nylon, polyester, polyacrylic, elastane, cotton, wool, or silk, for example. Moreover, the textiles may be non-stretch, may exhibit one-directional stretch, or may exhibit multi-directional stretch. Accordingly, a variety of materials are suitable for first material layer210and second material layer220.

Pad components230are located between and secured to each of material layers210and220. Each of pad components230has a first surface231secured to first material layer210, an opposite second surface232secured to second material layer220, and a side surface233that extends between surfaces231and232. Although the shapes of pad components230may vary significantly, each of surfaces231and232are depicted as having an elliptical or generally elongate shape with rounded end areas, and side surface233extends in a generally straight fashion between surfaces231and232. Pad components230are also depicted as being spaced evenly from each other and arranged in rows, particularly offset rows, but may be spaced or located in a variety of arrangements. An advantage of arranging pad components230in offset rows is that the area between pad components230is effectively minimized, while retaining a regular spacing between adjacent pad components230.

A variety of materials may be utilized for pad components230, including various polymer foam materials that return to an original shape after being compressed. Examples of suitable polymer foam materials for pad components230include polyurethane, ethylvinylacetate, polyester, polypropylene, and polyethylene foams. Moreover, both thermoplastic and thermoset polymer foam materials may be utilized. In some configurations of cushioning element200, pad components230may be formed from a polymer foam material with a varying density, or solid polymer or rubber materials may be utilized. Fluid-filled chambers may also be utilized as pad components230. Also, different pad components230may be formed from different materials, or may be formed from similar materials with different densities. As discussed in greater detail below, the polymer foam materials forming pad components230attenuate impact forces to provide cushioning or protection. By selecting thicknesses, materials, and densities for each of the various pad components230, the degree of impact force attenuation may be varied throughout cushioning element200to impart a desired degree of cushioning or protection.

The compressible polymer foam materials forming pad components230attenuate impact forces that compress or otherwise contact cushioning element200. When incorporated into an article of apparel, for example, the polymer foam materials of pad components230may compress to protect a wearer from contact with other athletes, equipment, or the ground. Accordingly, cushioning element200may be utilized to provide cushioning or protection to areas of individual10or other wearers that are covered by cushioning element200.

Bonding element240joins material layers210and220around a perimeter of pad components230. Referring toFIG. 7, for example, bonding element240is located at an edge of first material layer210and extends entirely around first material layer210. Although bonding element240is located at a perimeter of first material layer210, bonding element240is absent from a central area of first material layer210. That is, bonding element240has an aperture that exposes the central area of first material layer210. In effect, therefore, bonding element240is absent from the portion of first material layer210that joins with pad components230. In other configurations, however, bonding element240may be located in the central area of first material layer210and may be utilized to join pad components230to first material layer210.

A variety of materials may be utilized for bonding element240, including thermoplastic polymer materials (e.g., polyurethane), various adhesives, or heat-activated adhesives, for example. When formed from a thermoplastic polymer material, for example, the application of heat and pressure may be utilized to bond material layers210and220to each other with bonding element240. A thermoplastic polymer material melts when heated and returns to a solid state when cooled sufficiently. Based upon this property of thermoplastic polymer materials, heat-bonding or thermalbonding processes may be utilized to form a thermalbond that joins material layer210and220.

With regard to bonding element240, thermalbonding may involve, for example, the melting or softening of thermoplastic materials within bonding element240to join material layers210and220together. Additionally, thermalbonding does not generally involve the use of stitching or adhesives, but involves directly bonding elements to each other with heat. In some situations, however, stitching or adhesives may be utilized to supplement the thermalbond or the joining of elements through thermalbonding. As an alternative to thermalbonding, or in addition to thermalbonding, an adhesive, a thermally-activated adhesive, or other securing structure may be utilized to join material layers210and220.

First Manufacturing Process

A variety of techniques may be utilized to manufacture printed element100. With reference toFIG. 6, a manufacturing apparatus300is disclosed as including a heating plate330and a press plate340. The configurations depicted inFIG. 6and discussed below for manufacturing apparatus300are intended to provide an example of a manufacturing apparatus that may be utilized in the manufacture of printed element100. A variety of other manufacturing apparatuses that operate in a similar manner may also be utilized.

Heating plate330includes a base331that may also be formed from a durable and rigid material, such as steel or aluminum, and incorporates heating elements. More particularly, electric coils may extend through base331to heat base331to temperatures that bond material layers110and120to each other with bonding element140. As an alternative, base331may incorporate fluid channels through which a heated fluid passes, radiant heaters, radio frequency emitters, or other devices may be utilized. In some configurations of heating plate330, a surface of base331that contacts portions of printed element100during the manufacturing process may incorporate a rubber or silicone material.

Press plate340includes a base341. As with base331, base341may be formed from a durable and rigid material, such as steel or aluminum.

With reference toFIGS. 7A-7C, an example of a suitable manufacturing process utilizing manufacturing apparatus300is disclosed. Initially, press plate340is positioned adjacent to second material layer120, as depicted in FIG.7A. Second material layer120is positioned adjacent to first material layer110. First material layer110includes bonding element140and indicia150. Accordingly, second material layer120is located between press plate340and first material layer110. Additionally, a dye retention layer305is positioned adjacent to first material layer110, and heating plate330is positioned adjacent to dye retention layer305. More particularly, dye retention layer305is positioned adjacent to a surface of first material layer110that includes indicia150or upon which indicia150is printed. Accordingly, first material layer110is located between second material layer120and dye retention layer305, and dye retention layer305is located between first material layer110and heating plate330.

Dye retention layer305may be a sheet of material incorporating one or more layers of dye-resistant material. For example, dye retention layer305may be a wax paper or a release paper. Alternatively, dye retention layer305may be a sheet of material having one or more plasticized surfaces. As a further alternative, dye retention layer305may be a polymer sheet. Dye retention layer305may be any sheet having a surface to which dyes used in dye-sublimation printing processes do not adhere or adhere minimally, or any sheet having a surface that does not absorb dyes used in dye-sublimation printing processes, or any sheet having a surface to which dyes used in dye-sublimation printing processes otherwise do not transfer.

Following positioning of the various elements of printed element100, press plate340and heating plate330close upon and compress first material layer110, bonding element140, second material layer120, and dye retention layer305, as depicted inFIG. 7B. As discussed above, base331of heating plate330incorporates heating elements. As such, the temperature of base331may be elevated to a point where bonding (e.g., thermalbonding) occurs between first material layer110, bonding element140, and second material layer120. Dye retention layer305may inhibit the movement of dye away from first material110during the thermalbonding step. For example, dye retention layer305may inhibit the transfer of re-sublimated dye away from first material110.

When compressed between heating plate330and press plate340, energy from heating plate330may be utilized to bond first material layer110, bonding element140, and second material layer120to each other. As discussed above, a thermoplastic polymer material melts when heated and returns to a solid state when cooled sufficiently. Based upon this property of thermoplastic polymer materials, thermalbonding processes may be utilized to form a thermalbond that joins first material layer110, bonding element140, and second material layer120. In this context, thermalbonding may involve, for example, (a) the melting or softening of thermoplastic materials within any of first material layer110, bonding element140, and second material layer120that joins the elements together, (b) the melting or softening of a thermoplastic material within bonding element140such that the thermoplastic polymer material extends into or infiltrates the structure of a textile utilized for first material layer110or second material layer120, or (c) the melting or softening of a thermoplastic material within one of first material layer110or second material layer120such that the thermoplastic polymer material extends into or infiltrates the structure of the other material layer.

Thermalbonding may occur when only one element includes a thermoplastic polymer material or when both elements include thermoplastic polymer materials. Additionally, thermalbonding does not generally involve the use of stitching or adhesives, but involves directly bonding elements to each other with heat. In some situations, however, stitching or adhesives may be utilized to supplement the thermalbond or the joining of elements through thermalbonding. As an alternative to thermalbonding, an adhesive, a thermally-activated adhesive, or other securing structure may be utilized to join first material layer110and second material layer120.

Once compression and bonding are complete, heating plate330and press plate320separate to (a) expose printed element100in which first material layer110and second material layer120are bonded together and (b) remove dye retention layer305, as depicted inFIG. 7C. At this stage of the manufacturing process, the manufacture of printed element100is effectively complete.

The printing of indicia150utilizing a dye-sublimation process may, for example, occur at a temperature of 425° F. (i.e., approximately 218° C.). The bonding of first material layer110to second material layer120with bonding element140may occur at a lower temperature, such as 325° F. (i.e., approximately 163° C.). Although the bonding temperature is less than the dye-sublimation temperature, a portion of the dye forming indicia150may sublimate when exposed to the bonding temperature. The presence of dye retention layer305, however, ensures that a large percentage of the sublimated dye remains within indicia150, instead of escaping from printed element100. That is, dye retention layer305ensures that the dye forming indicia150remains does not escape or otherwise leave printed element100during the bonding of first material layer110to second material layer120with bonding element140.

The above discussion ofFIGS. 7A-7Cprovides an example of a suitable manufacturing process for printed element100. In general, an advantage of the manufacturing process is that various constituent elements of printed element100may be joined through thermalbonding while accommodating a previous dye-sublimation printing step. In particular, by inhibiting the movement of dye away from first material110in the thermalbonding step, the use of dye retention layer305may advantageously improve the final quality of indicia150, such as custom-ordered indicia, that may already have been transferred to the surface of first material layer110.

A variety of other manufacturing processes or variations of the manufacturing process discussed above may also be utilized. In some alternate configurations, optional stitching, adhesive, or thermalbonding steps may be utilized to supplement the joining of material layers110and120of printed element100. For example, a sewing or stitching machine may be utilized to further secure material layers110and120to each other around the periphery of printed element100. Additionally, a sewing or stitching machine may be utilized to incorporate printed element100into an article of apparel or another article.

Second Manufacturing Process

A variety of techniques may be utilized to manufacture cushioning element200. With reference toFIG. 8, a manufacturing apparatus400is disclosed as including a die410, an extractor420, a heating plate430, and a press plate440. The configurations depicted inFIG. 8and discussed below for manufacturing apparatus400are intended to provide an example of a manufacturing apparatus that may be utilized in the manufacture of cushioning element200. A variety of other manufacturing apparatuses that operate in a similar manner may also be utilized.

Die410includes a base411, a plurality of die elements412, a plurality of ejection members413, and a pair of registration pegs414. Base411is formed from a durable and rigid material, such as steel or aluminum, to provide a foundation for die410. Die elements412extend outward (e.g., upward) from base411and exhibit a general shape of pad components230. More particularly, an interior area of each die element412has the general shape of an individual pad component230. As discussed in greater detail below, edges415(e.g., upper edges) of die elements412are utilized to cut through a material that forms pad components230, thereby shaping and forming each of pad components230. Edges415may generally have a sharpened configuration that assists with cutting through the material that forms pad components230. Ejection members413are located within the interior areas of each die element412and are spaced (e.g., spaced downward) from edges415. As an example, ejection members413may be formed from a polymer foam material with lesser compressibility than a polymer foam material forming pad components230. Additionally, registration pegs414extend outward (e.g., upward) from base411.

In addition to having the general shape of pad components230, die elements412are arranged or otherwise located relative to each other in the same manner as pad components230. As noted above, pad components230are depicted as being spaced evenly from each other and arranged in offset rows. Similarly, die elements412are spaced evenly from each other and arranged in offset rows. That is, die elements412are arranged in a configuration that corresponds with the positions of pad components230in cushioning element200. If, however, a different arrangement is desired for pad components230, then die elements412may be moved or otherwise repositioned to correspond with the different arrangement.

Extractor420includes a base421, a plurality of extractor elements422, a pair of registration apertures423, and an extractor sheet424. Base421is formed from a durable and rigid material, such as steel or aluminum, to provide a foundation for extractor420. Extractor elements422have the configurations of pins that extend outward (e.g., downward) from base421and have sharpened or pointed end areas. As discussed in greater detail below, extractor elements422assist with retaining the positions of pad components230upon removal from die410. As an alternative to pins, extractor elements422(a) may have the configurations of needles, nails, spikes, or prongs or (b) may be a vacuum system that retains the positions of pad components230upon removal from die410, for example. Accordingly, extractor elements422may be any device or system that may be used to secure pad components230to extractor420and assist with retaining the positions of pad components230upon removal from die410. Additionally, registration apertures423form holes in base421that are positioned to correspond with and receive registration pegs414.

The positions of extractor elements422correspond with the locations of die elements412. Moreover, extractor elements422are arranged or otherwise located relative to each other in the same manner as die elements412, and die elements412are arranged or otherwise located relative to each other in the same manner as pad components230. That is, extractor elements422are arranged in a configuration that corresponds with the positions of pad components230in cushioning element200. If, however, a different arrangement is desired for pad components230, then extractor elements422and die elements412may be moved or otherwise repositioned to correspond with the different arrangement.

Extractor sheet424lays adjacent to base421and includes a plurality of apertures that receive extractor elements422. That is, extractor elements422extend through the apertures in extractor sheet424. A variety of materials may be utilized for extractor sheet424, including various polymer materials and metals.

Heating plate430includes a base431that may also be formed from a durable and rigid material, such as steel or aluminum, and incorporates heating elements. More particularly, electric coils may extend through base431to heat base431to temperatures that bond (a) pad components230to material layers210and220and (b) material layers210and220to each other with bonding element240. As an alternative, base431may incorporate fluid channels through which a heated fluid passes, or radiant heaters, radio frequency emitters, or other devices may be utilized. In some configurations of heating plate430, a surface of base431that contacts portions of cushioning element200during the manufacturing process may incorporate a rubber or silicone material.

Press plate440includes a base441and a compressible material442. As with bases411,421, and431, base441may be formed from a durable and rigid material, such as steel or aluminum. Compressible material442is recessed within a surface of base441and is formed from a material (e.g., silicone, polymer foam) that compresses or deforms when a force is applied and returns to an original shape when the force is removed. Although a single element of compressible material442is depicted, some configurations may incorporate multiple elements of compressible material442with different degrees of compressibility, depending upon the configuration of cushioning element200that is being manufactured.

With reference toFIGS. 9A-9J and 10A-10J, an example of a suitable manufacturing process utilizing manufacturing apparatus400is disclosed. Initially, die elements412are arranged in a configuration that corresponds with the positions of pad components230in cushioning element200, and extractor elements422are arranged in a configuration that corresponds with the positions of die elements412and pad components230in cushioning element200. A blank401is then placed between die410and extractor420, as depicted inFIGS. 9A and 10A. Blank401, from which pad components230are cut, is formed from the same material as pad components230and has a thickness of pad components230. Once blank401is positioned, die410and extractor420close upon, compress, and cut blank401, as depicted inFIGS. 9B and 10B. More particularly, (a) blank401is compressed against die elements412such that edges415pierce and cut through blank401and (b) extractor elements422pierce and enter blank401. Note that extractor elements422are positioned to correspond with each of die elements412and enter the interior area of each of die elements412, which is where ejection members413are located. Depending upon the lengths of extractor elements422, end areas of extractor elements422may pass through blank401and pierce ejection members413during this operation. In order to ensure that die elements412properly align with extractor elements422, registration pegs414are aligned with and enter registration apertures423.

At this stage of the process, die elements412have effectively cut through blank401. Referring toFIG. 10B, edges415of die elements412pass entirely through blank401to rest against a surface of extractor sheet424. As noted above, the interior area of each die element412has the general shape of an individual pad component230. Accordingly, the individual pad components230are located within die elements412and are compressed between a surface of extractor sheet424and ejection members413. As depicted inFIGS. 9C and 10C, die410and extractor420then separate to remove pad components230from within die elements412, and pad components230are secured to extractor420by the various extractor elements422. Referring again toFIG. 10B, portions of blank401within die elements412(i.e., the portions forming pad components230) are compressed more than portion of blank401that are exterior of die elements412. That is, portions of blank401within die elements412are compressed against ejection members413. When die410and extractor420separate, the compression of pad components230causes pad components230to expand outward from die elements412and remain properly positioned on extractor elements422. As a result, pad components230remain secured to extractor elements422upon the separation of die410and extractor420. Additionally, note that blank401may remain within die410(i.e., around the various die elements412) at this stage, or may be separated from die410, and also that blank401defines various apertures where pad components230were removed.

As a summary of the manufacturing process up to this point, pad components230have effectively been removed from blank401. More particularly, (a) die elements412were utilized to cut through blank401to form pad components230and (b) pad components230are removed from die elements412and remain secured to extractor420due to the presence of extractor elements422, which extend into the various pad components230. Additionally, pad components230are positioned and oriented in the same manner as die elements412and are, therefore, positioned and oriented as within cushioning element200. Accordingly, pad components230have been removed from blank401and are positioned and oriented to be incorporated into cushioning element200.

The combination of extractor420and pad components230is then positioned adjacent to first material layer210, as depicted inFIGS. 9D and 10D. First material layer210includes bonding element240and indicia250. First material layer210is positioned adjacent to dye retention layer405, and dye retention layer405is positioned adjacent to heating plate430. Accordingly, first material layer210is located between the combination of extractor420and pad components230and dye retention layer405, and dye retention layer405is located between first material layer210and heating plate430.

Dye retention layer405may be a sheet of material incorporating one or more layers of dye-resistant material. For example, dye retention layer405may be a wax paper or a release paper. Alternatively, dye retention layer405may be a sheet of material having one or more plasticized surfaces. As a further alternative, dye retention layer405may be a polymer sheet. Dye retention layer405may be any sheet having a surface to which dyes used in dye-sublimation printing processes do not adhere, or any sheet having a surface that does not absorb dyes used in dye-sublimation printing processes, or any sheet having a surface to which dyes used in dye-sublimation printing processes otherwise do not transfer.

Extractor420and heating plate430then close upon and compress pad components230, first material layer210, and dye retention layer405, as depicted inFIGS. 9E and 10E. As discussed above, base431of heating plate430incorporates heating elements. As such, the temperature of base431may be elevated to a point where bonding (e.g., thermalbonding) occurs between first material layer210and pad components230. Dye retention layer405may inhibit the movement of dye away from first material210during the thermalbonding step. For example, dye retention layer405may inhibit the transfer of re-sublimated dye away from first material210.

When compressed between extractor420and heating plate430, energy from heating plate430may be utilized to bond first material layer210and pad components230to each other. As discussed above, a thermoplastic polymer material melts when heated and returns to a solid state when cooled sufficiently. Based upon this property of thermoplastic polymer materials, thermalbonding processes may be utilized to form a thermalbond that joins first material layer210are pad components230. In this context, thermalbonding may involve, for example, (a) the melting or softening of thermoplastic materials within either of first material layer210and pad components230that joins the elements together, (b) the melting or softening of a thermoplastic material within pad components230such that the thermoplastic polymer material extends into or infiltrates the structure of a textile utilized for first material layer210, or (c) the melting or softening of a thermoplastic material within first material layer210such that the thermoplastic polymer material extends into or infiltrates the structure of pad components230.

Thermalbonding may occur when only one element includes a thermoplastic polymer material or when both elements include thermoplastic polymer materials. Additionally, thermalbonding does not generally involve the use of stitching or adhesives, but involves directly bonding elements to each other with heat. In some situations, however, stitching or adhesives may be utilized to supplement the thermalbond or the joining of elements through thermalbonding. As an alternative to thermalbonding, an adhesive, a thermally-activated adhesive, or other securing structure may be utilized to join first material layer210and pad components230.

As discussed above, a surface of base431that contacts portions of cushioning element200during the manufacturing process may incorporate a rubber or silicone material. Referring toFIG. 10E, extractor elements422are spaced from and do not contact base431. In situations where the compression of first material layer210and pad components230induces extractor elements422to contact base431, the rubber or silicone material may be present to receive end areas of extractor elements422. That is, the end areas of extractor elements422may pierce and enter the rubber or silicone material during the compression of first material layer210and pad components230.

Following compression and bonding, extractor420and heating plate430separate to expose the bonded first material layer210and pad components230. At this stage, the thermoplastic material, adhesive, or other element that joins first material layer210and pad components230may have an elevated temperature or may not be fully cured. In order to prevent separation between first material layer210and pad components230, extractor sheet424may be pulled from base421, which effectively pushes pad components230from extractor elements422, as depicted inFIGS. 9F and 10F. That is, extractor sheet424is separated from extractor elements422to push pad components230from extractor420. Upon fully separating extractor sheet424from extractor elements422, the combination of first material layer210and pad components230is free from extractor420, as depicted inFIGS. 9G and 10G.

Continuing with the manufacturing of cushioning element200, second material layer220is then placed adjacent to heating plate430, the combination of first material layer210and pad components230is turned over or otherwise oriented such that pad components230are between material layers210and220, and press plate440is located adjacent to first material layer210, as depicted inFIGS. 9H and 10H. Press plate440and heating plate430then close upon and compress first material layer210, second material layer220, and pad components230, as depicted inFIGS. 9I and 10I. Given the elevated temperature of base431, bonding (e.g., thermalbonding) occurs between second material layer220and pad components230.

In addition to bonding second material layer220and pad components230, material layers210and220are bonded (e.g., thermalbonded) with bonding element240. Pad components230are positioned to correspond with the location of compressible element442, as depicted inFIG. 10I. When compressed, the thicknesses of pad components230and compressible element442are reduced, thereby allowing base431and base441to compress bonding element240between material layers210and220. By compressing these elements together, coupled with heat from base431, second material layer is bonded (e.g., thermalbonded) to bonding element240. In effect, therefore, material layers210and220are bonded together with bonding element240. In configurations where pad components230have varying thicknesses, for example, multiple elements of compressible material442with different degrees of compressibility may be utilized to ensure that all elements of cushioning element200are properly bonded.

Once compression and bonding are complete, heating plate430and press plate440separate to (a) expose cushioning element200in which first material layer210, pad components230, and second material layer220are bonded together and (b) remove dye retention layer405, as depicted inFIGS. 9J and 10J. At this stage of the manufacturing process, the manufacture of cushioning element200is effectively complete.

The above discussion ofFIGS. 9A-9J and 10A-10Jprovides an example of a suitable manufacturing process for cushioning element200. In general, an advantage of the manufacturing process is that the arrangement of die elements412determines the resulting arrangement of pad components230in cushioning element200. That is, die410is initially set such that die elements412are positioned in a particular arrangement, and the resulting positions of pad components230effectively mirrors the arrangement of die elements412. Accordingly, the positions of pad components230may be pre-selected through the arrangement of die elements412.

An additional advantage of the manufacturing process is that all the elements of cushioning element200may be joined through thermalbonding without the need for additional manufacturing steps. In some configurations, however, optional stitching, adhesive, or thermalbonding steps may be utilized to supplement the joining of material layers210and220around the periphery of pad components230. As an example, a sewing or stitching machine may be utilized to further secure material layers210and220to each other. Additionally, the sewing or stitching machine may be utilized to incorporate cushioning element200into an article of apparel or another article.

Another advantage of the manufacturing process is that various constituent elements of cushioning element200may be joined through thermalbonding while accommodating a previous dye-sublimation printing step. In particular, by inhibiting the movement of dye away from first material210in the thermalbonding step, the use of dye retention layer405may advantageously improve the final quality of indicia250, such as custom-ordered indicia, that may already have been transferred to the surface of first material layer210.

A variety of other manufacturing processes or variations of the manufacturing process discussed above may also be utilized. In some alternate configurations, optional stitching, adhesive, or thermalbonding steps may be utilized to supplement the joining of material layers210and220of cushioning element200. For example, a sewing or stitching machine may be utilized to further secure material layers210and220to each other around the periphery of cushioning element200. Additionally, a sewing or stitching machine may be utilized to incorporate cushioning element200into an article of apparel or another article.

Additionally, extractor elements422may retract such that extractor420may also be utilized as press plate440. In other configurations, ejection members413may be absent or a mechanized ejector may be utilized within die elements412. Moreover, extractor elements422may be removable or positioned in various locations to allow different configurations of pad components230. Moreover, specialized machinery may be formed to automate the general manufacturing process discussed above.

As a further matter, extractor420and press plate440are depicted as being located below heating plate430in various steps. An advantage to this configuration relates to the positioning of elements forming cushioning element200. More particularly, when extractor420and press plate440are below heating plate430, the elements forming cushioning element200may be arranged or otherwise positioned on extractor420and press plate440prior to the application of heat from heating plate430. In this configuration, heat is applied to the elements of cushioning element200only when heating plate430compresses the elements against either extractor420or press plate440. Accordingly, the elements forming cushioning element200may be arranged in the absence of applied heat in configurations where heating plate430is above extractor420and press plate440.

Apparel and Other Product Configurations

With reference toFIG. 11, an individual10is depicted as wearing a first article of apparel20with the general configuration of a shirt-type garment and a second article of apparel30with the general configuration of a shorts-type garment. Although articles of apparel20and30are depicted as being exposed, articles of apparel20and30may be worn under other articles of apparel, may be worn over other articles of apparel, or may be worn alone.

Although depicted as having the general configurations of a shirt-type garment and a shorts-type garment, articles of apparel20and30may have the general configuration of any type of garment or apparel covering other areas of individual10. For example, articles of apparel20and30may have the general configuration of pants, skirts, dresses, robes, long-sleeved shirts, short-sleeved shirts, tank tops, underclothes, jackets, coats, hats, wraps, footwear, socks, gloves, scarves, shawls, or stoles. As a further example, articles of apparel20and30may have the general configuration of apparel used in athletic activities, such as sports gloves or helmets.

Additionally, articles of apparel20and30are separate, i.e., article of apparel20may be worn without article of apparel30, and article of apparel30may be worn without article of apparel20. However, in some configurations, articles of apparel20and30may be the same article. Articles of apparel20and30may also be worn in combination with other pieces of equipment (e.g., athletic or protective equipment). Accordingly, the configuration of articles of apparel20and30and the manner in which articles of apparel20and30are worn by individual10may vary significantly.

When worn, article of apparel20includes (a) exterior surfaces that face away from individual10and (b) opposite interior surfaces that face toward individual10and may contact individual10. A plurality of printed elements100are incorporated into various areas of article of apparel20. Printed elements100may be incorporated into article of apparel20in a variety of ways. For example, first material layer110of a printed element100may form a portion of an exterior surface of an article of apparel, and second material layer120may form a portion of both an exterior surface and an interior surface of the article of apparel. For example, second material120may be a portion of a base material of article of apparel20. Alternatively, first material layer110of a printed element100may form a portion of both an exterior surface and an interior surface of an article of apparel. For example, first material layer110may extend over an aperture in second material layer120.

Similarly, when worn, article of apparel30includes (a) exterior surfaces that face away from individual10and (b) opposite interior surfaces that face toward individual10and may contact individual10. A plurality of cushioning elements200are incorporated into various areas of article of apparel30to impart padding, cushioning, or otherwise attenuate impact forces. Cushioning elements200may be incorporated into article of apparel30in a variety of ways. For example, first material layer210may be positioned exterior of second material element220, such that cushioning element200protrudes outward from article of apparel30. That is, first material layer210may form a portion of an exterior surface of article of apparel30, whereas second material layer220may form a portion of both an exterior surface and an interior surface of article of apparel30. Alternately, first material layer210may form a portion of both an exterior surface and an interior surface of article of apparel30, whereas second material layer220form a portion of an interior surface of article of apparel30.

Although first article of apparel20is depicted as incorporating printed elements100and second article of apparel30is depicted as incorporating cushioning elements200, either printed elements100or cushioning elements200may be otherwise incorporated into articles of apparel20and30. For example, article of apparel20may incorporate printed elements100, or cushioning elements200, or both. Similarly, article of apparel30may incorporate printed elements100, or cushioning elements200, or both.

A variety of techniques may be used to incorporate printed elements100and cushioning elements200into articles of apparel20and30. For example, printed elements100and cushioning elements200may be bonded to other materials forming articles of apparel20and30. Alternatively, printed elements100and cushioning elements200may be stitched or otherwise secured to other materials forming articles of apparel20and30.

When article of apparel30is worn during athletic activities, cushioning elements200may protect individual10from contact with other athletes, equipment, or the ground. Cushioning elements200may be positioned in various areas of the articles of apparel to protect specific portions (e.g., muscles, bones, joints, impact areas) of individual10. Additionally, the shapes, sizes, and other properties of cushioning elements200, as well as the materials and components utilized in cushioning elements200, may vary significantly to provide a particular level of protection to the specific portions of individual10.

In addition to attenuating impact forces, cushioning element200has an advantage of simultaneously providing one or more of breathability, flexibility, a relatively low overall mass, and launderability. When incorporated into an article of apparel, such as article of apparel30, a wearer may perspire and generate excess heat. By utilizing a permeable textile for material layers210and220and also forming gaps between adjacent pad components230, areas for air to enter article of apparel30and for moisture to exit article of apparel30are formed through cushioning element200. More particularly, air and moisture may pass through material layers210and220and between pad components230to impart breathability to areas of article of apparel30having cushioning element200. Moreover, the materials and structure discussed above for cushioning element200impart flexibility and a low overall mass to cushioning element200. Furthermore, the materials and structure discussed above for cushioning element200permits cushioning element200to be laundered without significant shrinkage or warping, even when temperatures associated with commercial laundering processes are utilized. Accordingly, cushioning element200may simultaneously provide impact force attenuation, breathability, flexibility, a relatively low overall mass, and launderability to an article of apparel.

Furthermore, both printed elements100and cushioning elements200incorporated into various articles of apparel may advantageously incorporate various indicia, which may be custom-ordered, for various purposes including aesthetic enhancement, identification, or communication. The print quality of such indicia may be improved relative to the print quality present on other printed elements.

Printed elements100and cushioning elements200may be configured to have any size or shape, or any location on articles of apparel20and30or other products. For example, in various configurations, printed elements100and cushioning elements200may be incorporated into mats, pads, cushions, backpacks, tents, screens, banners, or flags. Accordingly, various configurations of printed elements100and cushioning elements200may be incorporated into a variety of products.

Further Cushioning Element Configurations and Manufacturing Processes

Aspects of first material layers110and210and second material layers120and220may vary significantly. As discussed above, material layers110,210,120, and220may be formed from various textiles, polymer sheets, leather, synthetic leather, or combinations of materials. For example, any of material layers110,210,120, and220may have the configuration of a mesh material that defines a plurality of holes. In addition to imparting greater breathability that allows the transfer of air and moisture, a mesh material may allow for various aesthetic properties.

Aspects of cushioning element200may also vary, depending upon the intended use for cushioning element200and the product in which cushioning element200is incorporated. Moreover, changes to the dimensions, shapes, and materials utilized within cushioning element200may vary the overall properties of cushioning element200. That is, by changing the dimensions, shapes, and materials utilized within cushioning element200, the compressibility, impact force attenuation, breathability, flexibility, and overall mass of cushioning element200may be tailored to specific purposes or products. For example, cushioning elements200may have any of the range of configurations depicted and described in U.S. Patent Application Publication Number 2009/0233511, U.S. patent application Ser. No. 12/709,819, and U.S. patent application Ser. No. 12/720,070. Any of these variations, as well as combinations of these variations, may be utilized to tailor the properties of cushioning element200to an intended use or particular product. Moreover, any of these variations may be manufactured through the process or variations of the process discussed above.

As depicted inFIGS. 3-5B, cushioning element200includes a plurality of pad components230. However, in other configurations, fewer pad components may be present. For example, as depicted inFIG. 12A, cushioning element200incorporates a single pad component230.

As depicted inFIGS. 3-5B, cushioning element200includes a first material layer210, a second material layer220, and a plurality of pad components230located between material layers210and220. However, in other configurations of cushioning element200, either of material layers210and220may be absent. For example, as depicted inFIG. 12B, cushioning element200does not include a second material layer220. In a further example, as depicted in FIG.12C, cushioning element200(which includes a single pad component230) does not include a first material layer210.

As depicted inFIGS. 1-5B, printed element100and cushioning element200are distinct. However, various aspects and features of printed element100and cushioning element200may be intermixed or combined in further configurations. For example, as depicted inFIG. 12D, one or more bonding elements240may secure (a) first material layer110and first material layer210to each other, and (b) first material layer210and second material layer220to each other. In a further example, as depicted inFIG. 12H, one or more bonding elements240have created two regions within cushioning element200: a first region having first material layer210, second material layer220, and pad components230located between material layers210and220, and a second region having first material layer210and second material layer220in a manner substantially similar to printed element100.

As depicted inFIGS. 1-5B, first material layer210is secured to second material layer220by bonding element240. However, in further configurations, other material layers may be secured in various ways to first material layer210, second material layer220, or both. More particularly, further configurations may include a base material260, as depicted inFIGS. 12E-12G. Base material260may be a material forming a portion of or substantially all of an article of apparel, and may include any of the various materials discussed above with respect to material layers110,120,210, and220. Cushioning elements may include base material layer260as well as material layers210and220in a variety of configurations, and may incorporate one or more bonding elements240to secure the various layers to each other in a variety of configurations.

For example, as depicted inFIG. 12E, cushioning element200may incorporate first material layer210, second material layer220, and base material layer260extending across second material layer220. In such a configuration, a bonding element240may secure second material layer220to base material layer260. In another example, as depicted inFIG. 12F, cushioning element200may incorporate first material layer210, base material layer260, pad components230located between first material layer210and base material layer260, and second material layer220also located between first material layer210and base material layer260. In such a configuration, bonding elements240may secure (a) second material layer220to first material layer210and (b) second material layer220to base material layer260. In a further example, as depicted inFIG. 12G, cushioning element200may incorporate first material layer210, base material layer260, pad components230located between first material layer210and base material layer260, and second material layer220having an aperture through which portions of first material layer210and pad components230extend. In such a configuration, bonding elements240may secure (a) second material layer220to base material layer260and (b) second material layer220to first material layer210.

As depicted inFIGS. 3-5B, cushioning elements200may include pad components230formed from a polymer foam material. However, in other configurations, cushioning elements200may include other pad components. For example, as depicted inFIG. 12I, cushioning component200includes fluid-filled chambers235, each of which has a first surface236secured to first material layer210, a second surface237secured to second material layer220, and a side surface238that extends between surfaces236and237. In another example, as depicted inFIG. 12J, cushioning component200includes first material layer210and fluid-filled chambers235, but does not include a second material layer220. In a further example, as depicted inFIG. 12K, printed element100is a single fluid-filled chamber235. In such a configuration, indicia may have been transferred to the components of fluid-filled chamber235before the formation of chamber235, and first surface236of fluid-filled chamber235may include the indicia.

As depicted inFIGS. 6-10Jand as discussed above, the use of dye retention layers in various manufacturing processes may have an advantage of improving the final quality of indicia transferred to the surface of a printed element when the printed element is subjected to a high-temperature thermalbonding step after the indicia has been transferred to it. However, in other manufacturing processes, the use of a dye retention layer may improve the final quality of transferred indicia when the printed element is subjected to other high-temperature steps. For example, dye-retention layers may improve the final quality of transferred indicia when a printed element is subjected to a curing step, or a dehydrating step, or an annealing step.