Articles of apparel incorporating cushioning elements and methods of manufacturing the articles of apparel

Patent metadata

Field	Value
Publication number	US-9756884-B2
Application number	US-201615191145-A
Country	US
Kind code	B2
Filing date	Jun 23, 2016
Priority date	Feb 25, 2011
Publication date	Sep 12, 2017
Grant date	Sep 12, 2017

Abstract

A method of making articles of apparel that include a base layer having a first surface and an opposite second surface. The base layer is associated with a thermoplastic polymer element, then an aperture is formed through the base layer and the thermoplastic polymer element. A cushioning elements that may have a first material layer, a second material layer, and a plurality of foam components is positioned proximate the aperture. The first material layer and the second material layer are bonded to the second surface of the base layer. The foam components are located between and secured to the first material layer and the second material layer. In addition, the foam components are positioned to correspond with a location of the aperture.

First claim

The invention claimed is:

1. An article of apparel comprising:
a base layer having a first surface and an opposite second surface, the base layer defining an aperture extending through the base layer and form the first surface to the second surface; and
a cushioning element having a first material layer, a second material layer, and at least one foam component,
wherein the first material layer is in indirect contact with and secured to the second surface of the base layer, and wherein the second material layer is in indirect contact with and secured to the second surface of the base layer, wherein the first material layer and the second material layer are separated from the second surface of the base layer by a bonding layer,
wherein the first material layer has an outermost edge and the second material layer has a length that extends beyond the outermost edge, and
wherein the at least on foam component is located between and secured to the first material layer and the second material layer, and the at least one foam component is positioned to correspond with a location of the aperture.

2. The article of apparel recited in claim 1 , further including a bonding element extending around the aperture, the bonding element securing the first material layer and the second material layer to the second surface of the base layer.

3. The article of apparel recited in claim 2 , wherein the first material layer is joined to a portion of the bonding element that is positioned adjacent to the aperture, and the second material layer is joined to the a portion of the bonding element that is spaced from the aperture.

4. The article of apparel recited in claim 2 , wherein the bonding element is located at an edge of the aperture.

5. The article of apparel recited in claim 2 , wherein the bonding element includes a thermoplastic polymer material.

6. The article of apparel recited in claim 1 , wherein the second material layer has a greater area than the first material layer.

7. The article of apparel recited in claim 1 , wherein both the first material layer and the first surface of the base layer form a portion of an exterior surface of the apparel.

8. An article of apparel comprising:
a base layer having a first surface and an opposite second surface, the base layer defining an aperture extending through the base layer and from the first surface to the second surface;
a cushioning component having a first material layer, a second material layer, and at least one foam component; and
a bonding element secured to the second surface of the base layer that extends continuously around the aperture, wherein the bonding element has a first side and an opposing second side,
wherein the bonding element includes a first portion that is positioned adjacent to the aperture, and the bonding element includes a second portion that is spaced from the aperture, wherein the first portion and the second portion are continuous so that the bonding element extends uninterrupted from a position adjacent the aperture to an edge of the second portion,
wherein the at least one foam component are located between and bonded to the first material layer and the second material layer, and the at least one foam component is positioned to correspond with a location of the aperture;
wherein the first material layer is in direct contact with the first portion of the bonding element on the first side of the bonding element and the second material layer is in direct contact with the second portion of the bonding element on the first side of the bonding element, and wherein the second surface of the base layer is in direct contact with the opposing second side of the bonding element;
wherein the first material layer has an outermost edge; and
wherein the second material layer has a length that extends beyond the outermost edge of the first material layer.

9. The article of apparel recited in claim 8 , wherein the bonding element is located at an edge of the aperture.

10. The article of apparel recited in claim 8 , wherein the first material layer separates the bonding element from the second material layer adjacent the first portion of the bonding element.

11. The article of apparel recited in claim 8 , wherein the second material layer has a greater area than the first material layer.

12. The article of apparel recited in claim 8 , wherein both the first material layer and the first surface of the base layer form a portion of an exterior surface of the apparel.

13. An article of apparel comprising:
a base layer having a first surface and an opposite second surface;
an aperture defined by the base layer and extending from the first surface to the second surface through the base layer;
a bonding layer that extends around a perimeter of the aperture, wherein the bonding layer has a first side and an opposing second side; and
a cushioning element including a first material layer, a second material layer, and at least one foam component,
wherein the first material layer is secured to the second material layer to form a pocket between the first material layer and the second material layer;
wherein the at least one foam component is disposed within the pocket;
wherein the first side of the bonding layer is in direct contact with the first material layer and the second side of the bonding layer is in direct contact with the second surface of the base layer to secure the first material layer to the second surface of the base layer so that the first material layer is exposed through the aperture,
wherein the first material layer has an outermost edge,
wherein the second material layer has a length that extends beyond the outermost edge of the first material layer, and
wherein the cushioning element is positioned to correspond with a location of the aperture so that the first material layer protrudes at least partially through the aperture.

14. The article of apparel recited in claim 13 , wherein the first side of the bonding layer is in direct contact with the second material layer to secure the second material layer to the second surface of the base layer.

15. The article of apparel recited in claim 14 , wherein the bonding layer comprises a first portion and a second portion, wherein the first portion is positioned adjacent the aperture and the second portion is spaced apart from the aperture.

16. The article of apparel recited in claim 15 , wherein the second material layer has a greater area than the first material layer, and wherein the first portion secures the first material layer to the second surface and the second portion secures the second material layer to the second surface.

17. The article of apparel recited in claim 13 , wherein the at least one foam component is positioned so that the perimeter of the aperture extends around the at least one foam component.

18. The article of apparel recited in claim 17 , wherein the at least one foam component is positioned below the aperture when in a neutral position and extend at least partially through the aperture when subjected to a force.

19. The article of apparel recited in claim 18 , wherein the force is exerted when the article of apparel is positioned on a user's body.

20. The article of apparel recited in claim 13 , wherein the first material layer and the second material layer are selected so that the cushioning element is configured to increase the breathability of the article of apparel.

Assignees

• Nike Inc

Inventors

• Turner David

Classifications

• A41D13/0593

  in a sealed pocket · CPC title

• A41D13/05

  protecting only a particular body part (ear protectors A61F11/06) · CPC title

• A41D13/0543

  Legs (knee or foot A41D13/06; protectors for the legs of players or sportmen A63B71/1225) · CPC title

• A41B1/08

  Details · CPC title

• A41D31/005

  Human Necessities · mapped topic