Abstract: Cushioning elements include a breathable material configured to allow gases to pass through at least a portion thereof, and a plurality of discrete segments of thermoplastic elastomeric gel (“gel”) heat-fused or otherwise attached to the breathable material. The gel comprises an elastomeric polymer and a plasticizer, with a plasticizer-to-polymer ratio of from about 0.3 to about 50. The plurality of discrete segments defines at least one breathable gap between adjacent discrete segments. Methods of forming cushioning elements include forming a plurality of discrete segments of gel, securing each segment to a breathable material, and providing a gas path through the breathable material and between adjacent segments. Another method includes providing molten gel within a mold, providing at least a second portion of the gel within a permeable material, and solidifying the gel to form discrete segments of gel.

Abstract: A molding system includes a plurality of injection heads each configured to inject molten polymer into a mold cavity. Each injection head has an outer body, a piston disposed within the outer body and defining a polymer chamber on a first side of the piston and a pressure chamber on an opposite second side of the piston. The piston moves from a retracted position to an extended position responsive to pressurization of the pressure chamber. Molten polymer is injected from the polymer chamber into the mold cavity as the piston moves from the retracted position to the extended position. Such systems may be used to mold relatively large articles of manufacture.

Abstract: Cushioning elements include a breathable material configured to allow gases to pass through at least a portion thereof, and a plurality of discrete segments of thermoplastic elastomeric gel (“gel”) heat-fused or otherwise attached to the breathable material. The gel comprises an elastomeric polymer and a plasticizer, with a plasticizer-to-polymer ratio of from about 0.3 to about 50. The plurality of discrete segments defines at least one breathable gap between adjacent discrete segments. Methods of forming cushioning elements include forming a plurality of discrete segments of gel, securing each segment to a breathable material, and providing a gas path through the breathable material and between adjacent segments. Another method includes providing molten gel within a mold, providing at least a second portion of the gel within a permeable material, and solidifying the gel to form discrete segments of gel.

Abstract: A molding system includes a plurality of injection heads each configured to inject molten polymer into a mold cavity. Each injection head has an outer body, a piston disposed within the outer body and defining a polymer chamber on a first side of the piston and a pressure chamber on an opposite second side of the piston. The piston moves from a retracted position to an extended position responsive to pressurization of the pressure chamber. Molten polymer is injected from the polymer chamber into the mold cavity as the piston moves from the retracted position to the extended position. Such systems may be used to mold relatively large articles of manufacture.

Abstract: Cushioning elements include a breathable material configured to allow gases to pass through at least a portion thereof, and a plurality of discrete segments of thermoplastic elastomeric gel (“gel”) heat-fused or otherwise attached to the breathable material. The gel comprises an elastomeric polymer and a plasticizer, with a plasticizer-to-polymer ratio of from about 0.3 to about 50. The plurality of discrete segments defines at least one breathable gap between adjacent discrete segments. Methods of forming cushioning elements include forming a plurality of discrete segments of gel, securing each segment to a breathable material, and providing a gas path through the breathable material and between adjacent segments. Another method includes providing molten gel within a mold, providing at least a second portion of the gel within a permeable material, and solidifying the gel to form discrete segments of gel.