Cushioning element for sports apparel

<u>1. Technical Field</u>

0001The present invention concerns cushioning elements.

<u>2. Prior Art</u>

0002Cushioning elements play a great role in the field of sports apparel and are used for clothing for the most varied types of sports. Exemplarily, winter sports clothing, running wear, outdoor clothing, football wear, golf clothing, martial arts apparel or the like may be named here. Generally, cushioning elements serve to protect the wearer from shocks or blows, and for padding, for example, in case the wearer falls down. For this, the cushioning elements comprise typically one or more deformation elements which deform under an external effect of pressure or a shock impact and thereby absorb the impact energy.

0003A particularly important role is to be attributed to the cushioning elements in the construction of shoes, especially sports shoes. By means of cushioning elements in the form of soles, shoes are provided with a large number of different properties which can vary considerably, according to the specific type of the shoe. Primarily, shoe soles have a protective function. By their stiffness, which is higher than that of the shoe shaft, they protect the foot of the respective wearer against injuries caused, e.g., by pointed or sharp objects which the wearer of the shoe may step on. Furthermore, the shoe sole, due to its increased abrasion resistance, usually protects the shoe against an excessive wear. In addition, shoe soles may improve the contact of the shoe on the respective ground and thereby enable faster movements. A further function of a shoe sole may consist in providing certain stability. Moreover, a shoe sole may have a cushioning effect in order to, e.g., cushion the effects produced by the contact of the shoe with the ground.

0004Finally, a shoe sole may protect the foot from dirt or spray water and/or provide a large variety of other functionalities.

0005In order to accommodate the large number of functionalities, different materials are known from the prior art which can be used for manufacturing cushioning elements for sports apparel.

0006Exemplarily, reference is made here to cushioning elements made of ethylene-vinyl-acetate (EVA), thermoplastic polyurethane (TPU), rubber, polypropylene (PP) or polystyrene (PS), in the form of shoe soles. Each of these different materials provides a particular combination of different properties which are more or less well suited for soles of specific shoe types, depending on the specific requirements of the respective shoe type. For instance, TPU is very abrasion-resistant and tear-resistant. Furthermore, EVA distinguishes itself by a high stability and relatively good cushioning properties. Furthermore, the use of expanded materials, in particular, of expanded thermoplastic urethane (eTPU) was taken into account for the manufacture of a shoe sole. Expanded thermoplastic urethane has a low weight and particularly good properties of elasticity and cushioning. Furthermore, according to <patcit id="pcit0001" dnum="WO2005066250A"><text>WO 2005/066250</text></patcit>, a sole of expanded thermoplastic urethane can be connected to a shoe shaft without additional adhesive agents.

0007Moreover, <patcit id="pcit0002" dnum="US20050150132A1"><text>US 2005/0150132 A1</text></patcit> discloses footwear (e.g., shoes, sandals, boots, etc.) that is constructed with small beads stuffed into the footbed, so that the beads can shift about due to pressure on the footbed by the user's foot during normal use. <patcit id="pcit0003" dnum="WO2007082838A1"><text>WO 2007/082838 A1</text></patcit> discloses foams based on thermoplastic polyurethanes. <patcit id="pcit0004" dnum="US20110047720A1"><text>US 2011/0047720 A1</text></patcit> discloses a method of manufacturing a sole assembly for an article of footwear. <patcit id="pcit0005" dnum="WO2006015440A1"><text>WO 2006/015440 A1</text></patcit> discloses a method of forming a composite material.

0008<patcit id="pcit0006" dnum="WO8906501A"><text>WO 89/06501</text></patcit> discloses a resilient or padded insert for footwear. The insert is composed of individual beads of a thermoplastically deformable resilient foam material. The beads have a closed surface essentially impermeable to air and are fixed in their mutual positions under the influence of heat during sintering.

0009<patcit id="pcit0007" dnum="DE3605662C1"><text>DE 36 05 662 C1</text></patcit> relates to a method for the manufacture of a malleable, elastic damping- or cushioning body.

0010<patcit id="pcit0008" dnum="DE102011108744A1"><text>DE 10 2011 108 744 A1</text></patcit> relates to a method for the manufacture of a sole or part of a sole of a shoe, in particular a sports shoe, comprising the following steps: a) producing plastic bodies with dimensions in the three directions of space between 2 mm and 15 mm, preferably between 3 mm and 9 mm, wherein the plastic bodies consist of a foamed thermoplastic elastomer on the basis of urethane (TPU, E-TPU, TPE-U) and/or on the basis of polyetherblockamide (PEBA), b) loading the plastic bodies into a molding tool comprising a cavity corresponding to the shape of the sole or part of the sole to be manufactured, and c) connecting the plastic bodies which abut each other in the molding tool, wherein a binder is introduced into the molding tool and/or heat is applied to the plastic bodies for the connecting.

0011One disadvantage of the cushioning elements which are known from prior art, in particular of the known shoe soles, is, however, that these have a low breathability. This can considerably restrict the wearing comfort of the sports clothing which contains the cushioning element, since it leads to increased formation of sweat or a heat accumulation under the clothing. This is disadvantageous particularly in cases where the clothing is worn continuously for a longer time, as, for instance, during a walking tour or a round of golf or during winter sports. Furthermore, cushioning elements often increase the overall weight of the sports clothing in a not insignificant amount. This may have an adverse effect on the wearer's performance, in particular in sports of endurance or running.

0012Starting from prior art, it is therefore an object of the present invention to provide better cushioning elements. A further object of the present invention consists in improving the breathability of such a cushioning element and in further reducing its weight.

<u>3. Summary of the invention</u>

0013The claimed invention is defined by independent claim 1. Further embodiments of the claimed invention are described in the dependent claims. Any "aspect", "embodiment", or "example" described in the following that does not fall within the scope of the claimed invention thus defined is to be interpreted as background information provided to facilitate the understanding of the claimed invention.

0014Specifically, according to the claimed invention as defined by independent claim 1, a cushioning element comprises a first deformation element comprising a plurality of randomly arranged particles of an expanded material, wherein there are first voids between the particles. The first voids form cavities in which air is trapped.

0015The use of expanded material for the construction of a deformation element for a cushioning element of sports clothing is particularly advantageous, as this material is very light and has, at the same time, very good cushioning properties. The use of randomly arranged particles of the expanded material facilitates the manufacture of such a cushioning element considerably, since the particles can be handled particularly easily and no orientation is necessary during the manufacture. So, for instance, the particles can be filled, under pressure or by using a transport fluid, into a mold used for producing the deformation element or the cushioning element, respectively. Due to the voids between or within the particles of the expanded material, the weight of the deformation element und thus of the cushioning element is further reduced.

0016In a preferred embodiment, the particles of the expanded material comprise one or more of the following materials: expanded ethylene-vinyl-acetate, expanded thermoplastic urethane, expanded polypropylene, expanded polyamide, expanded polyether block amide, expanded polyoxymethylene, expanded polystyrene, expanded polyethylene, expanded polyoxyethylene, expanded ethylene propylene diene monomer. According to the specific requirement profile, one or more of these materials can be used advantageously for the manufacture due to their substance-specific properties.

0017In a further preferred embodiment, the particles of the expanded material have one or more of the following cross-sectional profiles: ring-shaped, oval, square, polygonal, round, rectangular, star-shaped. By the form of the particles, the size, the arrangement, and the shape of the voids between or within the particles and thus the density of the finished deformation element can be influenced. This, for their part, can have effects on the weight, heat insulation and breathability of the cushioning element.

0018According to another aspect of the invention, the first deformation element is manufactured by inserting the particles of the expanded material into a mold and exposing them after said insertion into the mold to a heating- and/or pressurizing- and/or steaming process. Thereby, the surfaces of the particles can be melted at least in part, so that the surfaces of the particles bond after cooling. Furthermore, the particles, due to the heating- and/or pressurizing- and/or steaming process, can also form a bond by a chemical reaction. Such a bond is highly robust and durable and does not require a use of further bonding agents, e.g. adhesives.

0019This allows the manufacture of a cushioning element with a first deformation element comprising a "loose" arrangement of randomly arranged particles of the expanded material, with voids and also channels or cavities (cf. below) in between the randomly arranged particles, or even a network of such voids, channels and cavities, without the danger of losing the necessary stability of the first deformation element. By at least partially fusing the particle surfaces, e.g. by means of a steaming process or some other process, the resulting bond is strong enough to ensure that, in particular, particles arranged at the surface of such a first deformation element or cushioning element are not "picked off' during use of the element.

0020Moreover, this renders the manufacture, inter alia, simpler, safer, more cost-effective and more environment-friendly. By adjusting, e.g., the pressure or the duration of the treatment, the size and shape of the voids between the particles of the expanded materials can be influenced, which, as already mentioned, can have effects on the weight, heat insulation and breathability of the cushioning element.

0021In a preferred embodiment, the particles comprise, before being inserted into the mold, a density of 10 - 150 g/l, preferably of 10 - 100 g/l and particularly preferably of 10 - 50 g/l.

0022According to a further aspect of the invention, the first deformation element can be manufactured by intermixing the particles of the expanded material with a further material which is removed later or which remains at least in part in the first voids of the first deformation element. This enables, on the one hand, a further exertion of influence on the properties of the voids forming between the particles. If, on the other hand, the second material is not removed completely from the voids, it can increase the stability of the deformation element.

0023In a further embodiment, a solidified liquid resides in the first voids of the deformation element. This solidified liquid may, for instance, be a transport fluid which is used for filling a form with the particles of the expanded material and which has solidified during the heating-/pressurizing-/steaming process. Alternatively, the particles inserted in the mold can also be coated continuously with the liquid during the heat-/pressure-/steam treatment, whereby said liquid solidifies gradually.

0024The first voids form cavities in which air is trapped. In this manner, the heat insulation of the cushioning element is increased.

0025As will be appreciated, air can comprise a lower heat conduction than solid materials, e.g. the particles of the expanded material. Hence, by interspersing the first deformation element with air filled cavities, the overall heat conduction of the first deformation element and thus the cushioning element can be reduced so that the foot of a wearer, e.g., is better insulated against loss of body heat through the foot.

0026In principle, the cavities could also trap another type of gas or liquid inside them or they could be evacuated.

0027According to a further aspect of the invention, the first voids form one or more channels through the first deformation element that are permeable to air and/or liquids. Thereby, the breathability of the deformation element is increased.

0028In this case, the use of randomly arranged particles is particularly advantageous. By the random arrangement, such channels develop alone with a certain statistical probability without a requirement of a specific arrangement of the particles when they are filled into a mold. This reduces the manufacturing expenses of such a deformation element significantly.

0029It will be appreciated that in general some of the first voids form cavities that trap air inside them and some of the first voids may form one or more channels throughout the first deformation element which are permeable to air and/or liquids.

0030Whether the first voids between the randomly arranged particles predominantly form cavities which trap air inside them or predominantly form channels as described above may dependent on the size, shape, material, density and so forth of the randomly arranged particles and also on the manufacturing parameters like temperature, pressure, packing density of the particles, etc.. It may also depend on the pressure load on the first deformation element.

0031For example, a first deformation element arranged in the heel region or forefoot region of a shoe will experience a strong compression during a gait cycle, e.g. during landing on the heel or push-off over the forefoot. Under such a pressure load, potential channels through the first deformation element might be sealed by the compressed and deformed randomly arranged particles. Also, during landing or push-off, the foot may be in close contact with the inner surface of the shoe. This might reduce the breathability of the sole. The sealing of the channels may, however, lead to the formation of additional cavities within the first deformation element, trapping air inside them, and may thus increase the heat insulation of the sole, which is particularly important when the sole contacts the ground, because here a large amount of body heat might be lost.

0032After push-off of the foot, on the other hand, the randomly arranged particles of the first deformation element might re-expand, leading to a re-opening of the channels. Also, in the expanded state, some of the cavities present in the loaded state might open up and form channels through the first deformation element that are permeable to air and/or liquids. Also the foot may not be in tight contact with the inner surface of the shoe anymore in such periods of the gait cycle.

0033Hence, breathability might be increased during this phase whereas heat insulation might be reduced.

0034This interplay between the formation of channels and cavities within the first deformation element depending on the state of compression may provide a preferred direction to an airflow through the first deformation element, e.g. in the direction of the compression and re-expansion of the first deformation element. For a first deformation element arranged in the sole of a shoe, e.g., the compression and re-expansion in a direction from the foot to the ground during a gait cycle may guide and control an airflow in the direction from the ground through the first deformation element to the foot, or out of the shoe.

0035Such a guided airflow can, in particular, be advantageously employed in combination with the high energy return provided by a first deformation element comprising randomly arranged particles of an expanded material, e.g. eTPU. For example, a first deformation element arranged in the forefoot region comprising randomly arranged particles of eTPU may, on the one side, provide high energy return to the foot of a wearer when pushing off over the toes. On the other hand, the re-expansion of the first deformation element after push-off may also lead to a guided or directed inflow of air into the forefoot region, leading to good ventilation and cooling of the foot. The re-expansion of the first deformation element may even lead to a suction effect, sucking air into channels through the first deformation element, and may thus facilitate ventilation and cooling of the foot even further. Such an efficient cooling can provide the foot of a wearer with additional "energy" and generally improve performance, wellbeing and endurance of an athlete.

0036While the above example was specifically directed to a first deformation element arranged in the forefoot region, its main purpose was to exemplified the advantageous combination of energy return and directed airflow that may be provided by embodiments of inventive cushioning elements with first deformation elements. It is clear to the skilled person that this effect can also be advantageously employed in other regions of a sole. Herein, the direction of compression and re-expansion and the direction of guidance of the airflow may vary depending on the specific arrangement of the first deformation element and its intended use.

0037In addition, it is also possible that the manufacture of the cushioning element comprises the creation of one or more predefined channels through the first deformation element that are permeable to air and/or liquids.

0038This allows further balancing the heat insulating properties vs. e.g. the breathability of the cushioning element. The predefined channel(s) may e.g. be created by corresponding protrusions or needles in a mold that is used for the manufacture of the cushioning element.

0039In a further optional embodiment, the cushioning element further comprises a reinforcing element, in particular, a textile reinforcing element and/or a foil-like reinforcing element and/or a fiber-like reinforcing element. This enables to manufacture a deformation element with very low density/very low weight and a high number of voids and to ensure, at the same time, the necessary stability of the deformation element.

0040In a preferred embodiment, the reinforcing element is provided as a foil comprising thermoplastic urethane. Thermoplastic urethane foils are particularly well suited for use in combination with particles of expanded material, especially particles of expanded thermoplastic urethane.

0041Furthermore, in preferred embodiments, the foil can be provided permeable to air and/or liquids in at least one direction. So, the foil may, for instance, be permeable to air in one or both directions, said foil, however, being permeable to liquids only in one direction, thus being able to protect against moisture from the outside, e.g. water.

0042In a particularly preferred embodiment, a cushioning element in which the first voids form one or more channels permeable to air and/or liquids through the first deformation element, is combined with a reinforcing element, in particular a textile reinforcing element and/or a foil-like reinforcement element, especially a foil comprising thermoplastic urethane, and/or a fiber-like reinforcing element, whereby the reinforcing element comprises at least one opening which is arranged in such a way that air and/or liquid passing through one or more channels in the first deformation element can pass in at least one direction through the at least one opening of the reinforcing element. This enables a sufficient stability of the deformation element without influencing the breathability provided by the channels. In case the at least one opening of the reinforcing element is furthermore, for example, only permeable to liquids in the direction from the foot towards the outside, the reinforcing element can also serve to protect from moisture from the outside.

0043According to a further aspect of the invention, the first deformation element takes up a first partial region of the cushioning element, and the cushioning element further comprises a second deformation element. Thereby, the properties of the cushioning element can be selectively influenced in different areas, what increases the constructive freedom and the possibilities of exerting influence significantly.

0044In a preferred embodiment, the second deformation element comprises a plurality of randomly arranged particles of an expanded material, whereby second voids are provided within the particles and/or between the particles of the second deformation element which on average are smaller than the first voids of the first deformation element. In this case, a size of the second voids which is smaller on average means, for example, a greater density of the expanded material of the second deformation material and thus a higher stability and deformation stiffness, but, possibly, also a lower breathability. By combining different deformation elements with voids of different sizes (on average), hence, the properties of deformation elements can be selectively influenced in different areas.

0045It is for example conceivable that the randomly arranged particles in the first deformation element and the manufacturing parameters are chosen such that the first voids predominantly form channels throughout the first deformation element permeable to air and/or liquids, thus creating good breathability in this region. The randomly arranged particles in the second deformation element and the manufacturing parameters may be chosen such that the second voids predominantly form cavities trapping air inside them, thus creating good heat insulation in this region. The opposite is also conceivable.

0046For example, the toe region and the forefoot region are preferred regions where permeability to air should be enabled. Furthermore, the medial region is preferably configured more inflexibly so as to ensure a better stability. In order to optimally support the walking conditions of a shoe, the heel region and the forefoot region of a sole preferably have a particular padding. Owing to the most varied requirements for different shoe types and kinds of sports, the sole can be adapted exactly to the requirements, according to the aspects described herein.

0047According to a further aspect of the invention, a possibility to arrange the different regions or the different deformation elements, respectively, in a cushioning element consists in manufacturing these in one piece in a manufacturing process. For doing this, for example, a mold is loaded with one or more types of particles of expanded materials. For instance, a first partial region of the mold is loaded with a first type of particles of an expanded material, and a second partial region of the mold is loaded with a second type of particles. The particles may differ in their starting materials, their size, their density, their color etc. In addition, individual partial regions of the mold may also be loaded with non-expanded material. After insertion of the particles and, if necessary, further materials into the mold, these may be subjected, as already described herein, to a pressurizing- and/or steaming- and/or heating process. By an appropriate selection of the parameters of the pressurizing- and/or steaming- and/or heating process - such as, for example, the pressure, the duration of the treatment, the temperature, etc. - in the individual partial regions of the mold as well as by suitable tool- and machine adjustments, the properties of the manufactured cushioning element can be further influenced in individual partial regions.

<u>4. Short Description of the Figures</u>

0048In the following detailed description, currently preferred embodiments of the cushioning elements according to the invention are described with reference to the following figures. These figures show: <dl id="dl0001"><dt><b>Fig. 1</b></dt><dd>An embodiment of a cushioning element configured as midsole;</dd><dt><b>Fig. 2</b></dt><dd>An embodiment of particles of an expanded material which have an oval cross-sectional profile;</dd><dt><b>Fig. 3</b></dt><dd>An embodiment of a cushioning element provided as midsole, wherein a solidified liquid resides in the first voids;</dd><dt><b>Fig. 4</b></dt><dd>An embodiment of a cushioning element provided as midsole with a first reinforcing element and a second foil-like reinforcing element;</dd><dt><b>Fig. 5</b></dt><dd>A cross-section of a shoe according to an aspect of the present invention, with a cushioning element configured as a sole, and a reinforcing element which comprises a series of openings which are permeable to air and liquids;</dd><dt><b>Fig. 6</b></dt><dd>A further embodiment of a cushioning element provided as a midsole and with a deformation element which constitutes a first partial region of the cushioning element;</dd><dt><b>Fig. 7</b></dt><dd>A cushioning element configured as a midsole, according to a further aspect of the invention, which comprises a first deformation element and a second deformation element;</dd><dt><b>Figs. 8a-b</b></dt><dd>An illustration of the influence of the compression and re-expansion of the randomly arranged particles on an airflow through a first deformation element; and</dd><dt><b>Figs. 9a-f</b></dt><dd>An embodiment of a shoe according to the invention comprising an embodiment of a cushioning element according to the invention.</dd></dl>

<u>5. Detailed description of preferred embodiments</u>

0049In the following detailed description, currently preferred embodiments of the invention are described with respect to midsoles.

0050<figref idref="f0001"><b>Fig. 1</b></figref> shows a cushioning element <b>100</b> configured as part of a midsole, according to an aspect of the invention, which comprises a deformation element <b>110.</b> The deformation element <b>110</b> has a plurality of randomly arranges particles <b>120</b> of an expanded material, whereby first voids <b>130</b> are comprised within the particles <b>120</b> and/or between the particles <b>120</b>.

0051In the embodiment shown in <figref idref="f0001"><b>Fig. 1</b></figref>, the deformation element <b>110</b> constitutes the whole cushioning element <b>100</b>. In further preferred embodiments, however, the deformation element <b>110</b> takes up only one or more partial regions of the cushioning element <b>100</b>. It is also possible that the cushioning element <b>100</b> comprises several deformation elements <b>110</b> which each form a partial region of the cushioning element <b>100</b>. Thereby, the different deformation elements <b>110</b> in the various partial regions of the cushioning element <b>100</b> may comprise particles <b>120</b> of the same expanded material or of different expanded materials. The voids <b>130</b> between the particles <b>120</b> of the expanded material of the respective deformation elements <b>110</b> may each, on average, also have the same size or different sizes.

0052The average size of the voids is to be determined, for example, by determining the volume of the voids in a defined sample amount of the manufactured deformation element, e.g. in <b>1</b> cubic centimeter of the manufactured deformation element. A further possibility to determine the average size of the voids is, for example, to measure of the diameter of a specific number of voids, e.g. of 10 voids, and to subsequently form of the mean value of the measurements. As a diameter of a void, for example, the largest and the smallest distance between the walls of the respective void may come into question, or another value which can be consistently measured by the skilled person.

0053By an appropriate combination of different expanded materials and/or different average sizes of the voids <b>130</b>, deformation elements <b>110</b> with different properties for the construction of a cushioning element <b>100</b> can be combined with each other. Thereby, the properties of the cushioning element <b>100</b> can be influenced locally by selection.

0054In a preferred embodiment, the particles <b>120</b> of the expanded material can comprise in particular one or more of the following materials: expanded ethylene-vinyl-acetate (eEVA), expanded thermoplastic urethane (eTPU), expanded polypropylene (ePP), expanded polyamide (ePA), expanded polyether block amid (ePEBA), expanded polyoxymethylene (ePOM), expanded polystyrene (ePS), expanded polyethylene (ePE), expanded polyethylene(ePOE), expanded polyoxyethylene (ePOE), expanded ethylene-propylene-diene monomer (eEPDM).

0055Each of these materials has characteristic properties which, according to the respective requirement profile of the cushioning element <b>100</b>, can be advantageously used for manufacture. So, in particular, eTPU has excellent cushioning properties which remain unchanged also at higher or lower temperatures. Furthermore, eTPU is very elastic and returns the energy stored during compression almost completely during subsequent expansion. This is particularly advantageous in embodiments of cushioning elements <b>100</b> which are used for shoe soles.

0056For manufacturing such a cushioning element <b>100</b>, the particles <b>120</b> of the expanded material, according to a further aspect of the invention, can be introduced into a mold and subjected to a heating- and/or pressurization- and/or steaming process after the filling of the mold. By varying the parameters of the heating- and/or pressurization- and/or steaming process, the properties of the manufactured cushioning elements can be further influenced. So, in particular, it is possible, by the pressure to which the particles <b>120</b> are subjected in the mold, to influence the resulting thickness of the manufactured cushioning element or the shape or the size, respectively, of the voids <b>130</b>. The thickness and the size of the voids <b>130</b> thereby depend also on the pressure used for inserting the particles <b>120</b> into the mold. So, for example, in one embodiment, the particles <b>120</b> may be introduced into the mold by means of compressed air or a transport fluid.

0057The thickness of the manufactured cushioning element <b>100</b> is further influenced by the (mean) density of the particles <b>120</b> of the expanded material before the filling of the mold. In one embodiment, before the filling of the mold, this density lies in a range between 10 - 150 g/l, preferably in a range between 10 - 100 g/l, and particularly preferred in a range of 10 - 50 g/l. These ranges have turned out to be particularly advantageous for the manufacture of cushioning elements <b>100</b>. In general, by appropriately selecting the density of the particles <b>120</b> the properties of the cushioning element <b>100</b> can be advantageously influenced according to the respective profile of requirements.

0058It is to be appreciated that the manufacturing methods, options and parameters described herein allow the manufacture of a cushioning element <b>100</b> with a first deformation element <b>110</b> comprising a "loose" arrangement of randomly arranged particles <b>120</b>, as shown in <figref idref="f0001"><b>Fig. 1</b></figref>. Even in the presence of first voids <b>130</b>, which may further form channels or cavities (cf. below) or even a network of voids, channels and cavities in between the randomly arranged particles <b>120</b>, the necessary stability of the first deformation element <b>110</b> can be provided. E.g. by at least partially fusing the surfaces of the particles <b>120</b>, for example by means of a steaming process or some other processes, the resulting bond is strong enough to ensure that, in particular, particles <b>120</b> arranged at the surface of such a first deformation element <b>110</b> or cushioning element <b>100</b> are not "picked off' during use.

0059According to a further aspect of the invention, the particles <b>120</b> of the expanded material for the manufacture of the cushioning element <b>100</b> are first intermixed with a further material. This may be particles of another expanded or non-expanded material, a powder, a gel, a liquid or the like. In a preferred embodiment, wax-containing materials or materials that behave like wax are used. In a preferred embodiment, the additional material is removed from the voids <b>130</b> in a later manufacturing step, for example, after filling the mixture into a mold and/or a heating- and/or pressurizing- and/or steaming process. The additional material can, for example, be removed again from the voids <b>130</b> by a further heat treatment, by compressed air or by means of a solvent. By an appropriate selection of the further material and of the ratio between the amount of particles <b>130</b> and the amount of further material as well as the manner in which the further material is removed again, the properties of the deformation element <b>110</b> and thereby of the cushioning element <b>110</b> and, in particular, the shape and size of the voids <b>130</b> can be influenced. In another embodiment of the present invention, the additional material, however, remains at least partially in the voids <b>130</b>. This can, for example, have a positive influence on stability and/or tensile strength of the cushioning element <b>100</b>.

0060According to a further aspect of the invention, the particles <b>120</b> can also show different cross-sectional profiles. There may, for example, be particles <b>120</b> with ring-shaped, oval, square, polygonal, round, rectangular or star-shaped cross-section. The particles <b>120</b> may have a tubular form, i.e. comprise a channel, or else have a closed surface which may surround a hollow space inside. The shape of the particles <b>120</b> has a substantial influence on the packing density of the particles <b>120</b> after insertion into the mold. The packing density depends further on, e.g., the pressure under which the particles <b>120</b> are filled into the mold or to which they are subjected in the mold, respectively. Furthermore, the shape of the particles <b>120</b> has an influence on whether the particles <b>120</b> comprise a continuous channel or a closed surface. The same applies to the pressure used during the filling of the mold or within the mold, respectively. In a similar manner, also the shape and the average size of the voids <b>130</b> between the particles <b>120</b> can be influenced.

0061Furthermore, the configuration of the particles <b>120</b> and the pressure used during the filling and/or in the mold determine the likelihood that the voids <b>130</b> form one or more channels permeable to air and/or to liquids through the deformation element <b>110</b>. As the particles <b>120</b> are arranged randomly, according to an aspect of the invention, such continuous channels develop, with certain statistic likelihood, on their own, without the need of specific expensive manufacturing processes as, for example, an alignment of the particles <b>120</b> or the use of complicated molds. The likelihood of this depends, as already mentioned, inter alia, on the shape of the particles <b>120</b>, in particular on the maximum achievable packing density of the particles <b>120</b> in case of a given shape. So, for instance, cuboid particles <b>120</b> can, as a rule, be packed more densely than star-shaped or round/oval particles <b>120</b>, what leads to smaller voids <b>130</b> on the average and to a reduced likelihood of the development of channels permeable to air and/or liquids. There is also a higher probability that channels develop which are permeable to air, because air is gaseous and therefore able to pass also through very small channels which are not permeable to liquids due to the surface tension of the liquid. This means, in particular, that according to an aspect of the invention, deformation elements <b>120</b> can be manufactured without increased manufacturing efforts by an appropriate selection of the shape and size of the particles <b>120</b> and/or an appropriate filling pressure of the particles <b>120</b>, and/or an adaption of the parameters of the heating- and/or pressurizing- and/or steaming process to which the particles <b>120</b> are possibly subjected in the mold, these deformation elements <b>110</b> being indeed breathable, but, at the same time, impermeable to liquids. This combination of properties is particularly advantageous for sports apparel which is worn outside closed rooms.

0062Moreover, the first voids 130 form cavities in which air is trapped. In this manner, the heat insulation of the cushioning element 100 is increased. As will be appreciated, air can comprise a lower heat conduction than solid materials, e.g. the particles 120 of the expanded material. Hence, by interspersing the first deformation element 110 with air filled cavities, the overall heat conduction of the first deformation element 110 and thus the cushioning element 100 is reduced so that the foot of a wearer, e.g., is better insulated against loss of body heat through the foot.

0063In general some of the first voids <b>130</b> form cavities that trap air inside them and some of the first voids <b>130</b> may form one or more channels throughout the first deformation element <b>110</b> which are permeable to air and/or liquids.

0064As already hinted at above, whether the first voids <b>130</b> between the randomly arranged particles <b>120</b> predominantly form cavities which trap air inside them or predominantly form channels permeable to air and/or liquids may dependent on the size, shape, material, density and so forth of the randomly arranged particles <b>120</b> and also on the manufacturing parameters like temperature, pressure, packing density of the particles <b>120</b>, etc.. It may also depend on the pressure load on the first deformation element <b>110</b> or cushioning element <b>100</b>.

0065For example, the forefoot region or the heel region of the first deformation element <b>110</b> will experience a strong compression during a gait cycle, e.g. during landing on the heel or push-off over the forefoot. Under such a pressure load, potential channels through the first deformation element <b>110</b> might be sealed. Also, during landing or push-off, the foot may be in close contact with the top surface of cushioning element <b>100</b>. This might reduce the breathability. The sealing of the channels may, however, lead to the formation of additional cavities within the first deformation element <b>110</b>, trapping air inside them, and thus increase the heat insulation of the cushioning element <b>100</b>, which is particularly important during ground contact, because here a large amount of body heat might be lost.

0066After push-off of the foot, on the other hand, the randomly arranged particles <b>120</b> of the first deformation element <b>110</b> might re-expand, leading to a re-opening of the channels. Also, in the expanded state, some of the cavities present in the loaded state might open up and form channels through the first deformation element <b>110</b> that are permeable to air and/or liquids. Also the foot may not be in tight contact with the top surface of the cushioning element <b>100</b> anymore in such periods of the gait cycle. Hence, breathability might be increased during this phase whereas heat insulation might be reduced.

0067This interplay between the formation of channels and cavities within the first deformation element <b>110</b> depending on the state of compression may provide a preferred direction to an airflow through the first deformation element <b>110</b> and cushioning element <b>100</b>, e.g. in the direction of the compression and re-expansion. For a cushioning element <b>100</b> arranged in the sole of a shoe, e.g., the compression and re-expansion in a direction from the foot to the ground during a gait cycle may guide and control an airflow in that.

0068<figref idref="f0005"><b>Figs. 8a</b></figref><b>-b</b> show an illustration of a directed airflow through a cushioning /deformation element discussed above. Shown is cushioning element <b>800</b> with a first deformation element <b>810</b> that comprises randomly arranged particles <b>820</b> of an expanded material. There are also first voids <b>830</b> between and/or within the particles <b>820.</b><figref idref="f0005"><b>Fig. 8a</b></figref> shows a compressed state wherein the compression is effected by a pressure acting in a vertical direction in the example shown here. <figref idref="f0005"><b>Fig. 8b</b></figref> shows a re-expanded state of the first deformation element <b>810</b>, wherein the (main) direction of re-expansion is indicated by the arrow <b>850</b>.

0069It is clear to the skilled purpose that <figref idref="f0005"><b>Figs. 8a</b></figref><b>-b</b> only serve illustrative purposes and the situation shown in these figures may deviate from the exact conditions found in an actual cushioning element. In particular, in an actual cushioning element the particles <b>820</b> and voids <b>830</b> form a three-dimensional structure whereas here only two dimensions can be shown. This means, in particular, that in an actual cushioning element the potential channels formed by the voids <b>830</b> may also "wind through" the first deformation element <b>810</b>, including in directions perpendicular to the image plane of <figref idref="f0005"><b>Figs. 8a</b></figref><b>-b.</b>

0070In the compressed state, <figref idref="f0005"><b>Fig. 8a</b></figref>, the individual particles <b>820</b> are compressed and deformed. Because of this deformation of the particles <b>820</b>, the voids <b>830</b> in the first deformation element <b>830</b> may change their dimensions and arrangement. In particular, channels winding through the first deformation element <b>810</b> in the unloaded state might now be blocked by some of the deformed particles <b>820</b>. On the other hand, additional cavities may, for example, be formed within the first deformation element <b>810</b> by sections of sealed or blocked channels. Hence, an airflow through the first deformation element might be reduced or blocked, as indicated by the arrows <b>860</b>.

0071With re-expansion <b>850</b> of the first deformation element <b>810</b>, cf. <figref idref="f0005"><b>Fig. 8b</b></figref>, the particles <b>820</b> may also re-expand and return (more or less) to the form and shape they had before the compression. By this re-expansion, which may predominantly occur in the direction the pressure which caused the deformation had acted (i.e. a vertical direction in the case shown here, cf. <b>850</b>), previously blocked channels might reopen and also previously present cavities might open up and connect to additional channels through the first deformation element <b>810.</b> The re-opened and additional channels may herein predominantly "follow" the re-expansion <b>850</b> of the first deformation element <b>810</b>, leading to a directed airflow through the first deformation element <b>810</b>, as indicated by arrows <b>870</b>. The re-expansion of the first deformation element <b>810</b> might even actively "suck in" air, further increasing the airflow <b>870</b>.

0072Returning to the discussion of <figref idref="f0001"><b>Fig. 1</b></figref>, a guided airflow as discussed above can, in particular, be advantageously employed in combination with the high energy return provided by a first deformation element <b>110</b> comprising randomly arranged particles <b>120</b> of an expanded material, e.g. eTPU. For example, in the forefoot region, the cushioning element <b>100</b> with first deformation element <b>110</b> may, on the one side, provide high energy return to the foot of a wearer when pushing off over the toes. On the other hand, the re-expansion of the first deformation element <b>110</b> after push-off may also lead to a guided inflow of air into the forefoot region, leading to good ventilation and cooling of the foot. The re-expansion of the first deformation element <b>110</b> may even lead to a suction effect, sucking air into channels through the first deformation element <b>110</b>, and may thus facilitate ventilation and cooling of the foot even further. Such an efficient cooling can provide the foot of a wearer with additional "energy" and generally improve performance, wellbeing and endurance of an athlete.

0073A similar effect may also be provided, e.g., in the heel region of the cushioning element <b>100.</b>

0074As a further option, it is also possible that the manufacture of the cushioning element <b>100</b> comprises the creation of one or more predefined channels (not shown) through the first deformation element <b>110</b> that are permeable to air and/or liquids. This may allow further balancing the heat insulating properties vs. e.g. the breathability of the cushioning element <b>100</b>. The predefined channel(s) may e.g. be created by corresponding protrusions or needles in a mold that is used for the manufacture of the cushioning element <b>100</b>.

0075<figref idref="f0001"><b>Fig. 2</b></figref> shows an embodiment of particles <b>200</b> of an expanded material which have an oval cross-section. The particles have, in addition, a wall <b>210</b> and a continuous channel <b>220</b>. Due to the oval shape of the particles <b>200</b> of the expanded material, voids <b>230</b> develop between the particles. The average size of these voids <b>230</b> is dependent on the shape of the particles <b>200</b>, in particular on the maximum achievable packing density of the particles <b>200</b> in case of a given mold, as already explained above. So, for example, cuboid or cube-shaped particles can, as a rule, be packed more densely than spherical or oval-shaped particles <b>200</b>. Furthermore, in a deformation element manufactured from the randomly arranged particles <b>200</b>, due to the random arrangement of the particles <b>200</b>, one or more channels permeable to air and/or liquids develop with a certain statistical probability, without an alignment of the particles or the like being necessary. This facilitates the manufacturing effort significantly.

0076In the embodiment of the particles <b>200</b> shown in <figref idref="f0001"><b>Fig. 2</b></figref>, the probability of a development of such channels is further increased by the tubular configuration of the particles <b>200</b> with a wall <b>210</b> and a continuous channel <b>220</b>, since the channels permeable to air and/or liquids may extend along the channels <b>220</b> within the particles as well as along the voids <b>230</b> between the particles and along a combination of channels <b>230</b> within and voids 220 between the particles <b>200</b>.

0077The average size of the voids <b>220</b> as well as the probability of developing channels permeable to air and/or liquids in the finished deformation element depend furthermore on the pressure with which the particles are filled into a mold used for manufacture and/or on the parameters of the heating- and/or pressurizing- and/or steaming process to which the particles are possibly subjected in the mold. In addition, it is possible that the particles <b>200</b> have one or more different colors. This influences the optical appearance of the finished deformation element or cushioning element, respectively. In a particularly advantageous embodiment, the particles <b>200</b> are made of expanded thermoplastic urethane and are colored with a color comprising liquid thermoplastic urethane. This leads to a very durable coloring of the particles and hence of the deformation element or cushioning element, respectively.

0078<figref idref="f0002"><b>Fig. 3</b></figref> shows a further embodiment of a cushioning element <b>300</b> configured as a midsole and comprising a deformation element <b>310</b>, according to an aspect of the present invention. The deformation element <b>310</b> comprises a number of randomly arranged particles <b>320</b> of an expanded material, whereby first voids <b>330</b> are present between the particles <b>320</b>. In the embodiment shown in <figref idref="f0002"><b>Fig. 3</b></figref>, however, a solidified liquid resides between the voids <b>330</b>. Said solidified liquid <b>330</b> may, for instance, be a solidified liquid <b>330</b> comprising one or more of the following materials: thermoplastic urethane, ethylene-vinyl-acetate or other materials which are compatible with the respective expanded material of the particles <b>320</b>. Furthermore, in an embodiment, the solidified liquid <b>330</b> may serve as transport fluid for filling the particles <b>320</b> of the expanded material into a mold used for manufacturing the cushioning element <b>300</b>, whereby the transport fluid solidifies during the manufacturing process, for example, during a heating- and/or pressurizing- and/or steaming process. In a further embodiment, the particles <b>320</b> introduced into a mold are continuously coated with the liquid <b>330</b> which solidifies gradually during this process.

0079The solidified liquid increases the stability, elasticity and/or tensile strength of the deformation element <b>330</b> and thus allows the manufacture of a very thin cushioning element <b>300</b>, according to an aspect of the invention. This may, on the one hand, reduce the weight of such a cushioning element <b>300</b> additionally. Furthermore, the low thickness of such a cushioning element <b>300</b> allows the use of the cushioning element <b>300</b> in regions where too great a thickness would lead to a significant impediment of the wearer.

0080By means of an appropriate combination of the materials of the particles <b>320</b> and the solidified liquid <b>330</b> as well as a variation of the respective percentages in the deformation element <b>310</b>, according to the present invention, deformation elements <b>310</b> with a plurality of different properties such as thickness, elasticity, tensile strength, compressibility, weight and the like can be manufactured.

0081<figref idref="f0002"><b>Fig. 4</b></figref> shows a further embodiment according to an aspect of the invention. <figref idref="f0002"><b>Fig. 4</b></figref> shows a cushioning element <b>410</b> configured as a midsole. The cushioning element <b>400</b> comprises a deformation element <b>410</b> which comprises a number of randomly arranged particles of an expanded material, with first voids being present within the particles and/or between the particles. The cushioning element <b>400</b> further comprises a first reinforcing element <b>420</b> which preferably is a textile and/or fiber-like reinforcing element <b>420</b>. The reinforcing element <b>420</b> serves to increase the stability of the deformation element <b>410</b> in selected regions, in the embodiment shown in <figref idref="f0002"><b>Fig. 4</b></figref> in the region of the midfoot. The use of a textile and/or fiber-like reinforcing element <b>420</b> in combination with a deformation element <b>410</b> allows, according to one or more aspects of the present invention, the manufacture of a very light cushioning element <b>400</b> which nevertheless has the necessary stability. Such an embodiment of a cushioning element <b>400</b> can be used in a particularly advantageous manner in the construction of shoe soles. In further embodiments, the reinforcing element <b>420</b> can also be another element increasing the stability of the deformation element <b>420</b> or a decorative element or the like.

0082According to a further aspect of the invention, the cushioning element <b>400</b> shown in <figref idref="f0002"><b>Fig. 4</b></figref> furthermore comprises a foil-like reinforcing element <b>430</b>. In a particularly preferred embodiment, this is a foil comprising thermoplastic urethane. In particular in combination with a deformation element <b>410</b>, which comprises randomly arranged particles which, for their part, comprise expanded thermoplastic urethane, such a foil <b>430</b> can be used advantageously, as the foil can form a chemical bound with the expanded particles which is extremely durable and resistant and does not require an additional use of adhesives. This makes the manufacture of such cushioning elements <b>400</b> easier, more cost-effective and more environment-friendly.

0083The use of a foil-like reinforcing element <b>430</b> can, on the one hand, increase the (form) stability of the cushioning element <b>400</b>, and, on the other hand, the foil-like reinforcing element <b>430</b> can protect the cushioning element <b>400</b> against external influences as, for example, abrasion, moisture, UV light or the like. In a further preferred embodiment, the first reinforcing element <b>420</b> and/or the foil-like reinforcing element <b>430</b> further comprise at least one opening which is arranged such that air and/or liquids flowing through one or more channels permeable to air and/or liquids, which, as described above, may develop, according to an aspect of the invention within the deformation element <b>410</b>, can pass in at least one direction through the at least one opening in the first reinforcing element <b>420</b> and/or the foil-like reinforcing element <b>430</b>. This facilitates, for example, the manufacture of breathable cushioning elements <b>400</b> which, at the same time, use the advantages of additional reinforcing elements <b>420, 430</b> described above and which at the same time protect against moisture from the outside. Thereby, in a particularly preferred embodiment, the foil-like reinforcing element <b>430</b> is designed as a membrane which is breathable, but is permeable to liquids in one direction only, preferably in the direction from the foot outwards, so that no moisture from the outside can penetrate from the outside into the shoe and to the foot of the wearer, while at the same time the permeability to air of the membrane ensures breathability.

0084<figref idref="f0003"><b>Fig. 5</b></figref> shows a schematic cross-section of a shoe <b>500</b>, according to another aspect of the present invention. The shoe <b>500</b> comprises a cushioning element designed as a midsole <b>505</b>, which cushioning element comprises a deformation element <b>510</b> which, on its part, comprises randomly arranged particles of an expanded material. Here, voids are present within the particles and/or between the particles. Preferably, the voids, as described above, develop one or more channels permeable to air or liquids through the deformation element <b>510</b>. In a particularly preferred embodiment, the materials and the manufacturing parameters are selected such that the channels, as described above, are indeed permeable to air, but not to liquids. This enables the manufacture of a shoe <b>500</b> which, though being breathable, protects the foot of the wearer at the same time against moisture from the outside.

0085The cushioning element <b>505</b> shown in <figref idref="f0003"><b>Fig. 5</b></figref> further comprises a reinforcing element <b>520</b> which is configured as a cage element in the presented embodiment and which, for example, encompasses a shoe upper three-dimensionally. In order to avoid negative influences on the breathability of the shoe, the reinforcing element <b>520</b> preferably comprises a succession of openings <b>530</b> arranged such that air and/or fluid flowing through the channels in the deformation element <b>510</b> can flow, in at least one direction, through the at least one opening <b>530</b> in the reinforcing element <b>520</b>, e.g. from the inside to the outside. Furthermore, the cushioning element <b>530</b> preferably comprises a series of outer sole elements <b>540</b>. These can fulfill a number of functions. So, the outer sole elements <b>540</b> can additionally protect the foot of the wearer against moisture and/or influence the cushioning properties of the sole <b>505</b> of the shoe <b>500</b> in a favorable manner and/or further increase the ground contact of the shoe <b>500</b> and so forth.

0086<figref idref="f0003"><b>Fig. 6</b></figref> and <figref idref="f0004"><b>Fig. 7</b></figref> show further embodiments of cushioning elements <b>600, 700</b> provided as midsoles, each comprising a first deformation element <b>610, 710</b> which takes up a first partial region of the cushioning element <b>600, 700,</b> and, in addition, each comprising a second deformation element <b>620, 720</b> which takes up a second partial region of the cushioning element <b>600, 700.</b> The different deformation elements <b>610, 710, 620, 720</b> each comprise randomly arranged particles of an expanded material, with voids being present within the particles and/or between the particles of the deformation elements <b>610, 710, 620, 720.</b> For the different deformation elements <b>610, 710, 620, 720,</b> particles of the same expanded material or of different materials may be used. Furthermore, the particles may have the same cross-sectional profile or different shapes. The particles may also have different sizes, densities, colors etc. before the filling into the molds (not shown) which are used for the manufacture of the cushioning elements <b>600, 700.</b> According to an aspect of the invention, the particles for the first deformation element <b>610, 710</b> and the second deformation element <b>620, 720</b> as well as the manufacturing parameters are selected such that the voids in the first deformation element <b>610</b> or <b>710,</b> respectively, show a different size on average than the voids in the second deformation element <b>620</b> or <b>720.</b>

0087For example, the particles and the manufacturing parameters (e.g. pressure, duration and/or temperature of a heating- and/or pressurizing- and/or steaming process) can be selected such that the voids in the second deformation element <b>620</b> or <b>720</b>, respectively, are smaller on average than the voids in the first deformation element <b>610</b> or <b>710</b>, respectively. Therefore, by combining different deformation elements, properties such as, e.g., elasticity, breathability, permeability to liquids, heat insulation, density, thickness, weight etc. of the cushioning element can be selectively influenced in individual partial regions. This increases the constructional freedom to a considerable extent. In further preferred embodiments, the cushioning element comprises an even higher number (three or more) of different deformation elements which each take up a partial region of the cushioning element. Here, all deformation elements may comprise different properties (e.g., size of the voids), or several deformation elements may have similar properties or comprise the same properties.

0088As one example, it is conceivable that the randomly arranged particles in the first deformation element <b>610, 710</b> and the manufacturing parameters are chosen such that the first voids between and/or within the randomly arranged particles of the first deformation element <b>610, 710</b> predominantly form channels throughout the first deformation element <b>610, 710</b> that are permeable to air and/or liquids, thus creating good breathability in this region. The randomly arranged particles in the second deformation element <b>620, 720</b> and the manufacturing parameters, on the other hand, may be chosen such that the second voids between and/or within the randomly arranged particles in the second deformation element <b>620, 720</b> predominantly form cavities which trap air inside them, thus creating good heat insulation in this region. The opposite situation is also possible.

0089Finally, <figref idref="f0006"><b>Figs. 9a</b></figref><b>-f</b> show an embodiment of a shoe <b>900</b> according to the invention comprising an embodiment of a cushioning element <b>905</b> according to the invention.

0090<figref idref="f0006"><b>Fig. 9a</b></figref> shows the lateral side of the shoe <b>900,</b><figref idref="f0006"><b>Fig. 9b</b></figref> the medial side. <figref idref="f0007"><b>Fig. 9c</b></figref> shows the back of the shoe <b>900</b> and <figref idref="f0008"><b>Fig. 9d</b></figref> the bottom side. Finally, <figref idref="f0008"><b>Figs. 9e</b></figref> and <figref idref="f0009"><b>9f</b></figref> show enlarged pictures of the cushioning element <b>905</b> of the shoe <b>900</b>.

0091The cushioning element <b>905</b> comprises a first deformation element <b>910</b>, comprising randomly arranged particles <b>920</b> of an expanded material with first voids <b>930</b> between the particles <b>920</b>. All explanations and considerations put forth above with regard to the embodiments of cushioning elements <b>100, 300, 400, 505, 600, 700, 800</b> and first deformation elements <b>110, 310, 410, 510, 610, 710, 810</b> also apply here.

0092Furthermore, emphasis is once again put on the fact that by at least partially fusing the particle surfaces, e.g. by means of a steaming process or some other process, the resulting bond is strong enough so that the particles <b>930</b> are not "picked of' during use of the shoe <b>900.</b>

0093The cushioning element further comprises a reinforcing element <b>950</b> and an outsole layer <b>960</b>. Both reinforcing element <b>950</b> and outsole layer <b>960</b> may comprise several subcomponents which may or may not form one integral piece. In the embodiment shown here, the reinforcing element <b>950</b> comprises a pronation support in the medial heel region and a torsion bar in the region of the arch of the foot. The outsole layer <b>960</b> comprises several individual subcomponents arranged along the rim of the sole and in the forefoot region.

0094Finally, the shoe <b>900</b> comprises an upper <b>940</b>.

0095The shoe <b>900</b> with cushioning element <b>905</b> may, in particular, provide a high energy return to the foot of a wearer, combined with good heat insulation properties during ground contact and high ventilation, potentially with directed airflow, during other times of a gait cycle, thus helping to increase wearing comfort, endurance, performance and general wellbeing of an athlete.