Athletic gear or other devices comprising post-molded expandable components

Abstract

A device (e.g., an article of athletic gear) comprising a post-molded expandable component, which is a part of the device that is configured to be expanded or has been expanded after being molded. This may allow the post-molded expandable component to have enhanced characteristics (e.g., be more shock-absorbent, lighter, etc.), to be cost-effectively manufactured (e.g., by using less material and/or making it in various sizes), and/or to be customized for a user (e.g., by custom-fitting it to the user).

1 .- 228 . (canceled) 
     
     
         229 . A component comprising expandable material formed into an initial three-dimensional configuration and subsequently expanded to an expanded three-dimensional configuration that is a scaled-up version of the initial three-dimensional configuration, wherein an elongation at break of the expandable material is at least 100%. 
     
     
         230 . The component of  claim 229 , wherein the elongation at break of the expandable material is at least 150%. 
     
     
         231 . The component of  claim 229 , wherein a resilience of the expandable material is at least 60% according to ASTM D2632-01. 
     
     
         232 . The component of  claim 229 , wherein a resilience of the expandable material is at least 80% according to ASTM D2632-01. 
     
     
         233 . The component of  claim 229 , wherein a tensile strength of the expandable material is at least 1 MPa. 
     
     
         234 . The component of  claim 229 , wherein a tensile strength of the expandable material is at least 2 MPa. 
     
     
         235 . The component of  claim 229 , wherein the expandable material is subsequently expanded to the expanded three-dimensional configuration in response to heat. 
     
     
         236 . The component of  claim 229 , wherein an expansion temperature of the expandable material is at least 150° C. 
     
     
         237 . The component of  claim 229 , wherein the expandable material is formed into the initial three-dimensional configuration using 3D printing. 
     
     
         238 . The component of  claim 237 , wherein the 3D printing comprises selective laser sintering (SLS). 
     
     
         239 . The component of  claim 237 , wherein the 3D printing comprises stereolithography (SLA). 
     
     
         240 . The component of  claim 237 , wherein the expandable material is molded into the initial three-dimensional configuration in a 3D-printed mold. 
     
     
         241 . The component of  claim 240 , wherein the expandable material molded into the initial three-dimensional configuration in the 3D-printed mold is injection molded into the initial three-dimensional configuration in the 3D-printed mold. 
     
     
         242 . The component of  claim 229 , wherein the expandable material comprises a polymeric substance and an expansion agent mixed with the polymeric substance. 
     
     
         243 . The component of  claim 242 , wherein the expansion agent constitutes at least 40% of the expandable material by weight. 
     
     
         244 . The component of  claim 242 , wherein the expansion agent constitutes a majority of the expandable material by weight. 
     
     
         245 . The component of  claim 242 , wherein the expansion agent comprises expandable microspheres. 
     
     
         246 . The component of  claim 242 , wherein the polymeric substance is elastomeric. 
     
     
         247 . The component of  claim 242 , wherein the elongation at break of the expandable material is greater than an elongation at break of the expansion agent. 
     
     
         248 . The component of  claim 247 , wherein the elongation at break of the expandable material is at least 200% of the elongation at break of the expansion agent. 
     
     
         249 . The component of  claim 247 , wherein the elongation at break of the expandable material is at least 400% of the elongation at break of the expansion agent. 
     
     
         250 . The component of  claim 242 , wherein a resilience of the expandable material is greater than a resilience of the expansion agent according to ASTM D2632-01. 
     
     
         251 . The component of  claim 242 , wherein a tensile strength of the expandable material is greater than a tensile strength of the expansion agent. 
     
     
         252 . The component of  claim 229 , wherein an expansion ratio of the expandable material is at least three. 
     
     
         253 . The component of  claim 229 , wherein an expansion ratio of the expandable material is at least five. 
     
     
         254 . The component of  claim 229 , wherein the component comprises a plurality of regions that differ in stiffness and are made of the expandable material. 
     
     
         255 . The component of  claim 254 , wherein: a first one of the regions of the component is configured to be disposed closer to a user during use of the component than a second one of the regions of the component; and the second one of the regions of the component is stiffer than the first one of the regions of the component. 
     
     
         256 . The component of  claim 229 , wherein the component comprises a plurality of portions that are at least one of curved and angular and are present in the initial three-dimensional configuration and in the expanded three-dimensional configuration. 
     
     
         257 . The component of  claim 229 , wherein the component comprises a predetermined arrangement of shaped elements that are made of the expandable material, intersect one another, and are present in the initial three-dimensional configuration and in the expanded three-dimensional configuration. 
     
     
         258 . The component of  claim 257 , wherein the shaped elements are relief elements of a texture of the component. 
     
     
         259 . The component of  claim 229 , wherein the component is configured to be part of an article wearable by a user. 
     
     
         260 . The component of  claim 259 , wherein: the article is a protective article configured to protect the user; the protective article comprises a pad; and the pad comprises the component. 
     
     
         261 . The component of  claim 260 , wherein: the protective article is a helmet configured to protect a head of the user; the helmet comprises an outer shell and a liner disposed within the outer shell; and the liner comprises the pad comprising the component. 
     
     
         262 . The component of  claim 229 , wherein the component is a pad. 
     
     
         263 . The component of  claim 229 , wherein the component is a cushion. 
     
     
         264 . A method of making a component, the method comprising:
 forming expandable material into an initial three-dimensional configuration; and   causing expansion of the expandable material from the initial three-dimensional configuration to an expanded three-dimensional configuration that is a scaled-up version of the initial three-dimensional configuration;   wherein an elongation at break of the expandable material is at least 100%.   
     
     
         265 . A method of making a component, the method comprising:
 forming expandable material into an initial three-dimensional configuration using 3D printing; and   causing expansion of the expandable material from the initial three-dimensional configuration to an expanded three-dimensional configuration that is a scaled-up version of the initial three-dimensional configuration;   wherein an elongation at break of the expandable material is at least 100%.