The present disclosure relates to footwear and, more particularly, to an article of footwear with a bladder and a method of manufacturing the same.
This section provides background information related to the present disclosure which is not necessarily prior art.
Articles of footwear can include an upper and a sole assembly. The upper can include layers or sections of material that wrap about a portion of the wearer's foot. The upper can also include laces, straps, or the like for securing the footwear to the wearer's foot. The sole assembly can be lasted to the upper and can be disposed underneath the wearer's foot. The sole assembly can include a footbed, a midsole, and an outsole. The footbed can be a thin layer of material with a surface that is disposed directly underneath the wearer's foot. The outsole can be a unitary piece of relatively high-friction material that provides traction for the footwear. Also, the midsole can include foam that is disposed between the footbed and the outsole for providing cushioned support for the wearer.
In some cases, the midsole can additionally include a bladder that contains a fluid, such as a gas or gel. The weight of the wearer and other loading on the bladder can cause the fluid to displace within the bladder. As such, the bladder can resiliently deform and conform to the wearer's foot in order to provide better support and comfort than some midsoles made entirely out of foam. Also, the bladder can dampen or attenuate shock loads or other loads during jumping, running, and other activities to provide better cushioning.
Although conventional footwear with bladders have been adequate for their intended purposes, they do suffer from certain disadvantages. For instance, manufacturing of the footwear can be significantly expensive and complicated. For instance, the bladder itself increases the part count of the footwear. Also, the bladder is typically manufactured separately from the rest of the sole assembly, and then the bladder is assembled into the sole assembly. As such, the bladder can increase part costs and manufacturing costs.
This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.
A method of manufacturing an article of footwear having an upper, a footbed, an outsole, and a bladder that is disposed between the footbed and the outsole is disclosed. The method includes providing a plurality of layers that are separate from each other in a molding apparatus. The plurality of layers include a top layer, an outsole layer, a first bladder layer, and a second bladder layer. The first and second bladder layers are provided between the top layer and the outsole layer. Also, the method includes molding the plurality of layers together substantially simultaneously to form the upper, the footbed, the outsole, and the bladder. The top layer is molded to a first outer surface of the first bladder layer. The outsole layer is molded to a second outer surface of the second bladder layer. A first inner surface of the first bladder layer is molded and sealed to a second inner surface of the second bladder layer to define a chamber between the first inner surface and the second inner surface. The chamber is operable to contain a fluid. The top layer at least partially defines the upper and the footbed. The outsole layer at least partially defines the outsole, and the first and second bladder layers cooperate to define the bladder.
An article of footwear is also disclosed that includes a top layer, an outsole layer, a first bladder layer that includes a first inner surface and a first outer surface, and a second bladder layer that includes a second inner surface and a second outer surface. The top layer, the outsole layer, the first bladder layer, and the second bladder layer are layered over each other. The top layer is molded to the first outer surface of the first bladder layer, and the outsole layer is molded to the second outer surface of the second bladder layer. The first inner surface of the first bladder layer is molded and sealed to the second inner surface of the second bladder layer to define a chamber between the first inner surface and the second inner surface. The chamber is operable to contain a fluid. The top layer at least partially defines an upper and a footbed of the article of footwear. The outsole layer at least partially defines an outsole of the article of footwear.
Still further, a method of manufacturing a sandal having a strap, a footbed, an outsole, a bladder that is disposed between the footbed and the outsole, and a light-transmissive member that is attached to the strap is disclosed. The method includes providing a plurality of layers that are separate from each other in a molding apparatus. The plurality of layers include a top layer, an outsole layer, a first bladder layer, and a second bladder layer. The first and second bladder layers are provided between the top layer and the outsole layer. Moreover, the method includes molding the plurality of layers together substantially simultaneously to form the upper, the footbed, the outsole, and the bladder. The top layer is molded to a first outer surface of the first bladder layer. The outsole layer is molded to a second outer surface of the second bladder layer. A first inner surface of the first bladder layer is molded and sealed to a second inner surface of the second bladder layer to define a first chamber and a second chamber between the first inner surface and the second inner surface. The first chamber and the second chamber are in fluid communication and each is operable to contain a fluid. The top layer defines the strap and the footbed, the outsole layer defines the outsole, and the first and second bladder layers cooperate to define the bladder and the light-transmissive member. The top layer includes at least one of an insignia and a symbol that is visible through the light-transmissive member. The outsole layer at least partially defines a fastener member that removably and selectively fastens to the strap.
Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Example embodiments will now be described more fully with reference to the accompanying drawings.
Referring initially to
The sandal 12 can generally include an upper 14 and a sole assembly 16. As shown in
The upper 14 can include a strap 24. As shown in
As stated, the second end 27 can removably connect to the second side 28 of the sandal 12. More specifically, as shown in
The sole assembly 16 can also include a footbed 34, a midsole 36, and an outsole 38. The footbed 34 can be a layer of material and/or a surface that extends continuously between the forefoot, midfoot, and rearfoot regions 18, 20, 22 and can be disposed directly beneath the wearer's foot. The outsole 38 can be a layer of high-friction material that extends continuously between the forefoot, midfoot, and rearfoot regions 18, 20, 22 and can be operable to be disposed directly on the ground, pavement, floor, etc. The outsole 38 can also include treading, grooves, high surface roughness, or other features for enhancing traction. The midsole 36 can be one or more layers of material that is operable to be disposed between the footbed 34 and the outsole 38. The midsole 36 can be resilient and compressible to provide cushioned support. The midsole 36 can be fixedly attached to both the footbed 34 and the outsole 38.
The footbed 34, midsole 36, and outsole 38 can be made out of any suitable material. In some embodiments, the footbed 34 is made out of a material disclosed in U.S. Patent Publication No. 2010/0199406, filed Feb. 6, 2009 and published Aug. 12, 2010 and/or U.S. Patent Publication No. 2010/0199520, filed Oct. 15, 2009 and published Aug. 12, 2010, the entire disclosures of which are incorporated by reference. Also, in some embodiments, the midsole 36 includes one or more layers of a monopolymeric material, thermoplastic polyurethane (TPU), etc. The outsole 38 can be made of a polymeric material that has a substantially high coefficient of friction.
Moreover, the sandal 12 can include a light-transmissive member 33. The light-transmissive member 33 can be layered on a top, exterior surface 39 of the strap 24 in some embodiments. The light-transmissive member 33 can be colorless and clear, or the light-transmissive member 33 can be colored. Also, in some embodiments, the light-transmissive member 33 can define a first chamber 35 that is operable to contain a fluid (e.g., air, gel, etc.). Moreover, an insignia, a design, a picture, a symbol, or some other illustrated object 37 can be included on the top, exterior surface 39 of the strap 24, and the object 37 can be visible through the light-transmissive member 33. Thus, the light-transmissive member 33 and the object 37 can enhance the aesthetics of the sandal 12.
As shown in
Referring now to
As shown in
The footwear 10 can also be constructed from a first bladder layer 54 having an outer surface 56 and an inner surface 58. The first bladder layer 54 can be a continuous layer of material with a main body 57 and a first extension 59 that extends from the main body 57. As will be discussed, the main body 57 can be configured to partially define the bladder 40 of the midsole 36, and the extension 59 can be configured to partially define the light transmissive member 33. The first bladder layer 54 can be flat and can have any suitable thickness. The first bladder layer 54 can also be made from any suitable material, such as thermoplastic polyurethane (TPU), etc.
Moreover, the footwear 10 can be constructed from a second bladder layer 60 having an outer surface 64 and an inner surface 62. The second bladder layer 60 can be a continuous layer of material with a main body 61 and a second extension 63 that extends from the main body 57. As will be discussed, the main body 61 can be configured to partially define the bladder 40 of the midsole 36, and the extension 63 can be configured to partially define the light transmissive member 33. The second bladder layer 60 can be flat and can have any suitable thickness. Also, the second bladder layer 60 can be made from any suitable material, such as thermoplastic polyurethane (TPU), etc.
Still further, the footwear 10 can be constructed from an outsole layer 66. The outsole layer 66 can be a flat, continuous sheet of high-friction polymeric material. The outsole layer 66 can include an outer surface 70 and an inner surface 68. Furthermore, the outsole layer 66 can include a main body 65 and a fastener support member 67 that extends from the main body 65.
As shown in
Also, the molding apparatus 80 can include an actuator 90 that is operable to move the molds 79, 81 and/or the handling members 82, 84, 86, 88 relative to each other. The actuator 90 can be a pneumatic actuator, an electric motor, a hydraulic actuator, or any other type.
Furthermore, the molding apparatus 80 can include a heat source 92. The heat source 92 can heat the molds 79, 81 or otherwise heat the molding apparatus 80 to change the shape of the layers 48, 54, 60, 66 and join the layers 48, 54, 60, 66 together to form the sandal 12.
Additionally, the molding apparatus 80 can include an inflation device 94, such as a pump, etc. As will be discussed, the inflation device 94 can inflate one or both of the chambers 35, 42 of the sandal 12. In some embodiments, the inflation device 94 can include a tube or other similar feature (not shown), which can extend between the first and second bladder layers 54, 60 and supply a fluid (e.g., air, etc.) thereto to inflate the chambers 35, 42.
As shown in
Additionally, in some embodiments, the first and second chambers 35, 42 are inflated to different pressures. For instance, the chambers 35, 42 can be initially inflated to the same pressure, then the chambers 35, 42 can be sealed off from each other. Next, the pressure for at least one of the chambers 35, 42 can be adjusted such that the chambers 35, 42 are at different pressures. In some embodiments, the chambers 35, 42 can be formed and inflated according to the teachings of U.S. Pat. No. 5,353,459, filed Sep. 1, 1993 and issued Oct. 11, 1994, which is incorporated by reference in its entirety.
It will be appreciated that once the layers 48, 54, 60, 66 are joined and thermoformed, the main body 57 of the first bladder layer 54 (
Once formed, the sandal 12 can be removed from the molding apparatus 80, and excess material can be trimmed away. Also, the first and second chambers 35, 42 can be inflated outside the molding apparatus 80 if necessary.
Accordingly, the sandal 12 can be formed in a very efficient manner. For instance, the bladder 40 can be inflated and incorporated within the sandal 12 in substantially a single step to thereby increase manufacturing efficiency. Also, the layers 48, 54, 60, 66 can be joined together in a substantially simultaneous manner.
In additional embodiments illustrated in
Referring now to
As shown, the sandal 112 can include a strap 124 and a sole assembly 116. The sole assembly 116 can include a footbed 134, a midsole 136, and an outsole 138. The midsole 136 can include a bladder 140 (shown in phantom) that is arranged at the midfoot region 120 and that is embedded between the footbed 134 and the outsole 138.
In some embodiments, the footbed 134 can include a plurality of grooves 102. The grooves 102 can each extend transversely between the first and second sides 126, 128 of the sandal 112.
Also, the strap 124 can be made from a variety of materials. For instance, the strap 124 can be made from textiles, fabrics, foam, leather, and elastomeric materials that include multiple material layers. In the embodiments illustrated, the strap 124 is fixed at each end to the sole assembly 116; however, the strap 124 could be removably attached at one end to the sole assembly 116 in some embodiments as well.
In some embodiments, the strap 124 can include a plurality of thread members 104 that are included within a base material 106. The base material 106 can be a polymeric material of some type, and the thread members 104 can be fibers of relatively high-strength, nonextendable material. The thread members 104 can be arranged in a plurality of groups 108a, 108b, 108c that each extend longitudinally along the strap 124 between the first and second sides 126, 128. More specifically, the thread members 104 can curve arcuately along the strap 124. Also, the thread members 104 can be closely bundled at the sides 126, 168, and the midsections of the thread members 104 can be spaced further apart from each other such that the thread members 104 collectively fan out over the width of the strap 124. Additionally, some of the thread members 104 can overlap other thread members 104 of other groups 108a, 108b, 108c.
In some embodiments, the thread members 104 can increase the tensile strength of the strap 124 and inhibit elongation of the strap 124. The thread members 104 can individually have relatively high tensile strength; thus, the thread members 104 can collectively increase tensile strength of the strap 124. Also, the thread members 104 can help distribute forces through the strap 124 because the thread members 104 extend over the majority of the strap 124. Thus, the strap 124 is unlikely to fail, and the thread members 104 can increase comfort for the wearer because there is less likelihood of stress concentrations in the strap 124.
In some embodiments, each end of the thread members 104 can be bonded or otherwise joined directly to the bladder 140. The thread members 104 can be joined via adhesives, thermoplastic bonds, or otherwise. In additional embodiments, the thread members 104 can wrap around a bottom region (not shown) of the bladder 140 to extend annularly and continuously (i.e., uninterrupted) between the bladder 140 and the strap 124. As such, the thread members 104 can bias the bladder 140 upward toward the strap 124. In some embodiments, this biasing can place the bladder 140 in compression.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
This application is a divisional of co-pending application Ser. No. 13/455,976, filed Apr. 25, 2012, the disclosure of which is hereby incorporated by reference.
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Child | 14499650 | US |