Patent Grant
8572786
1. Field of the Invention
The present invention relates to methods for manufacturing inflatable bladders and also to inflatable bladders and footwear and other articles of manufacture which include such inflatable bladders.
2. Background Art
Inflatable articles of manufacture or bladders for use in inflatable articles of manufacture have been known for decades. Such articles of manufacture include inflatable air mattresses and pillows, inflatable life preservers and rafts, and athletic equipment. In the field of athletic equipment, inflatable bladders have been incorporated in the interior of balls (e.g., basketballs, footballs, soccer balls, etc.), as well as in apparel and protective equipment such as baseball and boxing gloves, helmets, chest protectors and footwear. When utilized in footwear, an inflatable bladder may be used to provide customized cushioning to the wearer's foot and to enhance fit. In some instances, an inflatable bladder may take the place of a lacing system to secure the shoe to the foot of the wearer. Inflatable bladders may also be used in the sole of a shoe to provide cushioning to the bottom of the wearer's foot and to absorb impact forces from walking, running and jumping.
U.S. Pat. No. 7,278,445 discloses a Shoe Having an Inflatable Bladder, the disclosure of which is incorporated herein by reference in its entirety.
U.S. Pat. No. 5,113,599 to Cohen et al. (the '599 patent) discloses an athletic shoe having an inflatable bladder. This patent discloses a variety of inflatable bladder configurations for use in the tongue, on lateral and medial sides, around the ankles, beneath the foot, or in the entirety of the shoe. The bladder of the patent is formed from a first thermoplastic urethane (TPU) film and a co-extensive second TPU film. The first and second films are attached to each other along pre-defined weld or pattern lines. A peripheral weld line of the bladder creates a sealed bladder compartment or chamber and prevents air from escaping from the bladder. The first and second films are further attached to each other at a number of circular points or interior weld lines to control the thickness of the bladder to prevent undesired “bulging”, which could cause discomfort to the wearer or inhibit proper fit.
The first and second films of the bladder of the '599 patent are welded together using radio frequency (RF) or dielectric welding. RF or dielectric welding uses high frequency radio energy to agitate the molecules of thermoplastic materials to a point where they melt and weld together to form a strong bond. To weld the bladder of the '599 patent, the coextensive films are placed between a brass die (having raised areas representing the desired peripheral, circular and interior weld lines) and a platten on an RF machine. After bringing the brass die and RF platten into contact with each other, the RF machine is activated and the first and second films are bonded to each other only at the raised areas on the brass die to form the peripheral, circular and interior weld lines. Upon completion of the welding step, the inflatable bladder is die-cut from the remainder of the coextensive first and second films and assembled into the shoe as appropriate by adhesives, conventional stitching or other fastening means. The first and second films of the '599 patent may also be adhered to each other by conventionally heated and appropriately patterned brass dies or by application of chemical adhesives or bonding agents suitable for use with thermoplastic films.
The patent further discloses inflation of the bladder by a pump permanently affixed to the bladder using the RF welding technique described above or any other sealing method appropriate for use with the films thereof. Alternatively, the bladder may be inflated by an off-board pump connectable to an inflation/deflation valve, also affixed to the bladder in a location easily accessed by the wearer. Other pumps and valves, suitable for use with inflatable bladders for footwear, are disclosed in U.S. Pat. Nos. 5,074,765 and 5,144,708.
While manufacture of an inflatable bladder using RF welding requires no adhesives or additional materials and has the advantages of precise patterning, decreased heat-degradation in areas of the film adjacent to weld lines and strength of seal, it is costly and time consuming to machine or chemically etch the brass dies for the inflatable bladder patterns, particularly where an article of manufacture is produced in a large range of sizes and in multiple configurations. Conventionally heated brass dies are also expensive to machine, while chemical adhesion is messy and requires cure time in controlled environments. Moreover, RF welding techniques are extremely sensitive, require that the films be sufficiently thick to prevent excessive melting of the film (which could cause a breach of the bladder), and often result in finished bladders that “curl” along their edges (which can complicate their assembly into articles of manufacture such as footwear).
Thus, it is desirable to provide a method for manufacturing inflatable bladders for use in footwear and other articles which is relatively inexpensive, time efficient and allows for the manufacture of a variety of bladder configurations and sizes, utilizing a process and materials resulting in little to no interruption or delay in the manufacturing process.
The manufacturing method of the present invention is advantageous over those known in the art, in that it is simpler, can be semi-continuous or semi-automatic in nature, easily modified to permit manufacture of a variety of bladder configurations, and more economical by avoiding the need for expensive configuration-specific, brass-machined tooling. In one aspect of the present invention, a method for manufacturing an inflatable article comprises the steps of providing a first polymer film having an inner side and an outer side, applying a curable release coating to the inner side of the first polymer film in a pattern that corresponds to the configuration of an inflatable compartment of an inflatable bladder, curing the release coating to the inner side of the first polymer film by the application of ultra-violet light, providing a second polymer film having an inner side and an outer side with the first polymer film to form a layered element, such that the release coating is disposed between the inner side of the first polymer film and the inner side of the polymer film, positioning the layered element between a first ply of material and a second ply of material, applying heat and pressure to the first and second plies of material positioned about the layered element to adhere the first polymer film to the second polymer film except in the area where the release coating has been applied to the inner side of the first polymer film to form an inflatable compartment surrounded by a sealed perimeter, and removing the first and second plies of material from the adhered first and second polymer films. The curable release coating may be silicone fortified. The curable release coating may be applied to the inner side of the first polymer film by screen printing. The first and second plies of material may be polytetrafluoroethylene-coated, fiberglass-reinforced cloths. At least one of the first and second plies of material may be textured. The applying heat and pressure step may be accomplished by rotary lamination. The method may further comprise the step of cutting along the sealed perimeter to form an inflatable bladder having a sealed attachment margin and incorporating the inflatable bladder into an article of footwear by attaching the inflatable bladder to the article of footwear at the attachment margin. The method may further comprise the step of coupling an inflation device and a deflation device to the inflatable bladder. One of the first or second polymer films may be a laminate comprised of a polymer layer and a substrate.
In another aspect of the present invention, a method for manufacturing an inflatable bladder comprises the steps positioning a barrier material between a first film and a second film in a configuration that corresponds to the shape of an inflatable compartment of the inflatable bladder, positioning the first and second films with the barrier material positioned thereinbetween between a first ply of material and a second ply of material, adhering the first film to the second film except in the vicinity of the barrier material to form the inflatable bladder having the inflatable compartment surrounded by a sealed, continuously substantially flat perimeter, and removing the first and second plies of material from the inflatable bladder. The method may further comprise the step of incorporating the inflatable bladder into an article of footwear by securing the inflatable bladder to the article of footwear at the perimeter of the inflatable bladder. The barrier material may be a paint, ink, paper, textile, photosensitive agent, wire, foil, or particulate. The barrier material may be a curable release coating, and the step of positioning the barrier material between the first film and the second film may include the substep of applying the release coating to the first film, curing the release coating to the first film, and sandwiching the cured release coating between the first and second films. The release coating may be applied to the first film using a screen, template, or stencil. The release coating may be cured by the application of ultra violet light. The first and second plies of material may be polytetrafluoroethylene-coated, fiberglass-reinforced cloths. At least one of the first and second plies may be textured. The adhering step may be accomplished by rotary lamination, by heated pressing between platens, or by application of vacuum and heat. The method may further comprise the step of coupling an inflation device and a deflation device to the inflatable bladder. At least one of the first or second films may be a laminate comprised of a polymer layer and a substrate. The barrier material may include at least two release coatings. Where two release coatings are provided, the step of positioning the barrier material between the first film and the second film may include the substep of applying a first release coating to the first film, applying a second release coating to the second film, curing at least one of the release coatings, and sandwiching the release coatings between the first and second films. The release coating applied to the second film may be a discontinuous coating.
In yet another aspect of the invention, an inflatable article of footwear comprises a sole and an upper having an inflatable bladder attached to the sole. The inflatable bladder comprises a first film, a release agent applied and cured to the first film in a pattern that corresponds to the shape of an inflatable compartment of the inflatable bladder, a second film adhered to the first film such that said release agent is disposed between the first film and the second film and the first film and the second film do not adhere to each other in the vicinity of the release agent thereby forming the inflatable compartment with a peripheral edge, whereby the inflatable bladder is devoid of raised weld lines or raised adhering seams and wherein at least a portion of the exterior surface of the inflatable bladder is textured. Substantially all of the exterior surface of the inflatable bladder may be textured. The textured exterior surface of the inflatable bladder may correspond to the texture of a ply of textured material that was positioned adjacent to the exterior surface of at least one of the first film or the second film while the first and second films were adhered to each other. The ply of material may be polytetrafluoroethylene, fiberglass-reinforced cloth. The inflatable bladder may include a substantially flat, adhered attachment margin extending from the peripheral edge of the inflatable compartment to an edge of the inflatable bladder to facilitate attachment of the inflatable bladder to the upper of the article of footwear. The cured release agent may be silicone fortified and cured by the application of ultra violet light. At least one of the films may be a polymer bonded to a substrate. The article of footwear may comprise an inflation device and a deflation device.
In still another embodiment, an inflatable article of footwear comprises an upper, a sole attached to the upper, and an inflatable bladder attached to the article of footwear. The inflatable bladder comprises a first single-layered film having an inner surface and a textured outer surface, a release agent applied and cured to the inner surface of the first single-layered film in a pattern that corresponds to the shape of an inflatable compartment of the inflatable bladder, a second single-layered film having an inner surface and a textured outer surface disposed in facing relationship with and adhered to the first single-layered film such that the release agent is disposed between the inner surface of the first single-layered film and the inner surface of the second single-layered film, the release agent preventing the first single-layered film from adhering to the second single-layered film in the area where the release agent is applied to form the inflatable compartment of the inflatable bladder. The texture of the outer surfaces of the first and second single-layered films may be imparted thereto by a woven material disposed adjacent to the outer surfaces of the first and second single-layered films during adherence of the first single-layered film to the second single-layered film.
The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the present invention and to enable a person skilled in the relevant art to practice the same.
It is desirable for inflatable articles of manufacture or bladders to be durable, as well as quick, easy and inexpensive to manufacture. The present invention seeks to reduce the cost and time typically associated with the manufacture of inflatable articles or bladders for use in inflatable articles of manufacture, by simplifying the manufacturing process and avoiding the need for brass tooling, which can be expensive and time-consuming to machine or form, as well as to change-out, to permit the manufacture of inflatable articles or bladders having numerous sizes and configurations.
While conventional bladder manufacturing methods rely on tooling specific to the configuration of the bladder to weld or seal two or more films together to form inflatable areas or compartments, the method of the present invention employs a barrier material (also referred to herein as a release coating or agent) applied to one of the films (or both of the films), in accordance with a pre-defined or customized pattern, to prevent the films from adhering together to create inflatable areas or compartments, when heat and/or pressure are applied thereto. The barrier material can be easily applied to either of the films, in various configurations, to permit manufacture of an inflatable article or bladder inexpensively, quickly, essentially continuously and with a high degree of manufacturing flexibility.
As shown in
Turning now to the steps of the method of
Moreover, while the method of
Turning now to Step 1(b) of the method set forth in
Where the barrier material is a paint, for example, the paint could be applied to the first film in accordance with Step 1(b) of the method in a manner similar to silk-screening. Silk-screening (or screen printing) is a long-used process for economically mass producing signage, prints and fabric designs, etc. The basic idea in silk-screening (as generally shown in
The framed silk is placed against the object upon which the design is to be imparted. Paint is then applied thereto and pulled across the silk with a squeegee or similar device to transfer the design through the silk to the object below. Where a design having multiple colors is desired, a separate screen must be prepared for each color (similar to the color separation process in conventional ink-printing methods). With the silk-screening method, thousands of “prints” can be made from a single silk. More recently, the printing screens are formed from monofilament materials such as polyester, rather than silk.
By applying the silk-screening technique described above to the method of the present invention, a variety of bladder configurations and sizes can be “printed” on or imparted to the first film of Step 1(a) to function as the barrier material of the present invention. For example,
It should also be realized by those skilled in the relevant art that while a particular negative bladder design or configuration has been illustrated in
Likewise, the described linear and circular elements may be placed in any position to accommodate the function of the bladder and to control inflation and/or bulging of the bladder, as necessary. In addition, the linear and/or circular elements need not be linear or circular, but may be elongated, curved or of any geometry to meet the functional objectives of the bladder or the anatomy of the user, where the bladder is to be incorporated into an article of manufacture to be worn by a human.
Continuing with the steps of the method of
In Step 1(d) of the method of
The first and second films may be adhered by a heated platten brought into contact with the films, or the coextensive films could be fed together through heated rollers commonly known in the laminating art, for example. Other known means for sealing or laminating thermoplastic films (e.g., ultrasonic welding) could also be employed to achieve the objects of the present invention. The films could also be made photosensitive so that they would adhere to one another upon application of light.
In Step 1(e) of the method of
Inflatable bladder 60 of
Thus, as described above, this embodiment of the method of the present invention enables an inflatable article or bladder for an inflatable article, to be manufactured quickly, easily and without the use of expensive article or bladder configuration-specific, metal tooling. Indeed, the method can be utilized with known silk-screening or printing and laminating techniques to allow for the continuous manufacture of multiple-shaped inflatable articles or bladders at relatively low cost. Moreover, and most advantageously, when a bladder configuration change is required, there is no need to order, machine and replace an expensive piece of metal tooling in the manufacturing process. Instead, a new screen/negative image of the newly desired bladder configuration is made and exchanged for the prior screen/negative image—a simple, quick and inexpensive process, which is also compatible with the down-stream steps of the manufacturing process (i.e., adhering and cutting). Alternatively, a new screen/negative image could be digitally fed to the manufacturing process.
Returning to a discussion of Step 1(b) of the method of
While the barrier material and application step of the present invention has been described above with respect to paint or ink as used with a silk-screening or printing technique, it is envisioned that the barrier material may take other forms. For example, the barrier material may be a paper (e.g., adhesive-backed paper), fabric, foil, wire, particulate, or plastic material (such as polyethylene) applied to the first side of the first film to prevent the first and second films from adhering together to form at least one inflatable chamber.
It is also possible that the barrier material may be “free-floating” and not attached to either the first or second film. Indeed, the barrier material could be a particular type of film (or films) positioned between the first and second films that would not bond to the first and second films (e.g., the film would release from the first and second films as they cool, following the application of heat). Other “free-floating” barrier materials can include, for example, paper, fabric, foil, wire, particulate, or plastic material positioned between the first and second films. Alternatively, the barrier material may be temporarily applied to one of the first or second films.
In another embodiment, the barrier material could be a particulate, soap, surfactant, release coating or agent, or a polytetrafluoroethylene or silicone coating, sprayed over an appropriately shaped stencil to transfer the barrier material, in the desired article or bladder configuration, onto a first side of the first film to prevent the first and second films from adhering to each other during the sealing step of the invention.
In yet another embodiment of the invention, and utilizing the silk-screening or printing technique described above, the barrier material could also be an acid or other liquid chemical, which is transferred to a first side of the first film to chemically etch, corrode or abrade the first film, to inhibit attachment of the first film to the second. It is also envisioned that a photosensitive material could be transferred to the first film and subsequently exposed to light to meet the objectives of the barrier material of the invention.
In still another embodiment, the first film could be calendared between a hot roller and another hot or cold roller to apply or emboss a texture (having the overall desired bladder configuration) on one side of the first film to prevent it from adhering to the second film to form an inflatable compartment.
It is also envisioned that the method of present invention is capable of applying printing techniques (that is, printing films and rollers) used by the newspaper or printing industry to transfer a variety of inflatable article or bladder shapes onto a first film for adhering to a second film to form an inflatable compartment.
In another aspect of the invention, and with reference to
In practice, a customer for a shoe, for example, might enter into a computer 74 a specific color or design that the customer wants to appear on the shoe. The design could be indicia such as a name, words, or symbols or could be a photograph of a person or place. It is also envisioned that an anatomical scan of the customer's foot could be entered (e.g., at a point-of-purchase kiosk or display) in order to enable customized manufacture of an inflatable article or bladder, which accommodates the anatomy of the customer's foot to enhance fit, cushioning and support. The entered information would then be transmitted to database 72 to which printer 70 has access. The printer would then access the database and print the unique design on a first film 76. First film 76 could be configured as a rolled sheet material, which is then joined with a similarly rolled second film 78. First film 76 and second film 78 would then be calendared through heated rollers 77, 79 to adhere the films together and create the inflatable compartment of the bladder. The bladder would then be cut from the films using the methods described above. Where the bladder is cut from the films using a laser, the laser could also be made “smart” by connecting the laser to the database to control cutting of the bladder from the films, in accordance with the customized bladder design printed on the film. The present invention also contemplates that the bladder could be “cut” from the films by providing a cutting die with a chemical that corrodes, dissolves or “eats” through the films.
This method of the present invention is not only customizable, but is continuous in nature, in that there is no need to interrupt the steps of the method to change-out for bladder designs of differing configurations, colors or indicia. When the bladder is built into a shoe, the bladder may form an exoskeleton of the shoe as described in U.S. Pat. No. 5,343,638. Because the bladder has a design printed on the inside of the film, the design may be made visible on the outside of the shoe to form a unique customized shoe.
Similarly, the barrier material could take the form of a thermally reflective material to provide the bladder with insulating properties. The bladder could then be constructed into apparel, for example, to form an insulating shirt, jacket, vest, pant, or other article of apparel.
It is further envisioned that the barrier material could be a printed background design (for example, an underwater scene), and that the bladder could be filed with a fluid and ornamental elements (for example, plastic fish and sparkles), for use in children's wear or other articles of manufacture directed to a specific type of consumer.
It is also contemplated that the bladder could be formed from more than two films, to create a bladder having multiple layered inflatable compartments. In this embodiment, specific barrier materials and films could be selected so that each layered, inflatable compartment of the bladder has a different inflation quality or characteristic to address the objectives of the inflatable article of manufacture.
As noted above, the inflatable bladder formed by the method of the present invention also comprises a conduit 50 for coupling with an inflation valve or a deflation valve. While this conduit serves as one means or structure for joining inflation and deflation fitments to the inflatable article or bladder per se, it is also envisioned that fitments known in the fluid transfer and control art could be attached to the article via an opening pre-formed in the second film prior to Step 1(c) of the method of
While a pump for bringing fluid into the bladder has been illustrated in
Turning now to a more detailed discussion of the method according to one embodiment, as shown in
As shown in
Release coating 1030 may be applied to first film 1000 using any suitable technique, including those discussed above in connection with the method of
The inflatable bladder pattern shown in
A perimeter 1080 extends about the periphery of the bladder pattern. Perimeter 1080 is also devoid of release coating 1030, so that the first and second films are able to adhere to each other during the adhering step of the method of
It should be realized by those skilled in the art that while an inflatable tongue bladder is shown in
Continuing with the steps of the method of
It will be realized by those skilled in the art that the release coating can be cured in accordance with known curing techniques (for example, with a hand-held UV light or a UV light tunnel), so long as the curing technique is appropriate to the formulation and properties of the applied release coating and the remaining steps of the method.
Turning now to
In accordance with Step 9(e) of the method of
The plies can perform several functions: (1) they can carry the layered element, comprised of the first and second films and release coating, through a laminating process to prevent the layered element from adhering or melting to the heated elements of the laminating apparatus; (2) the woven texture of the cloth can prevent air from being trapped on the first and/or second films (e.g., trapped on one or more surfaces of the films) or can reduce the amount of air being trapped on the first and/or second films, which could cause bubbling, warping, inconsistent lamination between the films, or weak or thin areas in the bladder; (3) the plies can prevent or reduce any unintended pre-heating of the layered element when in the proximity of heated elements of the laminating process (for example, when the layered element is proximate, but not yet inserted into the nip rolls of a rotary lamination machine) and/or (4) the plies can prevent or reduce shifting or movement of the components of the layered element relative to each other.
Examples of polytetrafluoroethylene/fiberglass reinforced material from which first and second plies 1300, 1310 can be made are available from Precision Coating Co., Inc. (Dedham, Mass.), under product nos. PC-10, PC-14, PC-10 TR, PC-10 Porous, PC-14 Porous, 100-8SW2, and 100-10sw. One example of a silicon/fiberglass reinforced material from which first and second plies 1300, 1310 can be made is available from Precision Coating Co., Inc., under product no. PC S/W 10. In some embodiments, the material from which first and second plies 1300, 1310 is made has a thickness of about 5 to about 20 mil (about 0.127 mm to about 0.508 mm) such as about 10 to about 15 mil (about 0.254 mm to about 0.381 mm). Plies 1300, 1310 can be cut or sized to accommodate the dimensions of the layered element sandwiched thereinbetween. While various types of suitable plies have been described, it should be realized by those skilled in the art, that any material which is capable of performing the primary functions above would be suitable for plies 1300, 1310.
Moving on to Step 9(f) of the method of
A rotary lamination machine 1400 is shown in
To bond or adhere first and second films 1000, 1200, rotary drum 1420 of machine 1400 is heated to operate at a temperature and set to run at a speed that is dependent upon the selection of films 1000, 1200, barrier material 80 (e.g., release coating 1030), and plies 1300, 1310, but which temperature and speed are selected to be sufficient to melt at least one of the films at least partially and in some embodiments, to completely melt at least one or both of the films, and to ensure proper melting and bonding of the films 1000, 1200. As plies 1300, 1310 are carried about the heated rotary drum (and pressure is applied to the plies and layered element by the drum and conveyor belt), first and second films 1000, 1200 melt and bond or adhere to each other except in the area where release coating 1030 has been applied to first film 1000. Conveyor belt 1440 carries plies 1300, 1310 with layered element thereinbetween to the lowermost tangential point of the heated rotary drum (arrows 3 and 4), where it then conveys the plies away from the drum and toward a spring loaded tray 1450 (arrow 5) that allows for removal of the plies and the now-adhered first and second films disposed thereinbetween from the rotary lamination machine (arrow 6).
While the adhering step has been described in connection with a heated rotary lamination machine, it should be understood by those skilled in the art that other laminating techniques can be utilized to accomplish the objectives of the methods described herein, including, but not limited to, use of a pressure source and a heat source. Examples of suitable pressure sources include presses (e.g., a hydraulic press) and application of vacuum (e.g., via vacuum bag or vacuum table). Examples of suitable heat sources include heated plates; heat lamps (e.g., infrared lamps); conventional, convection, or microwave ovens; and resistance heaters, among others.
In one embodiment, an ultrasonic bonding horn is used to perform the adhering step. The use of an ultrasonic bonding horn can include ultrasonic rotary/continuous bonding horn techniques such as those which include assembling two or more layers of materials by passing them between a vibrating horn and a rotary drum wherein high frequency mechanical motion of a vibrating horn and compressive force between the horn and a rotary drum create frictional heat at the point where the horn contacts the material(s).
In another embodiment, the adhering step can include application of vacuum. Application of vacuum can prevent air from being trapped on the first and/or second films (e.g., trapped on one or more surfaces of the films) or can reduce the amount of air being trapped on the first and/or second films during the adhering step and can prevent or reduce shifting or movement of the components of the layered element relative to each other during the adhering step.
For example, films 1000, 1200 can be placed between plies 1300, 1310 and the resulting layered element 1230 can be subjected to vacuum and heat and/or additional pressure. In one embodiment, layered element 1230 is placed into a vacuum bag and vacuum is drawn on the bag. Heat and/or additional pressure (e.g., via a press) can then be applied to the vacuum bag and layered element 1230 causing first and second films 1000, 1200 to melt and bond or adhere to each other except in the area where release coating 1030 has been applied to first film 1000. In another embodiment, layered element 1230 can be placed on a vacuum table, covered with a sheet or film, vacuum drawn on the layered element 1230, and heat and/or additional pressure (e.g., via a press) can then be applied to the layered element.
Obviously, other laminating techniques and devices known in the art for bonding or laminating thermoplastic or elastomeric films and materials would be suitable for achieving the objectives of the present invention.
Following removal of the plies and now-adhered first and second films from the rotary lamination machine, the plies and films are cooled. After cooling, plies 1300, 1310 are removed from the layered element by peeling ply 1300 from second film 1200 and ply 1310 from first film 1000 (Step 9(g) of the method). Plies 1300, 1310 can be conveniently and efficiently reused for the additional lamination of films. As stated previously, plies 1300, 1310, particularly textured plies, advantageously can prevent or reduce (a) air being trapped on the first and/or second films, and (b) shifting or movement of the components of the layered element relative to each other, both of which could result in an inconsistent bond or a bond of compromised integrity. With this lamination technique, the resulting adhered films are substantially flat across the surfaces thereof (that is, there are no raised weld lines, seams, ridges or bulges). This facilitates manipulation of the film for assembly of the inflatable bladder into the article of footwear or other article of manufacture.
It should also be noted that following the melting and lamination of films 1000, 1200, any textured surface (or warp and weave) of plies 1300, 1310 can be imparted to second or outer surface 1020 of first film 1000 and second or outer surface 1220 of second film 1200. This texturing of films 1000, 1200 (partially represented as texture T in
As stated above, first film 1000 is adhered to second film 1200 except in the area where the barrier material has been applied to form an inflatable compartment surrounded by a fully sealed perimeter.
Turning now to Step 9(h) of the method of
Finishing with Step 9(i) of the method shown in
Having described the fundamental steps of the method of
Valve body 1600 is formed from a material compatible with the material used to form first film 1000 and second film 1200 (e.g., low density polyethylene), to enable the valve body to be sealed thereto. Valve body 1600 may be formed from any material that enables the valve body to be sealed or bonded to the films of the inflatable bladder in a fluid-tight manner.
With reference now to
Following the application of heat and pressure to the sealing collar, the inflatable bladder and holding fixtures are moved to a cooling die station. The cooling dies may have a silicone sponge insert that applies soft compliant pressure to the seal of the valve body, to maintain the valve seal shape. When valve body seal has cooled, cloth strand 1810 is removed from conduit 1640 of valve body 1600 to provide for an open fluid conduit between the structure of the valve body and the interior of the inflatable bladder compartment, to allow for the ingress and egress of air (fluid) from the inflatable bladder. Following removal of cloth strand 1810, a conventional valve plunger 1910 and spring are press-fit (by a manually operated arbor press) into plunger housing 1610 of valve body 1600 (
Obviously, other inflation and deflation devices known in the art may be fluidly connected to the inflatable bladder manufactured by the method of
It is also contemplated that films 1000 and 1200 of the method of
It is further envisioned that the method of
It should be appreciated that while the method of
Another embodiment of a method for manufacturing an inflatable bladder is shown in
Further, in some inflatable articles of manufacture (e.g., footwear or protective vests), the inflatable bladder needs to bend to accommodate movement of the wearer or other functionality, and with certain inflatable bladder configurations, this can cause pinching or blockage of a fluid (e.g., air) passage within the bladder, to prohibit complete inflation or deflation thereof. A novel solution to this problem is to texturize the interior surface of the bladder. In one embodiment of the present invention, this may be accomplished using a variety of techniques including by texturing the interior surface of one or both of the films of the bladder. In another technique, a release coating is applied to the interior surface of one of the films in a pattern corresponding to the configuration of the inflatable bladder, while a discontinuous coating is applied to the interior surface of the other film. The discontinuously applied release coating layer could be a pattern of dots, lines, or other shapes that lend texture to the interior surface of the film to assist in keeping the fluid channels of the bladder open. The area of the discontinuously applied layer devoid of release coating could be oriented in the anticipated primary direction of fluid flow. Alternatively, both of the interior surfaces of the bladder films could have a discontinuously applied release coating layer, such that the release coating layer applied to one film overlaps with the release coating layer applied to the other film, permitting the release coating layers to work together to prevent adherence of the films to produce the desired inflatable compartment. In still other embodiments, a barrier material such as foil, paper, or fabric may be used in the vicinity of an anticipated bend in the inflatable bladder to help keep the fluid channel open in that area. It should be realized by those skilled in the art that the afore-described texturizing techniques may be employed with any of the methods described in
The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying the knowledge within the skill of the relevant art (including the contents of the references cited herein), readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept and spirit of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology used herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance presented herein, in combination with the knowledge of one of ordinary skill in the art.
| Number | Name | Date | Kind |
|---|---|---|---|
| 508034 | Moore | Nov 1893 | A |
| 510504 | Foster | Dec 1893 | A |
| 545705 | MacDonald | Sep 1895 | A |
| 547645 | LaCroix | Oct 1895 | A |
| 580501 | Mobberley | Apr 1897 | A |
| 586155 | Bascom | Jul 1897 | A |
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| 2365807 | Dialynas | Dec 1944 | A |
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| 2532742 | Stoiner | Dec 1950 | A |
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| 3397418 | Steadman et al. | Aug 1968 | A |
| 3410004 | Finn | Nov 1968 | A |
| 3469576 | Smith et al. | Sep 1969 | A |
| 3484881 | Krleger | Dec 1969 | A |
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| 3589037 | Gallagher | Jun 1971 | A |
| 3608215 | Fukuoka | Sep 1971 | A |
| 3628531 | Harris | Dec 1971 | A |
| 3642563 | Davis et al. | Feb 1972 | A |
| 3664043 | Polumbus, Jr. | May 1972 | A |
| 3685176 | Rudy | Aug 1972 | A |
| 3716930 | Brahm | Feb 1973 | A |
| 3738024 | Matsuda | Jun 1973 | A |
| 3739414 | Skelham | Jun 1973 | A |
| 3744159 | Nishimura | Jul 1973 | A |
| 3758964 | Nishimura | Sep 1973 | A |
| 3760056 | Rudy | Sep 1973 | A |
| 3765422 | Smith | Oct 1973 | A |
| 3791375 | Pfeiffer | Feb 1974 | A |
| 3795994 | Ava | Mar 1974 | A |
| 3854228 | Conroy | Dec 1974 | A |
| 3888242 | Harris et al. | Jun 1975 | A |
| 3931685 | Laukaitis | Jan 1976 | A |
| 3973336 | Ahn | Aug 1976 | A |
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| 4044867 | Fisher | Aug 1977 | A |
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| 4083127 | Hanson | Apr 1978 | A |
| 4100686 | Sgarlato et al. | Jul 1978 | A |
| 4106222 | Houck | Aug 1978 | A |
| 4115934 | Hall | Sep 1978 | A |
| 4123855 | Thedford | Nov 1978 | A |
| 4129951 | Petrosky | Dec 1978 | A |
| 4167795 | Lambert, Jr. | Sep 1979 | A |
| 4183156 | Rudy | Jan 1980 | A |
| 4211236 | Krinsky | Jul 1980 | A |
| 4217705 | Donzis | Aug 1980 | A |
| 4219945 | Rudy | Sep 1980 | A |
| 4232459 | Vaccari | Nov 1980 | A |
| 4271606 | Rudy | Jun 1981 | A |
| 4287250 | Rudy | Sep 1981 | A |
| 4292702 | Phillips | Oct 1981 | A |
| 4297797 | Meyers | Nov 1981 | A |
| 4316335 | Giese et al. | Feb 1982 | A |
| 4340626 | Rudy | Jul 1982 | A |
| 4342157 | Gilbert | Aug 1982 | A |
| 4350545 | Garabedian | Sep 1982 | A |
| 4358902 | Cole et al. | Nov 1982 | A |
| 4361969 | Vermonet | Dec 1982 | A |
| 4362777 | Miller | Dec 1982 | A |
| 4397104 | Doak | Aug 1983 | A |
| 4417407 | Fukuoka | Nov 1983 | A |
| 4446634 | Johnson et al. | May 1984 | A |
| 4458430 | Peterson | Jul 1984 | A |
| 4462171 | Whispell | Jul 1984 | A |
| 4483030 | Plick et al. | Nov 1984 | A |
| 4486964 | Rudy | Dec 1984 | A |
| 4508582 | Fink | Apr 1985 | A |
| 4536434 | Magnotta | Aug 1985 | A |
| 4542598 | Misevich et al. | Sep 1985 | A |
| 4546559 | Dassler | Oct 1985 | A |
| 4547919 | Wang | Oct 1985 | A |
| 4571853 | Medrano | Feb 1986 | A |
| 4610099 | Signori | Sep 1986 | A |
| 4628945 | Johnson, Jr. | Dec 1986 | A |
| 4654986 | George | Apr 1987 | A |
| 4662087 | Beuch | May 1987 | A |
| 4670995 | Huang | Jun 1987 | A |
| 4686130 | Kon | Aug 1987 | A |
| 4700403 | Vacanti | Oct 1987 | A |
| 4702022 | Porcher | Oct 1987 | A |
| 4711907 | Sterzel et al. | Dec 1987 | A |
| 4712316 | Baggio | Dec 1987 | A |
| 4722131 | Huang | Feb 1988 | A |
| 4730403 | Walkhoff | Mar 1988 | A |
| 4760651 | Pon-Tzu | Aug 1988 | A |
| 4763426 | Polus et al. | Aug 1988 | A |
| 4771554 | Hannemann | Sep 1988 | A |
| 4774776 | Gulli | Oct 1988 | A |
| 4776110 | Shiang | Oct 1988 | A |
| 4779359 | Famolare, Jr. | Oct 1988 | A |
| 4803029 | Iversen et al. | Feb 1989 | A |
| 4805601 | Eischen, Sr. | Feb 1989 | A |
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| 4845338 | Lakic | Jul 1989 | A |
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| D302764 | Peoples et al. | Aug 1989 | S |
| 4852274 | Wilson | Aug 1989 | A |
| 4856208 | Zaccaro | Aug 1989 | A |
| 4874640 | Donzis | Oct 1989 | A |
| 4887367 | Mackness et al. | Dec 1989 | A |
| 4891855 | Cheng-Chung | Jan 1990 | A |
| 4906502 | Rudy | Mar 1990 | A |
| 4912861 | Huang | Apr 1990 | A |
| D307508 | Miller et al. | May 1990 | S |
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| 4991317 | Lakic | Feb 1991 | A |
| 4995124 | Wridge, Jr. et al. | Feb 1991 | A |
| 4995173 | Spier | Feb 1991 | A |
| 4999072 | Dischler | Mar 1991 | A |
| 4999931 | Vermeulen | Mar 1991 | A |
| 4999932 | Grim | Mar 1991 | A |
| 5010661 | Chu | Apr 1991 | A |
| 5022109 | Pekar | Jun 1991 | A |
| 5025575 | Lakic | Jun 1991 | A |
| 5042176 | Rudy | Aug 1991 | A |
| 5044030 | Balaton | Sep 1991 | A |
| 5046267 | Kilgore et al. | Sep 1991 | A |
| 5074765 | Pekar | Dec 1991 | A |
| 5083320 | Halstead | Jan 1992 | A |
| 5083361 | Rudy | Jan 1992 | A |
| 5113599 | Cohen et al. | May 1992 | A |
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| 5144708 | Pekar | Sep 1992 | A |
| 5155864 | Walker et al. | Oct 1992 | A |
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| 5155927 | Bates et al. | Oct 1992 | A |
| 5158767 | Cohen et al. | Oct 1992 | A |
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| 5181279 | Ross | Jan 1993 | A |
| 5185943 | Tong et al. | Feb 1993 | A |
| 5193246 | Huang | Mar 1993 | A |
| 5195254 | Tyng | Mar 1993 | A |
| 5199191 | Moumdjian | Apr 1993 | A |
| 5224278 | Jeon | Jul 1993 | A |
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| 5230249 | Sasaki et al. | Jul 1993 | A |
| 5235715 | Donzis | Aug 1993 | A |
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| 5245766 | Warren | Sep 1993 | A |
| 5253435 | Auger et al. | Oct 1993 | A |
| 5257470 | Auger et al. | Nov 1993 | A |
| 5295313 | Lee | Mar 1994 | A |
| 5297349 | Kilgore | Mar 1994 | A |
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| 5375345 | Djuric | Dec 1994 | A |
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| Number | Date | Country |
|---|---|---|
| 8305004 | Apr 1985 | BR |
| 820 869 | Nov 1951 | DE |
| 867 585 | Feb 1953 | DE |
| 917 173 | Aug 1954 | DE |
| 2 005 365 | Jul 1972 | DE |
| 2 321 817 | Nov 1973 | DE |
| 2 308 547 | Aug 1974 | DE |
| 2 365 329 | Sep 1974 | DE |
| 24 56 612 | Jun 1975 | DE |
| 28 00 359 | Jul 1979 | DE |
| 32 45 182 | May 1983 | DE |
| 32 34 086 | Mar 1984 | DE |
| 34 27 644 | Jan 1986 | DE |
| 38 05 591 | Aug 1989 | DE |
| 92 01 758 | May 1992 | DE |
| 0 040 189 | Nov 1981 | EP |
| 0 094 868 | Nov 1983 | EP |
| 0 095 357 | Nov 1983 | EP |
| 0 215 974 | Apr 1987 | EP |
| 0 229 273 | Jul 1987 | EP |
| 0 389 215 | Sep 1990 | EP |
| 0 472 110 | Feb 1992 | EP |
| 0 629 360 | Dec 1994 | EP |
| 0 714 613 | Jun 1996 | EP |
| 720 257 | Feb 1932 | FR |
| 1 195 549 | Nov 1959 | FR |
| 2 026 062 | Sep 1970 | FR |
| 2 180 315 | Nov 1973 | FR |
| 2 404 413 | Apr 1979 | FR |
| 2 483 321 | Dec 1981 | FR |
| 2 484 215 | Dec 1981 | FR |
| 2 614 510 | Nov 1988 | FR |
| 233 387 | May 1925 | GB |
| 338 266 | Nov 1930 | GB |
| 520 514 | Apr 1940 | GB |
| 978 654 | Dec 1964 | GB |
| 1 128 764 | Oct 1968 | GB |
| 2 039 717 | Aug 1980 | GB |
| 2 085 278 | Apr 1982 | GB |
| 2 114 425 | Aug 1983 | GB |
| 2 114 869 | Sep 1983 | GB |
| 2 201 082 | Aug 1988 | GB |
| 2 240 254 | Jul 1991 | GB |
| 2 271 710 | Apr 1994 | GB |
| 04150808 | May 1992 | JP |
| 6-181802 | Jul 1994 | JP |
| 07171923 | Jul 1995 | JP |
| 07171923 | Jul 1995 | JP |
| WO 8703789 | Jul 1987 | WO |
| WO8703789 | Jul 1987 | WO |
| WO8906500 | Jul 1989 | WO |
| WO 8906500 | Jul 1989 | WO |
| WO8910074 | Nov 1989 | WO |
| WO 8910074 | Nov 1989 | WO |
| WO9004323 | May 1990 | WO |
| WO9111928 | Aug 1991 | WO |
| WO9111931 | Aug 1991 | WO |
| WO9116831 | Nov 1991 | WO |
| WO9118527 | Dec 1991 | WO |
| WO9208384 | May 1992 | WO |
| WO9312685 | Jul 1993 | WO |
| WO9314659 | Aug 1993 | WO |
| WO9321790 | Nov 1993 | WO |
| WO9520332 | Aug 1995 | WO |
| WO0119211 | Mar 2001 | WO |
| Entry |
|---|
| Zonic Product Descriptions, date unknown. cited by other. |
| Runner's World, pp. 58-59, 69 and 74 (Apr. 1991). |
| Brochure of the Nike Air Force 180 shoe, included with photographs of shoes on sale prior to Nov. 1993. |
| English Abstract of JP07171923 A. |
| Machine translation of JP07171923 A. |
| English Abstract of JP04150808. |
| ZONIC Product Descriptions, date unknown. |
| Brochure of the Nike Air Force 180 show, included with photographs of shoes on sale prior to Nov. 1993. |
| Machine English Translation of JP 07-141923. |
| English Translation of JP 07-171923 (Dec. 2008). |
| Millette et al., U.S. Appl. No. 12/624,232, “Method for Manufacturing Inflatable Footwear or Bladders for Use in Inflatable Articles,” filed Nov. 23, 2009. |
| Number | Date | Country | |
|---|---|---|---|
| 20120084999 A1 | Apr 2012 | US |
