Fluid-filled chambers with foam tensile members and methods for manufacturing the chambers
AssigneeNIKE, Inc.
InventorsEric S. Schindler, Zvi Rapaport
Life of this patent
Estimating the term…
Abstract
A fluid-filled chamber may include an outer barrier formed from a polymer material and a foam tensile member located within the outer barrier. In manufacturing the fluid-filled chamber, a mold may be contoured to substantially equalize compressive forces between the outer barrier and various portions of the tensile member, thereby providing substantially uniform bonding between the outer barrier and the tensile member. Surfaces of the tensile member may also be contoured to substantially equalize compressive forces. In some configurations, the outer barrier and tensile member may be formed from thermoplastic polymer materials that form a direct bond between the outer barrier and surfaces of tensile member.
Claims23
A method of manufacturing a fluid-filled chamber, the method comprising:
- placing a tensile member between a first layer and a second layer of polymer material, the tensile member having a first portion with greater compressibility than a second portion, the first portion being joined with the second portion and formed as a one-piece element, and a surface of the tensile member forming a protrusion in the first portion;
- locating the tensile member, the first layer, and the second layer within a mold that defines a void for forming the chamber;
- and
- compressing the tensile member, the first layer, and the second layer within the mold to bond the first layer and the second layer to the tensile member, the mold compressing the protrusion prior to compressing the second portion of the tensile member.
A method of manufacturing a fluid-filled chamber, the method comprising:
- locating a thermoplastic polymer foam tensile member within a mold and between a first layer and a second layer of thermoplastic polymer material, a first surface of the tensile member being located adjacent to the first layer, and a second surface of the tensile member being located adjacent to the second layer, the tensile member defining a cavity located between the first surface and the second surface, the cavity extending entirely through the tensile member and in a direction that is substantially parallel to the first surface and the second surface, and the tensile member defining a protrusion positioned adjacent to the cavity;
- compressing the tensile member, the first layer, and the second layer within the mold to directly bond (a) the first layer to the first surface of the tensile member, (b) the second layer to the second surface of the tensile member, and (c) the first layer and the second layer together around a periphery of the tensile member;
- and
- incorporating the chamber into an article of footwear.
A method of manufacturing a fluid-filled chamber, the method comprising:
- locating a tensile member within a mold and between a first layer and a second layer of polymer material, the tensile member having a first portion with greater compressibility than a second portion, the first portion being joined with the second portion and formed as a one-piece element, and the mold defining a void for forming the chamber, a surface of the tensile member having at least one protrusion extending outward from the first portion;
- and
- compressing the tensile member, the first layer, and the second layer within the void, the protrusion being compressed prior to the second portion of the tensile member.
A method of manufacturing a fluid-filled chamber, the method comprising:
- placing a thermoplastic polymer foam tensile member between a first layer and a second layer of thermoplastic polymer material, the tensile member having:
- a first surface located adjacent to the first layer,
- a second surface located adjacent to the second layer,
- a side surface extending between the first surface and the second surface,
- a plurality of cavities located between the first surface and the second surface, at least one of the cavities extending in a direction that is substantially parallel to the first surface and the second surface and extending through at least one area of the side surface, and
- a plurality of protrusions extending outward from the first surface and the second surface in areas adjacent to the cavities;
- and
- compressing the tensile member, the first layer, and the second layer with a mold such that:
- the mold contacts the first layer to directly bond the first layer to the first surface of the tensile member, the mold compressing the protrusions prior to areas of the tensile member where the protrusions are absent,
- the mold contacts the second layer to directly bond the second layer to the second surface of the tensile member, and
- the first layer and the second layer are compressed together around a periphery of the tensile member to form a direct bond between the first layer and the second layer.
Dependencies are inferred from the claim text.