Fluid-Filled Chamber With A Textile Tensile Member

• US 20090288312A1
• Filed: 05/20/2008
• Published: 11/26/2009
• Est. Priority Date: 05/20/2008
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Dua, Bhupesh
• Granted Patent: US 8,151,486 B2
• Time in Patent Office: Days
• US Class Current: 36/29
• CPC Class Codes: A41D 13/015 with shock-absorbing means A41D13/05 takes precedence
• CPC Class Codes: A42B 3/121 with at least one layer or pad containing a fluid
• CPC Class Codes: A43B 1/04 braided, knotted, knitted or crocheted
• CPC Class Codes: A43B 13/20 Pneumatic soles filled with a compressible fluid, e.g. air, gas inflatable linings for skiboots A43B5/0407
• CPC Class Codes: A43B 17/03 filled with a gas, e.g. air
• CPC Class Codes: A63B 41/08 Ball covers; Closures therefor
• CPC Class Codes: A63B 43/00 Balls with special arrangements
• CPC Class Codes: A63B 71/081 fluid-filled, e.g. air-filled
• CPC Class Codes: A63B 71/10 for the head A63B71/081 takes precedence ; in the form of caps or hats A42B1/08; helmets A42B3/00
• CPC Class Codes: A63B 71/141 in the form of gloves
• CPC Class Codes: D04B 1/22 specially adapted for knitting goods of particular configuration
• CPC Class Codes: D10B 2403/0122 Smooth surfaces, e.g. laminated or coated
• CPC Class Codes: D10B 2403/022 Lofty fabric with variably spaced front and back plies, e.g. spacer fabrics
• CPC Class Codes: D10B 2501/043 Footwear
• CPC Class Codes: D10B 2507/08 Balls

Abstract

A fluid-filled may include including an outer barrier, a tensile member, and a fluid. The tensile member may be located within barrier and formed from a textile element that includes a pair of spaced layers joined by a plurality of connecting members. In some configurations, an edge of the tensile member may have a finished configuration or the tensile member may be contoured. The fluid is also located within the barrier and pressurized to place an outward force upon the barrier. In manufacturing a fluid-filled chamber, a textile tensile member may be formed with at least one contoured surface or a finished edge. The tensile member is then located within a polymer barrier and bonded to opposite sides of the barrier.

Claims

1. A fluid-filled chamber comprising:

an outer barrier formed of a polymer material that defines an interior void;

a tensile member located within the interior void and bonded to opposite sides of the barrier, the tensile member being formed from a textile element that includes a pair of spaced layers joined by a plurality of connecting members, each of the layers having an edge, at least a portion of one of the edges having a finished configuration; and

a fluid located within the interior void, the fluid being pressurized to place an outward force upon the barrier and induce tension in at least a portion of the connecting members.

2. The chamber recited in claim 1, wherein at least a portion of the layers are non-parallel.

3. The chamber recited in claim 1, wherein at least one of the layers is contoured.

4. The chamber recited in claim 1, wherein the edges of both of the layers have the finished configuration.

5. The chamber recited in claim 1, wherein ends of yarn forming the layers are substantially absent from the edges.

6. The chamber recited in claim 1, wherein the chamber is incorporated into an article of footwear.

7. An article of footwear having an upper and a sole structure secured to the upper, at least one of the upper and the sole structure incorporating a fluid-filled chamber comprising:

an outer barrier formed of a polymer material that defines an interior void, the barrier having;

a first portion that forms a first surface of the chamber,

a second portion that forms an opposite second surface of the chamber, and

a sidewall portion that that extends between the first portion and the second portion to form a sidewall of the chamber;

a tensile member located within the interior void and formed from a plurality of yarns, the tensile member including;

a first layer joined to the first portion of the barrier, ends of the yarns being substantially absent from an edge of the first layer,

a second layer spaced from the first layer and joined to the second portion of the barrier, ends of the yarns being substantially absent from an edge of the second layer, and at least a portion of the second layer being non-parallel to the first layer, and

a plurality of connecting members extending between the first layer and the second layer; and

a fluid located within the void, the fluid being pressurized to place an outward force upon the barrier and induce tension in at least a portion of the connecting members.

8. The article of footwear recited in claim 7, wherein at least one of the first layer and the second layer is contoured.

9. The article of footwear recited in claim 7, wherein the chamber is located within the sole structure.

10. The article of footwear recited in claim 9, wherein a heel portion of the chamber has a greater thickness than a forefoot portion of the chamber.

11. The article of footwear recited in claim 9, wherein a peripheral portion of the chamber has a greater thickness than a central portion of the chamber.

12. A method of manufacturing a fluid-filled chamber, the method comprising:

knitting a tensile member to have a shape of the chamber; and

locating the tensile member within a polymer barrier and bonding the tensile member to opposite sides of the barrier.

13. The method recited in claim 12, wherein the step of knitting includes dimensioning the tensile member to have a lesser width and a lesser length than the chamber.

14. The method recited in claim 12, wherein the step of knitting includes utilizing a flat-knitting machine.

15. The method recited in claim 12, wherein the step of knitting includes utilizing yarn, and the step of knitting further includes finishing at least one edge of the tensile member such that ends of the yarn are substantially absent from the edge.

16. The method recited in claim 12, wherein the step of knitting includes forming a first area and a second area of the tensile member to have different thicknesses.

17. The method recited in claim 12, wherein the step of knitting includes forming a surface of the tensile member to have a contoured configuration.

18. The method recited in claim 12, further including a step of incorporating the chamber into an article of footwear.

19. A method of manufacturing a fluid-filled chamber, the method comprising:

utilizing a flat-knitting apparatus to form a textile tensile member with at least one contoured surface;

finishing at least one edge of the tensile member such that ends of yarn within the tensile member are substantially absent from the edge; and

locating the tensile member within a polymer barrier and bonding the tensile member to opposite sides of the barrier.

20. The method recited in claim 19, wherein the step of utilizing the flat-knitting apparatus includes forming the tensile member to have a shape of the chamber and dimensioning the tensile member to have a lesser width and a lesser length than the chamber.

21. The method recited in claim 19, further including a step of incorporating the chamber into an article of footwear.

22. A method of manufacturing a fluid-filled chamber, the method comprising:

knitting a tensile member with a first layer, a second layer spaced from the first layer, and a plurality of connecting members with varying lengths extending between the first layer and the second layer;

finishing edges of the first layer and the second layer such that ends of yarn within the tensile member are substantially absent from the edges;

locating the tensile member within a polymer barrier and bonding the first layer and the second layer to opposite sides of the barrier; and

pressurizing the barrier to place the connecting members in tension.

23. The method recited in claim 22, wherein the step of knitting includes forming the tensile member to have a shape of the chamber and dimensioning the tensile member to have a lesser width and a lesser length than the chamber.

24. The method recited in claim 22, wherein the step of knitting includes forming a first area and a second area of the tensile member to have different thicknesses.

25. The method recited in claim 22, further including a step of incorporating the chamber into an article of footwear.