Fluid-filled chambers with foam tensile members and methods for manufacturing the chambers
First Claim
1. 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;
locating the tensile member, the first layer, and the second layer within a mold, the mold having a protrusion in an area that contacts the first layer adjacent to the first portion of the tensile member; and
compressing the tensile member, the first layer, and the second layer within the mold to apply pressure with the protrusion to the first layer and the first portion of the tensile member and to also bond (a) the first layer to a first surface of the tensile member, (b) the second layer to a second surface of the tensile member, and (c) the first layer and the second layer together around a periphery of the tensile member.
1 Assignment
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Accused Products
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.
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Citations
29 Claims
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1. A method of manufacturing a fluid-filled chamber, the method comprising:
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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; locating the tensile member, the first layer, and the second layer within a mold, the mold having a protrusion in an area that contacts the first layer adjacent to the first portion of the tensile member; and compressing the tensile member, the first layer, and the second layer within the mold to apply pressure with the protrusion to the first layer and the first portion of the tensile member and to also bond (a) the first layer to a first surface of the tensile member, (b) the second layer to a second surface of the tensile member, and (c) the first layer and the second layer together around a periphery of the tensile member. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of manufacturing a fluid-filled chamber, the method comprising:
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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, and the mold having a protrusion positioned to contact the first layer adjacent to the cavity; compressing the tensile member, the first layer, and the second layer within the mold to apply pressure with the protrusion to the first layer and an area of the tensile member having the cavity and to also 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. - View Dependent Claims (12, 13, 14, 15)
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16. A method of manufacturing a fluid-filled chamber, the method comprising:
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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, and the mold defining a void for forming the chamber, a surface of the void having at least one protrusion; and compressing the tensile member, the first layer, and the second layer within the mold, the protrusion contacting the first layer in an area that is adjacent to the first portion of the tensile member, and the protrusion compressing the first layer and the first portion of the tensile member together. - View Dependent Claims (17, 18, 19, 20, 21)
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22. A method of manufacturing a fluid-filled chamber, the method comprising:
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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, and a plurality of cavities located between the first surface and the second surface; 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 having a plurality of protrusions that contact the first layer adjacent to the cavities of the tensile member, the protrusions compressing the first layer and portions of the tensile member that are adjacent to the cavities together, 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. - View Dependent Claims (23, 24, 25, 26, 27, 28, 29)
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Specification