Method for manufacturing inflatable footwear or bladders for use in inflatable articles

• US 7,622,014 B2
• Filed: 07/01/2005
• Issued: 11/24/2009
• Est. Priority Date: 07/01/2005
• Status: Active Grant

• Current Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Original Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Inventors: Millette, Frank, Davis, Paul M., Christensen, Brian, Litchfield, Paul E.
• Primary Examiner(s): Tucker; Philip C
• Assistant Examiner(s): Chan; Sing P
• Application Number:
  US11/171,475
• Publication Number:
  US 20070000605A1
• Time in Patent Office: 1,607 Days
• Field of Search: 156/209, 156/206, 156/289, 156/308.6, 156145-147, 156/250, 156/251, 156/267, 156/290, 156/308.2, 156/308.4, 156/310
• US Class Current: 156/267
• CPC Class Codes: A43B 13/189 filled with a non-compressible fluid, e.g. gel, water
• CPC Class Codes: A43B 13/203 provided with a pump or valve
• CPC Class Codes: A43B 23/0285 filled with a non-compressible fluid, e.g. gel or water
• CPC Class Codes: A43B 23/029 Pneumatic upper, e.g. gas filled
• CPC Class Codes: A43B 23/26 Tongues for shoes
• CPC Class Codes: A43D 25/06 Devices for gluing soles on shoe bottoms A43D25/18, A43D25/20 take precedence
• CPC Class Codes: B29C 2791/009 Using laser curing using laser B29C2035/0838, welding using laser beams B29C65/16
• CPC Class Codes: B29C 2793/0009 Cutting out
• CPC Class Codes: B29C 2793/009 after shaping
• CPC Class Codes: B29C 2795/002 before shaping
• CPC Class Codes: B29C 59/04 using rollers or endless belts
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 66/004 Preventing sticking together, e.g. of some areas of the parts to be joined
• CPC Class Codes: B29C 66/00461 being liquid, e.g. oil based
• CPC Class Codes: B29C 66/00463 being solid, e.g. a powder
• CPC Class Codes: B29C 66/0326 Cutting, e.g. by using waterjets, or perforating using heat B29C66/0346
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/133 : Fin-type joints, the parts to be joined being flexible the parts to be joined being rigid B29C66/1312
• CPC Class Codes: B29C 66/24 : said joint lines being closed or non-straight
• CPC Class Codes: B29C 66/43 : Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/4326 : for making hollow articles or hollow-preforms, e.g. half-shells
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/712 : the composition of one of the parts to be joined being different from the composition of the other part
• CPC Class Codes: B29C 66/72327 : consisting of natural products or their composites, not provided for in B29C66/72321 - B29C66/72324
• CPC Class Codes: B29C 66/7234 : comprising a barrier layer
• CPC Class Codes: B29C 66/83413 : cooperating rollers, cylinders or drums
• CPC Class Codes: B29K 2007/00 : Use of natural rubber as moulding material
• CPC Class Codes: B29K 2011/00 : Use of rubber derived from chloroprene as moulding material
• CPC Class Codes: B29K 2019/00 : Use of rubber not provided for in a single one of main groups B29K2007/00 - B29K2011/00, as moulding material
• CPC Class Codes: B29K 2021/00 : Use of unspecified rubbers as moulding material
• CPC Class Codes: B29K 2021/003 : Thermoplastic elastomers
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/083 : EVA, i.e. ethylene vinyl acetate copolymer
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2023/18 : Polymers of hydrocarbons having four or more carbon atoms, e.g. polymers of butylene, e.g. PB, i.e. polybutylene
• CPC Class Codes: B29K 2023/22 : Copolymers of isobutene, e.g. butyl rubber
• CPC Class Codes: B29K 2025/06 : PS, i.e. polystyrene
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2031/04 : Polymers of vinyl acetate, e.g. PVAc, i.e. polyvinyl acetate
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/003 : PET, i.e. poylethylene terephthalate
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2083/00 : Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2105/256 : Sheets, plates, blanks or films
• CPC Class Codes: B29L 2022/02 : Inflatable articles balls B29L2031/54 ; inner tyres B29L2023/245
• CPC Class Codes: B29L 2022/025 : Bladders
• CPC Class Codes: B29L 2031/50 : Footwear, e.g. shoes or parts thereof
• CPC Class Codes: B32B 2398/20 : Thermoplastics
• CPC Class Codes: B32B 2437/02 : Gloves, shoes
• CPC Class Codes: B32B 37/0076 : characterised in that the layers are not bonded on the totality of their surfaces
• CPC Class Codes: B32B 37/26 : with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
• CPC Class Codes: B32B 38/06 : Embossing
• CPC Class Codes: Y10T 156/1052 : with cutting, punching, tearing or severing
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal

Abstract

The present invention is a method for manufacturing inflatable articles, or bladders for inflatable articles, that is time-efficient, simple, inexpensive and permits the uninterrupted manufacture of numerous and even customized article or bladder configurations and sizes, without expensive configuration-specific, metal tooling. The method includes the steps of applying a barrier material to a side of a first film, providing a second film with the first film so that the barrier material is disposed between the first and second films, adhering the first film to the second film so that the films are sealed together in areas except where the barrier material has been applied to form at least one inflatable compartment and sealed peripheral edge, and cutting along the sealed peripheral edge to form an inflatable article or bladder for use in an article of manufacture. The barrier material may be a paint, ink, paper or surface treatment that effectively prevents the first film from adhering to the second. The inflatable article or bladder of the present invention may be used as or in athletic equipment, for example, including footwear.

Claims

1. A method for manufacturing an inflatable bladder, comprising the steps of:

(a) providing a first film having a first side and a second side;

(b) texturizing said first side of said first film in an area corresponding in shape to a pre-defined bladder configuration;

(c) providing a second film in contact with said first film, such that said first side of said first film faces said second film, to prevent said first film and said second film from adhering to each other to allow for inflation between said first film and said second film in the area where said first side of said first film has been texturized;

(d) adhering said first film to said second film to form a bladder having a sealed periphery in the area where said first side of said first film has not been texturized, and at least one inflatable compartment corresponding in overall shape to said pre-defined bladder configuration in the area where said first side of said first film has been texturized; and

(e) cutting along said sealed periphery to yield a bladder having at least one inflatable compartment and a sealed peripheral edge.

2. The method of claim 1, wherein said first or second film is a thermoplastic film.

3. The method of claim 2, wherein either of said first film or said second film is a laminate comprising a thermoplastic film attached to a textile.

4. The method of claim 1, wherein said cutting step is accomplished by a laser, water jet, a metal die or a cutting die provided with a corrosive or dissolving agent.

5. The method of claim 1, wherein said first film is adhered to said second film by calendaring said first and second films through first and second rollers.

6. The method of claim 1, wherein said texturizing step comprises embossing said first side of said first film.

7. A method for continuous feed manufacture of customized inflatable bladders for footwear, comprising the steps of:

(a) providing a database, wherein said database comprises at least one information record having at least one customized inflatable bladder design for incorporation into an article of footwear;

(b) providing a continuous feed of a first thermoplastic film;

(c) applying a baffler material to a first side of said first thermoplastic film in accordance with the configuration of said at least one customized inflatable bladder design of said at least one information record from said database, as said first thermoplastic film is continuously fed;

(d) providing a continuous feed of a second thermoplastic film with said continuous feed of said first thermoplastic film, such that said baffler material faces said second thermoplastic film, to prevent said first thermoplastic film and said second thermoplastic film from adhering to each other to allow for inflation between said first thermoplastic film and said second thermoplastic film in the area where said barrier material has been applied;

(e) adhering said continuous feed of said first thermoplastic film to said continuous feed of said second thermoplastic film in a continuous manner, to continuously form said customized inflatable bladder having a sealed periphery in the area where said barrier material has not been applied to said first thermoplastic film, and at least one customized inflatable compartment in the area where said barrier material has been applied to said first side of said first thermoplastic film, said customized inflatable bladder corresponding in configuration to said customized inflatable bladder design of said at least one information record; and

(f) cutting along said sealed periphery to yield said customized inflatable bladder having said at least one customized inflatable compartment and a sealed peripheral edge.

8. The method of claim 7 further comprising the step of attaching a fluid inlet valve to the customized inflatable bladder to allow for inflation of said bladder.

9. The method of claim 8 further comprising the step of attaching a release valve to the customized inflatable bladder to allow for the release of fluid from the bladder.

10. The method of claim 7 further comprising the step of attaching a pump to the customized inflatable bladder to allow for inflation of the bladder.

11. The method of claim 7, wherein said barrier material is applied to said first side of said first thermoplastic film by a digital printer in communication with said database.

12. The method of claim 11, wherein said barrier material is a paint or ink.

13. The method of claim 7, wherein said cutting step is accomplished by a laser, water jet, metal die or cutting die provided with a corrosive or dissolving agent.

15. The method of claim 7, wherein said database comprises at least two information records having at least two customized bladder designs for incorporation into footwear, and wherein said barrier material is applied in a continuous manner to said first side of said first thermoplastic film, first, in accordance with the configuration of one of said at least two customized bladder designs and, second, in accordance with the configuration of the other of said at least two customized bladder designs.

16. The method of claim 7 further comprising the step of incorporating said customized inflatable bladder into an article of footwear.

17. The method of claim 7, wherein said cutting step continuously follows said adhering step to continuously yield customized inflatable bladders, each of said customized inflatable bladders having at least one customized inflatable compartment and a sealed peripheral edge.

14. The method of 7, wherein said first thermoplastic film is adhered to said second thermoplastic film by calendaring said first and second thermoplastic films, with said barrier material disposed thereinbetween, through first and second rollers.

18. A method for continuous feed manufacture of inflatable bladders for footwear, comprising the steps of:

(a) providing a database, wherein said database comprises multiple information records, each one of said multiple information records having a design for an inflatable bladder for incorporation into an article of footwear;

(b) providing a continuous feed of a first thermoplastic film;

(c) selecting a design for an inflatable bladder from said database of said multiple information records;

(d) applying a barrier material to a first side of said thermoplastic film in accordance with the configuration of said selected inflatable bladder design selected from said multiple information records, as said first thermoplastic film is continuously fed;

(e) providing a continuous feed of a second thermoplastic film with said continuous feed of said first thermoplastic film, such that said barrier material faces said second thermoplastic film, to prevent said first thermoplastic film and said second thermoplastic film from adhering to each other to allow for inflation between said first thermoplastic film and said second thermoplastic film in the area where said barrier material has been applied;

(f) adhering said continuous feed of said first thermoplastic film to said continuous feed of said second thermoplastic film in a continuous manner, to continuously form an inflatable bladder having a sealed periphery in the area where said barrier material has not been applied to said first thermoplastic film, and at least one inflatable compartment in the area where said barrier material has been applied to said first side of said first thermoplastic film, said inflatable bladder corresponding in configuration to said selected inflatable bladder design selected from said multiple information records; and

(g) cutting along said sealed periphery to yield said inflatable bladder having at least one inflatable compartment and a sealed peripheral edge corresponding in shape to said selected inflatable bladder design.

19. The method of claim 18, wherein said multiple information records comprise various inflatable bladder designs for the components of a footwear upper.

20. The method of claim 18, wherein said cutting step continuously follows said adhering step to continuously yield inflatable bladders, each of one of said cut inflatable bladders having at least one inflatable compartment and a sealed peripheral edge corresponding to the inflatable bladder design of said selecting step.