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

• US 8,540,838 B2
• Filed: 11/23/2009
• Issued: 09/24/2013
• 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, Christensen, Brian, Davis, Paul, Litchfield, Paul
• Primary Examiner(s): Chan, Sing P
• Application Number:
  US12/624,232
• Publication Number:
  US 20100126661A1
• Time in Patent Office: 1,401 Days
• Field of Search: 156145-147, 156/206, 156/209, 156/289, 156/250, 156/251, 156/267, 156/290, 156/308.2, 156/308.4, 156/308.6, 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 article of footwear, comprising the steps of:

(a) providing a first film;

(b) applying a barrier material using a screen, template or stencil to a first side of said first film in a bladder configuration;

(c) providing a second film with said first film, such that said barrier material is disposed between said first film and said second film;

(d) adhering said first film to said second film to form a sealed peripheral area, except in the area where said barrier material has been applied to said first film, to form at least one inflatable compartment corresponding in overall shape to said bladder configuration;

(e) coupling an inflation device and a deflation device to said inflatable compartment, wherein said inflation device and said deflation device is a fitment coupled to said inflatable compartment at an opening through at least one of said first film or said second film and along a conduit formed between said first and second films;

(f) cutting along said sealed peripheral area to form a bladder having said at least one inflatable compartment and a sealed peripheral edge; and

(g) incorporating said bladder into footwear to form the inflatable article of footwear, wherein said inflation device and said deflation device permit selective, repeated inflation and deflation of said bladder.

2. The method of claim 1, wherein said barrier material is a paint, ink, photosensitive material, particulate or acid.

3. The method of claim 1, wherein said barrier material is a photosensitive material.

4. The method of claim 3 further comprising the step of exposing the photosensitive material to light.

5. The method of claim 1, wherein the barrier material is applied using screen printing.

6. The method of claim 1, wherein said first and second films are thermoplastic layers.

7. The method of claim 6, wherein said one of said first or second film is a laminate comprised of a thermoplastic layer and a substrate.

8. The method of claim 1, wherein said inflation device is a pump and said deflation device is a release valve.

9. The method of claim 1, wherein said step of adhering said first film to said second film is accomplished by calendaring said first and second films through first and second rollers.

10. The method of claim 1, wherein said step of adhering said first film to said second film is accomplished by applying a heated platen to a side of either said first film or said second film.

11. 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) applying a photosensitive barrier material to said first side of said first film;

(c) providing a second film and positioning said second film over said first side of said first film, such that said barrier material is disposed between said first film and said second film;

(d) adhering said first film to said second film to form a sealed peripheral area, except in the area where said barrier material has been applied to said first side of said first film, to form at least one inflatable compartment corresponding in overall shape to a bladder configuration;

(e)coupling an inflation device and a deflation device to said inflatable compartment, wherein said inflation device and said deflation device is a fitment coupled to said inflatable compartment at an opening through at least one of said first film or said second film and along a conduit formed between said first and second films; and

(f) cutting along said sealed peripheral area to form a bladder having said at least one inflatable compartment and a sealed peripheral edge, wherein said inflation device and said deflation device permit selective, repeated inflation and deflation of said bladder.

12. The method of claim 11 further comprising the step of exposing the photosensitive barrier material to light.

13. The method of claim 11, wherein the photosensitive barrier material is applied using a screen, template or stencil.

14. The method of claim 11, wherein the photosensitive barrier material is applied using screen printing.

15. The method of claim 11, wherein said first and second films are thermoplastic layers.

16. The method of claim 15, wherein said one of said first or second film is a laminate comprised of a thermoplastic layer and a substrate.

17. The method of claim 11, wherein said first film is sealed to said second film by application of a heated platen.

18. A method for manufacturing an inflatable article of footwear, comprising the steps of:

(a) providing a first film;

(b) applying a photosensitive barrier material using a screen, template or stencil to a first side of said first film in a bladder configuration;

(c) exposing the photosensitive barrier material to light;

(d) providing a second film and positioning said second film over said first film, such that said photosensitive barrier material is disposed between said first film and said second film;

(e) adhering said first film to said second film to form a sealed peripheral area, except in the area where said photosensitive barrier material has been applied to said first film, to form at least one inflatable compartment corresponding in overall shape to said bladder configuration;

(f) coupling an inflation device and a deflation device to said inflatable compartment, wherein said inflation device and said deflation device is a fitment coupled to said inflatable compartment at an opening through at least one of said first film or said second film and along a conduit formed between said first and second films;

(g) cutting along said sealed peripheral area to form a bladder having said at least one inflatable compartment and a sealed peripheral edge; and

(h) incorporating said bladder into footwear to form the inflatable article of footwear, wherein said inflation device and said deflation device permit selective, repeated inflation and deflation of said bladder.

19. The method of claim 18, wherein said inflation device and said deflation device is a fitment comprising a pump and a release valve.

20. 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) applying a photosensitive barrier material to said first side of said first film;

(c) providing a second film and positioning said second film over said first side of said first film, such that said barrier material is disposed between said first film and said second film;

(d) ultrasonically welding said first film to said second film to form a sealed peripheral area, except in the area where said barrier material has been applied to said first side of said first film, to form at least one inflatable compartment corresponding in overall shape to a bladder configuration;

(e) coupling an inflation device and a deflation device to said inflatable compartment, wherein said inflation device and said deflation device is a fitment coupled to said inflatable compartment at an opening through at least one of said first film or said second film and along a conduit formed between said first and second films; and

(f) cutting along said sealed peripheral area to form a bladder having said at least one inflatable compartment and a sealed peripheral edge, wherein said inflation device and said deflation device permit selective, repeated inflation and deflation of said bladder.

21. The method of claim 20, wherein said inflation device is a pump and said deflation device is a release valve.