Method for manufacturing inflatable bladders for use in footwear and other articles of manufacture

• US 8,572,786 B2
• Filed: 10/12/2010
• Issued: 11/05/2013
• Est. Priority Date: 10/12/2010
• Status: Active Grant

• Current Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Original Assignee: Reebok International Limited (Authentic Brands Group, LLC)
• Inventors: Davis, Paul M., Millette, Frank, Litchfield, Paul E.
• Primary Examiner(s): Patterson, Marie
• Application Number:
  US12/903,129
• Publication Number:
  US 20120084999A1
• Time in Patent Office: 1,120 Days
• Field of Search: 121/42.R, 121/46.R, 36/29, 36/35.B, 156/267, 156/290, 156/308.4, 156/308.6
• US Class Current: 12/142.R
• CPC Class Codes: A43B 13/203 provided with a pump or valve
• CPC Class Codes: A43B 17/03 filled with a gas, e.g. air
• CPC Class Codes: A43B 23/029 Pneumatic upper, e.g. gas filled
• CPC Class Codes: A43B 7/14 with foot-supporting parts
• CPC Class Codes: A43B 7/32 with shock-absorbing means resilient soles A43B13/18
• CPC Class Codes: A43D 111/00 Shoe machines with conveyors for jacked shoes or for shoes or shoe parts
• CPC Class Codes: A43D 27/00 Machines for trimming as an intermediate operation working on edges or margins, e.g. by trimming, of shoe part blanks A43D8/32; trimming as a finishing operation in shoemaking A43D87/00
• CPC Class Codes: B29C 2035/0827 using UV radiation
• CPC Class Codes: B29C 2793/009 after shaping
• CPC Class Codes: B29C 33/58 Applying the releasing agents
• CPC Class Codes: B29C 33/64 Silicone
• CPC Class Codes: B29C 37/0067 Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other separating agents B29C33/60
• CPC Class Codes: B29C 37/0075 using release sheets
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/04 Dielectric heating, e.g. high-frequency welding , i.e. radio frequency welding of plastic materials having dielectric properties, e.g. PVC
• CPC Class Codes: B29C 65/085 using a rotary sonotrode
• CPC Class Codes: B29C 65/086 using a rotary anvil
• CPC Class Codes: B29C 65/087 using both a rotary sonotrode and a rotary anvil
• CPC Class Codes: B29C 65/14 using wave energy , i.e. electromagnetic radiation, or particle radiation using mechanical waves B29C65/06; using ultrasonic waves B29C65/08; pressing means transparent to electromagnetic radiation B29C66/81267
• CPC Class Codes: B29C 65/1412 Infrared [IR] radiation
• CPC Class Codes: B29C 65/1425 : Microwave radiation
• CPC Class Codes: B29C 65/18 : using heated tools
• CPC Class Codes: B29C 65/26 : Hot fluid
• CPC Class Codes: B29C 65/74 : by welding and severing , or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
• CPC Class Codes: B29C 66/004 : Preventing sticking together, e.g. of some areas of the parts to be joined
• CPC Class Codes: B29C 66/0042 : of the joining tool and the parts to be joined B29C66/0046 takes precedence; joining tool characterized by its composition B29C66/8122; joining tool characterized by its microstructure B29C66/8124
• CPC Class Codes: B29C 66/0342 : Cooling, e.g. transporting through welding and cooling zone
• 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 66/244 : said joint lines being non-straight, e.g. forming non-closed contours
• CPC Class Codes: B29C 66/439 : Joining sheets for making inflated articles without using a mould
• CPC Class Codes: B29C 66/5326 : said single elements being substantially flat
• CPC Class Codes: B29C 66/5346 : said single elements being substantially flat
• CPC Class Codes: B29C 66/61 : Joining from or joining on the inside for making tubes by bending sheets and joining from the inside B29C53/387
• 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 66/7212 : characterised by the composition of the fibres
• CPC Class Codes: B29C 66/723 : being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/727 : being porous, e.g. foam
• CPC Class Codes: B29C 66/73713 : bi-axially or multi-axially
• CPC Class Codes: B29C 66/7392 : characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/7394 : characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29C 66/81455 : being a fluid inflatable bag or bladder, a diaphragm or a vacuum bag for applying isostatic pressure inflatable element positioned between the joining tool and a backing-up part B29C66/82421
• CPC Class Codes: B29C 66/8161 : said pressing elements being supported or backed-up by springs or by resilient material
• CPC Class Codes: B29C 66/8181 : characterised by the cooling constructional aspects
• CPC Class Codes: B29C 66/8242 : Pneumatic or hydraulic drives using fluid pressure directly acting on the parts to be joined B29C66/8266
• CPC Class Codes: B29C 66/83413 : cooperating rollers, cylinders or drums
• CPC Class Codes: B29C 66/83433 : the contact angle between said rollers, cylinders or drums and said bands or belts being a non-zero angle
• CPC Class Codes: B29D 35/146 : Uppers
• CPC Class Codes: B29K 2007/00 : Use of natural rubber as moulding material
• CPC Class Codes: B29K 2009/00 : Use of rubber derived from conjugated dienes, 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 2021/006 : Thermosetting elastomers
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/0616 : VLDPE, i.e. very low density polyethylene
• CPC Class Codes: B29K 2023/0633 : LDPE, i.e. low density 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 2023/16 : EPM, i.e. ethylene-propylene copolymers; EPDM, i.e. ethylene-propylene-diene copolymers; EPT, i.e. ethylene-propylene terpolymers
• 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 2027/18 : PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29K 2029/14 : Polyvinylacetals
• CPC Class Codes: B29K 2031/04 : Polymers of vinyl acetate, e.g. PVAc, i.e. polyvinyl acetate
• CPC Class Codes: B29K 2033/18 : Polymers of nitriles
• 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 2083/005 : LSR, i.e. liquid silicone rubbers, or derivatives thereof
• CPC Class Codes: B29K 2309/08 : Glass
• CPC Class Codes: B29K 2995/007 : Hardness
• CPC Class Codes: B29L 2022/025 : Bladders
• CPC Class Codes: B29L 2031/504 : Soles
• CPC Class Codes: B29L 2031/7496 : Pumps
• CPC Class Codes: B29L 2031/7506 : Valves
• CPC Class Codes: B32B 2037/1253 : curable adhesive
• CPC Class Codes: B32B 2255/24 : Organic non-macromolecular coating
• CPC Class Codes: B32B 2262/101 : Glass fibres
• CPC Class Codes: B32B 2315/085 : Glass fiber cloth or fabric
• CPC Class Codes: B32B 2327/18 : PTFE, i.e. polytetrafluoroethylene
• CPC Class Codes: B32B 2437/02 : Gloves, shoes
• CPC Class Codes: B32B 37/1292 : selectively, e.g. in stripes, in patterns B32B37/0076 takes precedence
• CPC Class Codes: B32B 38/004 : by physically contacting the layers, e.g. by the use of heated platens or rollers
• CPC Class Codes: B32B 7/14 : applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]

Abstract

The present invention is a method for manufacturing inflatable bladders for use in articles of manufacture. The method includes the steps of providing a first polymer film, applying a curable release coating to the polymer film in a pattern that corresponds to the configuration of the inflatable bladder, curing the release coating to the first polymer film, providing a second polymer film with the first polymer film to form a layered element such that the release coating is disposed between the polymer films, positioning the layered element between two plies of material, applying heat and pressure to adhere the polymer films together except in the area where the release coating has been applied to form an inflatable compartment surrounded by a sealed perimeter, and removing the plies of material from the adhered first and second polymer films.

Claims

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

(a) providing a first polymer film having an inner side and an outer side;

(b) applying a curable release coating to said inner side of said first polymer film in a pattern that corresponds to the configuration of an inflatable compartment of an inflatable bladder;

(c) curing said release coating to said inner side of said first polymer film by the application of ultra violet light;

(d) providing a second polymer film having an inner side and an outer side with said first polymer film to form a layered element, such that said release coating is disposed between said inner side of said first polymer film and said inner side of said second polymer film;

(e) positioning said layered element between a first ply of material and a second ply of material;

(f) applying heat and pressure to said first and second plies of material positioned about said layered element, to adhere said first polymer film to said second polymer film except in the area where said release coating has been applied to said inner side of said first polymer film to form an inflatable compartment surrounded by a sealed perimeter; and

(g) removing said first and second plies of material from said adhered first and second polymer films.

2. The method of claim 1, wherein said curable release coating is silicone fortified.

3. The method of claim 2, wherein said curable release coating is applied to said inner side of said first polymer film by screen printing.

4. The method of claim 1, wherein said first and second plies of material are polytetrafluoroethylene-coated, fiberglass-reinforced cloths.

5. The method of claim 1, wherein at least one of said first and second plies of material is textured.

6. The method of claim 1, wherein said applying heat and pressure step is accomplished by rotary lamination.

7. The method of claim 1 further comprising the step of coupling an inflation device and a deflation device to said inflatable bladder.

8. The method of claim 1, wherein one of said first or second polymer films is a laminate comprised of a polymer layer and a substrate.

9. The method of claim 1, further comprising the steps of:

(h) cutting along said sealed perimeter to form an inflatable bladder having a sealed attachment margin; and

(i) incorporating said inflatable bladder into an article of footwear by attaching said inflatable bladder to said article of footwear at said attachment margin.

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

(a) positioning a barrier material between a first film and a second film in a configuration that corresponds to the shape of an inflatable compartment of the inflatable bladder;

(b) positioning said first and second films, with said barrier material positioned thereinbetween, between a first ply of material and a second ply of material;

(c) adhering said first film to said second film, except in the vicinity of said barrier material, to form said inflatable bladder having said inflatable compartment surrounded by a sealed, continuously substantially flat perimeter; and

(d) removing said first and second plies of material from the inflatable bladder.

11. The method of claim 10, wherein the barrier material is a paint, ink, paper, textile, photosensitive agent, wire, foil, or particulate.

12. The method of claim 10 further comprising the step of incorporating the inflatable bladder into an article of footwear by securing the inflatable bladder to said article of footwear at said perimeter of the inflatable bladder.

13. The method of claim 10, wherein said barrier material is a curable release coating and wherein the step of positioning the barrier material between the first film and the second film includes the substeps of applying said release coating to said first film, curing said release coating to said first film, and sandwiching said cured release coating between the first and second films.

14. The method of claim 13, wherein said release coating is applied to said first film using a screen, template, or stencil.

15. The method of claim 13, wherein said release coating is cured by the application of ultra violet light.

16. The method of claim 10, wherein said first and second plies of material are polytetrafluoroethylene-coated, fiberglass-reinforced cloths.

17. The method of claim 10, wherein at least one of said first and second plies of material is textured.

18. The method of claim 10, wherein said adhering step is accomplished by rotary lamination, by heated pressing between platens, or by application of vacuum and heat.

19. The method of claim 10 further comprising the step of coupling an inflation device and a deflation device to the inflatable bladder.

20. The method of claim 10, wherein one of said first or second films is a laminate comprised of a polymer layer and a substrate.

21. The method of claim 10, wherein the barrier material includes at least two release coatings and wherein the step of positioning the barrier material between the first film and the second film includes the substeps of applying a first release coating to the first film, applying a second release coating to the second film, curing at least one of said release coatings, and sandwiching the release coatings between the first and second films.

22. The method of claim 21, wherein the release coating applied to the second film is a discontinuous coating.