Inflatable structure and method of manufacture

• US 8,673,102 B2
• Filed: 11/16/2006
• Issued: 03/18/2014
• Est. Priority Date: 12/23/2003
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Kemery, Michael, Rapaport, Zvi, Guild, Tobin N.
• Primary Examiner(s): Tucker, Philip
• Assistant Examiner(s): WU, VICKI H
• Application Number:
  US11/560,375
• Publication Number:
  US 20070069419A1
• Time in Patent Office: 2,679 Days
• Field of Search: 482/148, 264/241, 264/510, 264/248, 156/145, 156/221, 156/245, 156/285, 525/240, 428/220, 428/47.5, 472/134, 446/220, 277/583, 277/646, 425/405.1
• US Class Current: 156/242
• CPC Class Codes: A63B 2225/62 Inflatable
• CPC Class Codes: A63B 26/003 for improving balance or equilibrium balance beams A63B4/00; apparatus for rope dancing A63B7/08; balancing drums, balancing boards or the like A63B22/16
• CPC Class Codes: B29C 2793/009 after shaping
• CPC Class Codes: B29C 33/20 Opening, closing or clamping
• CPC Class Codes: B29C 49/0691 using sheet like material, e.g. sheet blow-moulding from joined sheets
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29C 51/267 Two sheets being thermoformed in separate mould parts and joined together while still in the mould B29C49/0691 takes precedence
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• 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 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/24221 being circular B29C66/51 takes precedence
• CPC Class Codes: B29C 66/53246 said single elements being spouts, e.g. joining spouts to containers
• 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 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29K 2023/083 EVA, i.e. ethylene vinyl acetate copolymer
• CPC Class Codes: B29K 2055/02 ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• 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: Y10S 482/907 : Stretching

Abstract

A method of thermoforming an inflatable structure of dissimilar materials includes the steps of providing a first sheet formed of a first material and a second sheet formed of a second material different than the first material, the second sheet being spaced from the first sheet, and a valve being positioned between the first and second sheets; heating the first and second sheets to a temperature above their glass transition temperature and below their melting point; bonding the first and second sheets together in a mold having an opposed pair of cavities to form an inflatable structure having a seal around a periphery thereof, the valve extending through the seal and being in fluid communication with an interior and exterior of the inflatable structure; and trimming excess material from the periphery of the inflatable structure.

Claims

1. A method of thermoforming an inflatable structure of dissimilar materials comprising the following steps, in combination:

providing a first sheet formed of a first material and a second sheet formed of a second material different than the first material, each of the first sheet and the second sheet having an interior surface and an opposed exterior surface, the interior surface of the second sheet being spaced from the interior surface of the first sheet, and a valve being positioned between the first and second sheets;

heating the first and second sheets to a temperature above their glass transition temperature and below their melting point;

bonding only peripheral edges of the first and second sheets together in a mold having an opposed pair of cavities to form an inflatable structure having a sidewall, a first portion of the sidewall being formed by the exterior surface of the first sheet and a second portion of the sidewall being formed by the exterior surface of the second sheet, a junction of the first and second portions of the sidewall defining a seal around a periphery thereof, the valve extending through the seal and being in fluid communication with an interior and exterior of the inflatable structure; and

trimming excess material from the periphery of the inflatable structure.

2. The method of claim 1, wherein the step of providing the first and second sheets includes the step of:

providing a frame for supporting the first and second sheets, the first and second sheets being spaced from one another and the valve being positioned between the first and second sheets.

3. The method of claim 2, further comprising the step of:

transporting the frame between steps of the thermoforming process with a shuttle mechanism.

4. The method of claim 2, wherein the frame comprises a first portion and a second portion secured to the first portion by a hinge.

5. The method of claim 2, further comprising a spacer positioned within the frame between the first and second sheets.

6. The method of claim 1, wherein the step of heating is performed in an oven.

7. The method of claim 1, further comprising the step of injecting pressurized air between the first and second sheets during the heating and bonding steps.

8. The method of claim 7, wherein the pressurized air is injected through the valve.

9. The method of claim 1, wherein one of the first material and the second material is a rigid thermoplastic and the other is a flexible plastic elastomer.

10. The method of claim 1, wherein the first material is a mixture of acrylonitrile butadiene styrene and polyurethane.

11. The method of claim 1, wherein the second material is polyurethane.