Bladder with multi-stage regionalized cushioning

• US 20030183324A1
• Filed: 04/24/2003
• Published: 10/02/2003
• Est. Priority Date: 03/16/2000
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Passke, Joel L., Herridge, David B., Aveni, Michael A., Potter, Daniel R., Naiman, Alaric, Tawney, John C., Colby, Edward G., Scarfe, Julian A., Ager, Colin D., MacGregor, Alastair R.
• Granted Patent: US 7,132,032 B2
• Time in Patent Office: Days
• US Class Current: 156/145
• CPC Class Codes: A43B 13/20 Pneumatic soles filled with a compressible fluid, e.g. air, gas inflatable linings for skiboots A43B5/0407

Abstract

A bladder which is particularly useful for a sole assembly of a shoe is formed of multiple layers of barrier film to provide multiple pressurized layers of cushioning fluid or gas when the bladder is filled. A multiple gas layer bladder enhances cushioning response by relying more on the response characteristics of the gas and reducing the amount of foam and the dependence on foam as a cushioning material. The internal film layers provide a truss-like geometry in cross section and act as tensile members to impart a generally smooth surface contour to the bladder. The bladder is constructed to provide complex regionalized cushioning profiles which are coupled to the anatomy of the foot and expected loads at known points.

Claims

1. A method of manufacturing a fluid-filled bladder for a shoe sole comprising the steps of:

providing a first outer barrier film and a second outer barrier film;

interposing an inner barrier film between the first and second outer films;

applying a pattern of adhesion inhibitor material to either the opposing sides of the inner film or the inner sides of the outer films;

adhering the first and second outer films and the inner film together along their peripheries to form an envelope with an interposed inner film;

adhering the outer films to the inner film in areas which are not weld inhibited; and

supplying fluid to the envelope so the outer films will pull away from one another and the inner film will act as a tensile member attached to the outer films to provide two fluid-filled layers.

2. The method of claim 1, wherein the step of supplying fluid to the envelope comprises supplying different fluids to the two fluid filled layers to vary the cushioning characteristics of the bladder in a vertical direction.

3. The method of claim 1, wherein the step of applying weld inhibitor material includes applying a pattern of weld inhibition to form two discrete sub-chambers in a fluid filled layer.

4. The method of claim 3, wherein the step of supplying fluid comprises supplying a gas to the envelope and pressurizing the sub-chambers to different pressures.

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

interposing a second inner barrier film between the outer films; and

applying a pattern of weld inhibitor material to opposing sides of the second inner barrier film so when fluid is supplied, the inner films pull away from one another to provide a complex tensile member attached to the outer films to provide three fluid filled layers and a generally smooth surface contour to the outer films.

6. The method of claim 1, wherein the step of supplying fluid comprises supplying a gas to pressurize the fluid filled layers.

7. The method of claim 6, wherein the step of supplying fluid comprises supplying a gas to pressurize the fluid filled layers.

8. A method of manufacturing a fluid-filled bladder for a shoe sole comprising the steps of:

forming an envelope from a first outer layer and a second outer layer of barrier film material sealed along their peripheries;

locating a first inner layer of barrier film material between the first outer layer and the second outer layer to define a first fluid layer between the first outer layer and the first inner layer;

attaching the first inner layer to the first outer layer to subdivide the first fluid layer into at least two first chambers isolated from fluid communication with each other;

pressurizing the first chambers with fluids having differing fluid pressures;

locating a second inner layer of barrier film material between the first inner layer and the second outer layer to form;

a second fluid layer located between the first inner layer and the second inner layer, and

a third fluid layer located between the second inner layer and the second outer layer,

 

that are isolated from fluid communication with each other; and

pressurizing at least one of the second fluid layer and the third fluid layer with a fluid having a fluid pressure that is different from at least one of the fluid pressures in the first chambers.

9. The method of claim 8, further including a step of attaching the second inner layer to the first inner layer to subdivide the second fluid layer into at least two second chambers isolated from fluid communication with each other.

10. The method of claim 9, wherein the step of attaching the second inner layer to the first inner layer further includes pressurizing the second chambers with fluids having differing fluid pressures to vary fluid pressures within the second fluid layer.

11. The method of claim 9, wherein the step of attaching the second inner layer to the first inner layer further includes pressurizing the second chambers with fluids having greater fluid pressures than the fluid pressures in the first chambers and the third fluid layer.

12. The method of claim 9, wherein the step of attaching the second inner layer to the first inner layer further includes pressurizing the second chambers located in peripheral portions of the second fluid layer with fluids having greater fluid pressures than the second chambers located in interior portions of the second fluid layer.

13. The method of claim 8, further including a step of selecting the fluids to be gasses.

14. The method of claim 8, further including a step of forming the bladder such that the first fluid layer, the second fluid layer, and the third fluid layer are isolated from fluid communication with each other.

15. The method of claim 8, further including a step of forming the bladder such that a portion of the first fluid layer is in fluid communication with a portion of the third fluid layer.

16. The method of claim 8, further including a step of applying an adhesion inhibitor material to at least one of the first outer layer and the first inner layer.

17. The method of claim 16, wherein the step of attaching the first inner layer to the first outer layer includes bonding the first inner layer to the first outer in areas that do not include the adhesion inhibitor material.

24. The method of claim 16, further including a step of attaching the first inner layer to the first outer layer to bond the first inner layer to the first outer in areas that do not include the adhesion inhibitor material.

18. A method of manufacturing a fluid-filled bladder for a shoe sole comprising the steps of:

forming an envelope from a first outer layer and a second outer layer of barrier film material sealed along their peripheries;

locating a first inner layer and a second inner layer of barrier film material between the first outer layer and second outer layer to divide the envelope into a first fluid layer, a second fluid layer, and a third fluid layer positioned between the first outer layer and the second outer layer;

pressurizing at least two of the fluid layers with fluids having different fluid pressures;

subdividing at least one of the fluid layers into at least two chambers isolated from fluid communication with each other; and

pressurizing the chambers with fluids having different fluid pressures.

19. The method of claim 18, further including a step of selecting the fluids to be gasses.

20. The method of claim 18, wherein the step of subdividing includes forming the chambers by attaching the first outer layer to the first inner layer.

21. The method of claim 18, wherein the step of subdividing includes forming the chambers by attaching the first inner layer to the second inner layer.

22. The method of claim 21, wherein the step of pressurizing the chambers includes selecting the different fluid pressures within the chambers to be greater than fluid pressures in the fluid layers positioned adjacent the first outer layer and the second outer layer.

23. The method of claim 18, further including a step of applying an adhesion inhibitor material to at least one of the first outer layer and the first inner layer.

25. A method of manufacturing a fluid-filled bladder for a shoe sole comprising the steps of:

forming an envelope from a first outer layer and a second outer layer of barrier film material sealed along their peripheries;

positioning a first inner layer and a second inner layer of barrier film material between the first outer layer and the second outer layer to form;

a first fluid layer between first outer layer and the first inner layer

a second fluid layer between the first inner layer and the second inner layer, and

a third fluid layer between the second inner layer and the second outer layer;

attaching the first inner layer to the first outer layer, attaching the second inner layer to the first inner layer to divide the second fluid layer into at least two second chambers, and attaching the second inner layer to the second outer layer; and

pressurizing the first fluid layer, the second fluid layer, and the third fluid layer such that fluid pressures in the chambers located in peripheral portions of the second fluid layer are greater than fluid pressures in the chambers located in interior portions of the second fluid layer, and the fluid pressures in the second chambers are different than fluid pressures in the first fluid layer and the third fluid layer.

26. The method of claim 25, further including a step of selecting the fluids to be gasses.

27. The method of claim 25, wherein the step of pressurizing includes selecting the fluid pressures in the second chambers to be greater than fluid pressures in the first fluid layer and the third fluid layer.

28. The method of claim 25, wherein the step of attaching includes isolating the first fluid layer, the second fluid layer, and the third fluid layer from fluid communication with each other.

29. The method of claim 25, wherein the step of attaching includes isolating the second fluid layer from fluid communication with the first fluid layer and the third fluid layer.

30. The method of claim 29, wherein the step of attaching further includes placing the first fluid layer and the third fluid layer in fluid communication with each other.

31. The method of claim 25, further including a step of applying an adhesion inhibitor material to at least one of the first outer layer and the first inner layer.

32. The method of claim 31, further wherein the step of attaching includes bonding the first inner layer to the first outer in areas that do not include the adhesion inhibitor material.