AIR CUSHION WITH MULTISTAGE SHOCK-ABSORBING ASSEMBLY AND FABRICATING METHOD

Abstract

An air cushion connected at least a cushioning element in a vertical stack configuration for absorbing both lighter and heaver heel impacts sequentially in a shoe mid-sole. The air cushion includes a first air bladder and a cushioning element forming a vertical stack configuration such that when the impact lighter than a predetermined value is applied to the vertical stack configuration, it is absorbed by deforming the first air bladder only, and when the impact heavier than the predetermined value is applied to the vertical stack configuration, it is absorbed by deforming both the first air bladder and the cushioning element.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application is a continuation-in-part of U.S. patent application Ser. No. 11/823,291, filed Jun. 27, 2007, entitled “AIR CUSHION WITH MULTISTAGE SHOCK-ABSORBING ASSEMBLY AND FABRICATING METHOD” by Jui Fen Shiao, which itself claims priority to and the benefit of Taiwan Patent Applications No. 095123163, filed Jun. 27, 2006, entitled “AIR CUSHION WITH MULTISTAGE SHOCK-ABSORBING ASSEMBLY AND FABRICATING METHOD” by Jul Fen Shiao, the contents of which are incorporated herein in their entireties by reference.

Some references, if any, which may include patents, patent applications and various publications, are cited and discussed in the description of this invention. The citation and/or discussion of such references is provided merely to clarify the description of the present invention and is not an admission that any such reference is “prior art” to the invention described herein. All references cited and discussed in this specification are incorporated herein by reference in their entireties and to the same extent as if each reference was individually incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to an air cushion assembly adapted for absorbing heel impacts in a shoe mid-sole, and more particularly, to an air cushion assembly having an air bladder associated with a cushioning element in a vertical stack configuration capable of absorbing more than one range of heel impacts against the ground.

BACKGROUND OF THE INVENTION

For most runners, initial foot impact occurs in the heel region. Therefore, the heel strike cushioning material, which is contained principally in the mid-sole of a running shoe, must have a firmness which provides for proper impact cushioning for a person of about average weight.

U.S. Pat. No. 297,980 to Sugiyama describes a cushioning for a shoe mid-sole comprised essentially of one cell having partition walls therein.

U.S. Pat. Nos. 4,342,157 and 4,472,890 to Gilbert describes the use of liquid-filled shock absorbing cushions in the heel portion and forefoot portion of a shoe. Typical liquids include water, glycerin, and mineral oil.

When the runner is heavy, the heel cushioning material may “bottom out” before heel impact is completely absorbed, which can results in shock-related injuries. On the other hand, if the cushioning material is too soft, poor lateral foot stability may result in injuries.

A considerable force generated during athletic activities requires the sole of an athletic shoe provide enhanced protection and shock absorption for the feet, ankles and legs of the wearer. For example, impacts which occur during walking have been known to generate forces of up to 1½ times the body weight at a normal walking speed, running activities up to 2-3 times the body weight of an individual.

For providing an air cushion with wider range of impact absorption, an easier conventional fabrication method of air cushion is shown in FIG. 1, including the steps of preparing a larger bladder 1, putting the larger bladder 1 in a hot pressing mold 13 for forming a plurality of ribs 11 which divides the larger bladder into smaller bladders 14, 15, and 16 in a substantially horizontal configuration for providing a plurality of cushioning areas.

However, the total cushioning area of the smaller bladders 14, 15, and 16 is less than the original of the larger bladder 1, and the ribs 11 form a plurality of vertical walls 110 around each of the small bladders 14, 15, and 16 that may cause the wearer feel pain when some smaller bladders 14 in the central portion become bottom out under some heavy heel impact.

The smaller bladder 14 in the central area can be made softer to comfort the heel of the wearer during taking a normal walking exercise; however this would cause the smaller bladder 14 tends to bottom out in normal running activity. If the smaller bladder 14 contains a higher inner pressure to provide adequate shock absorption for running, it would cause the wearer to feel it is too hard and suffer a pain from the bladder 14 in a normal walking.

In order to perfect the heel cushion in different athletic activities, such as walking and running, there is a need to improve the cushioning function at shoe mid-sole.

SUMMARY OF THE INVENTION

In order to perfect the heel cushioning design for athletic activities, the present invention provides an air cushion assembly and a fabrication method for producing such a cushion assembly. The air cushion assembly according to the present invention contains an air bladder associated with a cushioning element in a vertical stack configuration, so as to absorb a lighter heel impact and heavier heel impact sequentially.

The air bladder of the air cushion assembly may contain a lower inner pressure for providing a softer shock absorption during a wearer taking walking exercise, and the cushioning element may be an air bladder with higher inner pressure or a cushion which made from a resilient element for absorbing some other heavier heel impacts, such as running or playing ball, or the likes.

In one aspect of the present invention, an air cushion for cushioning in a shoe with multistage shock-absorbing assembly includes a first air bladder, having an inner wall which contains a first inner pressure, the inner wall having an upper surface and a lower surface, a tying element, having an upper side which is connected to the upper surface of the inner wall of the first air bladder, and a lower side; and a cushioning element, having an upper side connected to the lower side of the tying element and a lower side connected to the lower surface of the inner wall of the first air bladder, thereby forming a vertical stack configuration for absorbing heel impact in a mid-sole sequentially, such that when the impact lighter than a predetermined value is applied to the vertical stack configuration, it is absorbed by deforming the first air bladder only, and when the impact heavier than the predetermined value is applied to the vertical stack configuration, it is absorbed by deforming both the first air bladder and the cushioning element.

The air cushion for cushioning in a shoe with multistage shock-absorbing assembly may further include an upper frame and a base frame for fixing the first air bladder therebetween.

In one embodiment, the cushioning element is a resilient pad. The tying element is a plurality of inward protruding walls formed on the upper surface of the inner wall of the first air bladder, connected to the upper side of the cushioning element for keeping the first air bladder in a predetermined shape.

In one embodiment, the tying element has a pile of yarns, fabric or fibers which is glued between the first air bladder and the cushioning element, for keeping the first air bladder in a predetermined shape.

In one embodiment, the cushioning element includes a second air bladder which contains a second inner pressure.

In one embodiment, the second air bladder contains a tying element formed with a plurality of inward protruding walls for keeping the second air bladder in a predetermined shape thereof.

In another aspect, the present invention relates to an air cushion for cushioning in a shoe with multistage shock-absorbing assembly. In one embodiment, the air cushion has a first air bladder, having an inner wall which contains a first inner pressure, the inner wall having an upper surface and a lower surface, and a cushioning element, disposed in relation to the first air bladder to form a vertical stack configuration therewith such that when the impact lighter than a predetermined value is applied to the vertical stack configuration, it is absorbed by deforming the first air bladder only, and when the impact heavier than the predetermined value is applied to the vertical stack configuration, it is absorbed by deforming both the first air bladder and the cushioning element.

In one embodiment, the cushioning element is a second air bladder which contains a second air pressure. The air cushion may further have a resilient pad disposed on the upper side of the first air bladder.

In another embodiment, the cushioning element has a second air bladder and a resilient pad.

In yet another embodiment, the cushioning element is a resilient pad.

In a further embodiment, the cushioning element is a bladder containing a gel.

In yet a further embodiment, the cushioning element is a bladder containing a granules cushioning material.

In yet another aspect, the fabrication method of the air cushion assembly according to the present invention includes the steps of blowing a melting inflatable bladder or tube together with a cushioning element in a blowing mold, inflating the melting inflatable bladder with air in high pressure, so as to form a bladder with a passage way that confirming the inner shape of the blowing mold, and blowing air into the bladder in a preset inner pressure; and thereafter sealing the passage way for forming an air cushion with multistage shock-absorbing assembly.

Further scope of the applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings, which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:

FIG. 1 is a schematic view showing the steps of a conventional method for producing an air cushion;

FIG. 2 is a schematic view showing the steps of a fabrication method of an air cushion according to one embodiment of the present invention;

FIG. 3 is a schematic view showing the steps of a fabrication method of an air cushion according to another embodiment of the present invention;

FIG. 4 is a schematic view showing the variety of deformation of an air cushion in different impact loading, explaining the reason to associate an air bladder to a cushioning element in a vertical stack configuration, according to one embodiment of the present invention;

FIG. 5 shows schematically a cross-sectional view of an air cushion according to one embodiment of the present invention;

FIG. 6 shows schematically a cross-sectional view of an air cushion according to another embodiment of the present invention;

FIG. 7 shows schematically a cross-sectional view of an air cushion according to yet another embodiment of the present invention;

FIG. 8 shows schematically a cross-sectional view of an air cushion according to a further embodiment of the present invention;

FIG. 9 shows schematically a cross-sectional view of an air cushion according to yet a further embodiment of the present invention;

FIG. 10 shows schematically a cross-sectional view of an air cushion according to an alternative embodiment of the present invention;

FIG. 11 shows schematically a cross-sectional view of an air cushion according to one embodiment of the present invention;

FIG. 12 shows schematically a cross-sectional view of an air cushion according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 2 and 5, a fabrication method of an air cushion assembly according to one embodiment of the present invention includes the steps of inserting a melting inflatable bladder 40 or tube (not shown) together with a cushioning element 22 in a blowing mold 3 having an upper side, and an opposite, lower side, an exterior surface and an interior surface, inflating the melting inflatable bladder 40 with air in high pressure, so as to form a bladder 41 with a passage way 42 conforming to the inner shape of the blowing mold 3, and blowing air into the bladder 41 in a first inner pressure; and thereafter sealing the passage way 42 for forming a first air cushion 4 which connects the cushioning element 22 on one side. The resulting air cushion with multistage shock-absorbing assembly includes a stacked structure of the upper side of the blowing mold 3, the melting inflatable bladder 40, the cushioning element 22, and the lower side of the blowing mold 3 as shown in FIG. 2.

Preferably, in one embodiment, the cushioning element 22 may have glue or adhesive layer for bonding itself onto the lower side of the melting inflatable bladder 40 such that the resulting air cushion with multistage shock-absorbing assembly includes a stacked structure of the upper side of the blowing mold 3, the melting inflatable bladder 40, the cushioning element 22, and the lower side of the blowing mold 3 as shown in FIG. 2. In an alternative embodiment as shown in FIG. 3, the cushioning element 22 is connected to the interior surface of the melting inflatable tube 50 or bladder (not shown) and disposed into the blowing mold 30 together. The melting inflatable tube 50 comprises a first inner wall 501 and a second inner side 502.

The inner surface of the blowing mold 30 may comprise a plurality of inward protruding portions 31 for forming a bladder 51 with a plurality of indents or holes 52 and a passage way 53. While blowing air into the bladder 51 in a preset pressure; and thereafter sealing the passage way 53, it is forming an air cushion 5 with multistage shock-absorbing assembly. The walls of the indents or holes 52 have one end connected with the cushioning element 22, so as to inhibit bulging effect and keep the air cushion 5 in a predetermined shape.

Referring to FIG. 4, an air cushion 6 of an embodiment of the present invention for absorbing heel impacts in different athletic activities. The air cushion 6 has a cushioning element 22 disposed within an air bladder 60 at the bottom side 222 thereof, to form a vertical stack configuration for providing cushioning force against the heel impacts sequentially. The cushioning element 22 can be a resilient pad which contains a second cushioning material 221, such as liquid, gel cushioning material, air in high pressure, granules cushioning material, polyester elastomer or the like.

The air bladder 60 has an upper surface 61 for absorbing some lighter impacts 66 and 67 in walking exercise. When a wearer is walking, the heel strike yielding a plurality of impacts ranging from 0 to 1.5 times the body weight, therefore the heel imposes the impacts 66 or 67 onto the upper surface 61. In other words, a slighter impact 66 or 67 is absorbed by the deformation of the (first) air bladder 60 only. As the upper surface 61 provides cushioning effect on the heel with no rib, therefore the wearer would feel comfortable without paining caused by the ribs and the vertical walls of the conventional air cushion as being depicted in FIG. 1.

When the wearer is running or taking some other strenuous activities, the impact 68 may increase up to 2-3 times the body weight, this causes the air bladder 60 to be bottom out and deforms the upper portion of the cushioning element 22. By this way, while the air bladder 60 is bottom out, the cushioning element 22 provides a cushioning force to protect the heel from injury. In other words, a higher impact 68 is absorbed by the deformations of both the air bladder 60 and the cushioning element 22 together.

According to the present invention, as illustrated in FIG. 4, the air bladder 60 and the cushioning element 22 form a vertical stack configuration for absorbing heel impact in a mid-sole sequentially. For this arrangement, when the impact lighter 66 or 67 than a predetermined value is applied to the vertical stack configuration, it is absorbed by deforming the first air bladder 60 only, and when the impact 68 heavier than the predetermined value is applied to the vertical stack configuration, it is absorbed by deforming both the first air bladder 60 and the cushioning element 22. The predetermined value can be determined by the design specification of an air cushion, such as materials and the first and/or second air pressures in the first air bladder 60 and the cushioning element 22, respectively. For example, in one embodiment, the predetermined value is 1.5 times of the averaged human weight.

Referring to FIG. 6, an air cushion 4′ comprises a first air bladder 41′ and a resilient pad 43. The air bladder 41′ provides a softer cushioning force for cushioning lighter impacts from a wearer's walking exercise until being bottom out, and provides cushioning force together with the resilient pad 43 to absorb some stronger impacts from running or some other strenuous athletic activities.

Referring to FIG. 7, an alternative embodiment of air cushion 4″ comprises a first air bladder 41″ and a cushioning element 22 in a vertical stack configuration. The cushioning element 22 comprises a resilient pad 225 combined or attached with a second air bladder 226 which contains a second inner pressure. The first air bladder 41″ contains a first inner pressure relatively lower than the second inner pressure thereby to absorb the impact on wear's heel from walking until being bottom out; and thereafter to absorb even much stronger impact together with the second air bladder 226. Once the first air bladder 41″ and the second air bladder 226 are sequentially becoming bottom out, the resilient pad 225 provides a resilient force to buffer the impact, thereby to protect the wearer from possible lower extremity injuries.

Referring to FIG. 8, an alternative embodiment of air cushion 71 with multistage shock-absorbing assembly, comprises an air bladder 710 with a cushioning element 711 disposed therein, and a resilient pad 712 attached thereon. The cushioning element 711 may be a bladder filled with gel, foam, a particulate material, a liquid, or the like. The resilient pad 712 may be an air bladder, a polyester elastomer, fabric, a bladder filled with gel, foam, a particulate material, a liquid, or the like.

Referring to FIG. 9, a further alternative embodiment of air cushion 72 with a multistage shock-absorbing assembly, comprises a first air bladder 721 having an inner wall which contains a first inner pressure, the inner wall having an upper surface and a lower surface, a second air bladder 722, and a plurality of tying elements 723, that connected therebetween in a vertical stack configuration. The second air bladder 722 has one side attached to the lower surface of the inner wall of the first air bladder 721, and other side coupled to the upper surface of the inner wall of the first air bladder 721 via the plurality of tying elements 723, so as to keep the outer surface in flatten or in a predetermined shape without bulging out accidentally. The plurality of tying elements 723 can be a pile of yarns or fabric which is glued between the inner wall of the and the first air bladder 721 and the outside of the second air bladder 722 for eliminating possible bulging effect on outside of the air cushion 72. The first air bladder 721, the second air bladder 722 and the plurality of tying elements 723 are disposed in a vertical stack configuration for absorbing heel impact in a mid-sole sequentially. Accordingly, when the impact lighter than a predetermined value is applied to the vertical stack configuration, it is absorbed by deforming the first air bladder 721 only, and when the impact heavier than the predetermined value is applied to the vertical stack configuration, it is absorbed by deforming both the first air bladder 721 and the second air bladder 722.

Referring to FIGS. 4 and 10, a simplified alternative embodiment of air cushion 73 with a multistage shock-absorbing assembly, comprises a first air bladder 731 encapsulated in a second air bladder 732 in a vertical stack configuration.

Referring to FIG. 11, a refined alternative embodiment of air cushion 74 with a multistage shock-absorbing assembly, comprises a first air bladder 741, a cushioning element 742, a upper frame 743, and a base frame 744 in a vertical stack configuration.

Referring to FIG. 11, the cushioning element 742 may be resilient pad attached on the lower inner side of the first air bladder 741. The first air bladder 741 is contained the cushioning element 742 and can be fixed between the upper frame 743 and the base frame 744. The first air bladder 741 is formed with a plurality inward protruded walls 7410 connected with the outer surface of the cushioning element 742 for acting as tying element to eliminate bulging of the upper surface of the air cushion 74.

Referring to FIG. 12, the cushioning element 80 with a multistage shock-absorbing assembly, comprises a first air bladder 81, a tying element 811, and a second air bladder 82. The tying element 811 is connected between the inner side of the first air bladder 81 which has a first passage way for fill into a first inner pressure P1, and the outside of the second air bladder 82. The second air bladder 82 has a plurality of tying elements 821 formed therein, and a second passage way for fill compressible fluid into a second inner pressure P2. Preferably, the second inner pressure P2 of the second air bladder 82 is relative higher than the first inner pressure P1, thereby to absorb lighter impacts in normal walking exercise by the first air bladder 81, and absorb even more heaver impacts in running or strenuous athletic activity together with the second air bladder 82.

The tying elements 821 may be a plurality of inward protruding walls which connect the upper and lower inner walls of the second air bladder 82 and keep the outer surface of the second air bladder 82 in a predetermined shape.

The inward protruding walls functioning as tying elements 821 may be formed by a blowing mold with small pins that forming a plurality of indent or small holes on the second air bladder 82.

Accordingly to embodiments of the present invention, as shown in FIGS. 9 to 12, when a small impact is loaded, only the first air blade 721, 73, 741 and 81 shall be deformed to absorb such a small impact. However, when a bigger impact is loaded, the first air blade 721, 73, 741 and 81 and the cushioning element 722, 732, 742, and 82 shall be deformed to absorb the bigger impact together.

While the invention has been described by way of example and in terms of preferred embodiments, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures.

Claims

1. An air cushion for cushioning in a shoe with multistage shock-absorbing assembly, comprising:

a first air bladder, having an inner wall which contains a first inner pressure, the inner wall having an upper surface and a lower surface;

a tying element, having an upper side which is connected to the upper surface of the inner wall of the first air bladder, and a lower side; and

a cushioning element, having an upper side connected to the lower side of the tying element and a lower side connected to the lower surface of the inner wall of the first air bladder, thereby forming a vertical stack configuration for absorbing heel impact in a mid-sole sequentially, such that when the impact lighter than a predetermined value is applied to the vertical stack configuration, it is absorbed by deforming the first air bladder only, and when the impact heavier than the predetermined value is applied to the vertical stack configuration, it is absorbed by deforming both the first air bladder and the cushioning element.

2. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 1, wherein the cushioning element comprises a resilient pad.

3. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 2, wherein the tying element comprises a plurality of inward protruding walls disposed between the upper surface of the inner wall of the first air bladder and the upper side of the cushioning element for keeping the first air bladder in a predetermined shape.

4. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 1, wherein the tying element comprises a pile of yarns, fabric or fibers which is glued between the first air bladder and the cushioning element, for keeping the first air bladder in a predetermined shape.

5. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 1, further comprising an upper frame and a base frame for fixing the first air bladder therebetween.

6. The air cushion with multistage shock-absorbing assembly of claim 1, wherein the cushioning element comprises a second air bladder which contains a second inner pressure.

7. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 6, wherein the second air bladder contains a tying element formed with a plurality of inward protruding walls for keeping the second air bladder in a predetermined shape thereof.

8. An air cushion for cushioning in a shoe with multistage shock-absorbing assembly, comprising:

a first air bladder, having an inner wall which contains a first inner pressure, the inner wall having an upper surface and a lower surface; and

a cushioning element, disposed in relation to the first air bladder to form a vertical stack configuration therewith such that when the impact lighter than a predetermined value is applied to the vertical stack configuration, it is absorbed by deforming the first air bladder only, and when the impact heavier than the predetermined value is applied to the vertical stack configuration, it is absorbed by deforming both the first air bladder and the cushioning element.

9. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 8, wherein the cushioning element is a second air bladder which contains a second air pressure.

10. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 9, further including a resilient pad disposed on the upper side of the first air bladder.

11. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 8, wherein the cushioning element comprises a second air bladder and a resilient pad.

12. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 8, wherein the cushioning element is a resilient pad.

13. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 8, wherein the cushioning element is a bladder containing a gel.

14. The air cushion for cushioning in a shoe with multistage shock-absorbing assembly of claim 8, wherein the cushioning element is a bladder containing a granules cushioning material.