SOLE ASSEMBLY WITH BLADDER ELEMENT HAVING A PERIPHERAL OUTER WALL PORTION AND METHOD OF MANUFACTURING SAME
A sole assembly for an article of footwear includes a bladder element having a first polymeric sheet attached to a second polymeric sheet. The first polymeric sheet has an outer surface defining a recess and that has a heel region, a midfoot region, and a forefoot region in the recess. The first polymeric sheet has a peripheral outer wall portion extending around the recess. The second polymeric sheet is attached to the first polymeric sheet at the outer wall portion such that the first and second polymeric sheets define an interior cavity. A method of manufacturing the article of footwear is provided.
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The present teachings generally include a sole assembly with a bladder element for an article of footwear, and a method of manufacturing an article of footwear.
BACKGROUNDFootwear typically includes a sole configured to be located under a wearer's foot to space the foot away from the ground or floor surface. Soles can be designed to provide a desired level of cushioning. Athletic footwear in particular sometimes utilizes polyurethane foam or other resilient materials in the sole to provide cushioning. One traditional style of athletic shoe has a rubber sole bonded to a footwear upper in an autoclave process. The rubber sole of such footwear has generally vertical sides that surround and are secured to a lower portion of the sides of the footwear upper, as well as to the bottom of a strobel unit of the footwear upper. The rubber sole also generally has a flat outsole.
SUMMARYAn article of footwear has a sole assembly that includes a bladder element formed from a first and a second polymeric sheet. The sole assembly can be configured to have a similar shape as a traditional athletic shoe with a rubber sole formed in an autoclave. The bladder element can be at least partially transparent, which allows the footwear upper to be visible through the outer wall portions from the exterior of the article of footwear.
More specifically, a sole assembly for an article of footwear includes a bladder element having a first polymeric sheet attached to a second polymeric sheet to form an interior cavity, which can be a fluid-filled chamber. The first polymeric sheet has an outer surface defining a recess. The outer surface has a heel region, a midfoot region, and a forefoot region in the recess. The first polymeric sheet has a peripheral outer wall portion extending around the recess. The second polymeric sheet is attached to the first polymeric sheet at the outer wall portion such that the first and second polymeric sheets define the interior cavity. The first polymeric sheet defines a ridge between the recess and the outer wall portion, and the outer wall portion is substantially perpendicular to a peripheral edge of the second polymeric sheet. An outsole can be secured to the bladder element. The outsole can be an at least partially transparent thermoplastic polyurethane, or can be rubber or another suitable material. Optionally, a toe bumper is secured to the bladder member. The toe bumper can be at least partially thermoplastic polyurethane or can be rubber or another suitable material. In an embodiment in which a thermoplastic polyurethane outsole and toe bumper are used, the entire sole assembly can be at least partially transparent. Accordingly, in some embodiments, the sole assembly can be configured without any foam or rubber.
A method of manufacturing the article of footwear with the bladder element includes providing the bladder element formed from the first and second polymeric sheets configured with the recess and peripheral wall portion as described, and may include thermoforming the bladder element. Optionally, the method includes attaching a footwear upper to the first polymeric sheet at the recess so that the footwear upper is visible through the sidewall portion. Optionally, the method also includes securing an outsole to an outer surface of the second polymeric sheet of the bladder element, and securing a toe bumper to the sidewall portion.
“A,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate that at least one of the item is present; a plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.
The terms “comprising,” “including,” and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items.
Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” “bottom,” etc., are used descriptively for the figures, and do not represent limitations on the scope of the invention, as defined by the claims.
The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the best modes for carrying out the present teachings when taken in connection with the accompanying drawings.
Referring to the drawings, wherein like reference numbers refer to like components throughout the views,
The bladder element 14 is formed from two polymeric sheets, including a first polymeric sheet 16, and a second polymeric sheet 18. The first polymeric sheet 16 is also referred to herein as the upper polymeric sheet 16, and the second polymeric sheet 18 is also referred to herein as the lower polymeric sheet 18. The polymeric sheets 16, 18 are attached to one another as described herein to define a sealed interior cavity 20 that retains the fluid.
Referring to
In the embodiment shown, the upper polymeric sheet 16 is formed from a single, flat sheet, such as by thermoforming, to attain the relatively complex, contoured shape shown in
The bladder element 14 also includes the lower polymeric sheet 18 attached to the upper polymeric sheet 16 by bonding at a flange 106 near the terminal edge 48 of the outer wall portion 44 as further described herein. The upper and lower polymeric sheets 16, 18 define the interior cavity 20. As best shown in
The recess 32, the ridge 46, and the outer wall portion 44 define an inverted channel 65 at the inner surface 54 of the upper sheet 16. The inverted channel 65 is part of the interior cavity 20. Because the bonds 60 do not extend completely between the lateral side 64 of the outer wall portion 44 and the medial side 62 of the outer wall portion 44, the inverted channel 65 is in fluid communication with the interior cavity 20 and is a peripheral portion of the interior cavity 20.
The upper polymeric sheet 16 and the lower polymeric sheet 18 are at least partly thermoplastic polyurethane. Examples of polymer materials for the bladder element 14 include thermoplastic polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Moreover, each of the polymeric sheets 16, 18 of the bladder element 14 can be formed of layers of different materials. In one embodiment, the polymeric sheets 16, 18 of the bladder element 14 are each formed from thin films having one or more thermoplastic polyurethane (TPU) layers with one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein as disclosed in U.S. Pat. No. 6,082,025 to Bonk et al., which is incorporated by reference in its entirety. The polymeric sheets 16, 18 may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. Pat. Nos. 5,713,141 and 5,952,065 to Mitchell et al. which are incorporated by reference in their entireties. Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. The polymeric sheets 16, 18 of the bladder element 14 may also be flexible microlayer membranes that include alternating layers of a gas barrier material and an elastomeric material, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk et al. which are incorporated by reference in their entireties. Additional suitable materials for the bladder element 14 are disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy, which are incorporated by reference in their entireties. Further suitable materials for the bladder element 14 include thermoplastic films containing a crystalline material, as disclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy, and polyurethane including a polyester polyol, as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk et al. which are incorporated by reference in their entireties.
In selecting materials for the bladder element 14, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thicknesses of polymeric sheets 16, 18 used to form the bladder element 14 can be selected to provide these characteristics. The bladder element 14 is resilient and provides cushioning and flexibility that can be tuned such as by selecting a level of pressurization. In the embodiment shown in
Referring to
Like the upper polymeric sheet 16, the lower polymeric sheet 18 is also an at least partially transparent material. The outsole 24 provides the ground contact surface of the article of footwear 10, and can be a thermoplastic polyurethane with a greater hardness and thickness than the lower polymeric sheet 18 to provide durability, traction and abrasion resistance. An upper surface 70 of the outsole 24 is secured to a lower surface 72 of the lower polymeric sheet 18 after bladder element 14 is formed and inflated. The outsole 24 can be configured so that when it is secured to the lower polymeric sheet 18, the peripheral edge 73 of the outsole 24 is substantially perpendicular to the outer wall portion 44. The outsole 24 is an at least partially transparent TPU. In this case, the outsole 24 is secured to the bladder element 14 with adhesives or by radio frequency welding. Alternatively, the outsole 24 can be a rubber material, in which case a two-sided film, such as double-coated adhesive film 150 shown and described with respect to
The optional toe bumper 26 is secured to a portion of the upper polymeric sheet 16 that is the outward-facing surface 78 of the outer wall portion 44. Specifically, the toe bumper 26 is secured to the outward-facing surface 78 at the sidewall portion 44 adjacent the forefoot region 40. Like the outsole 24, the toe bumper 26 may also be an at least partially transparent material, and can be a thermoplastic polyurethane with a greater hardness and thickness than the lower polymeric sheet 18 to provide durability and abrasion resistance. In this case, the toe bumper 26 is secured to the bladder element 14 with adhesives or by radio frequency welding. Alternatively, the toe bumper 26 can be a rubber material, in which case a two-sided film, such as double-coated adhesive film 150 shown and described with respect to
As shown in
In the embodiment of
The upper and lower polymeric sheets 16, 18 are originally planar, but take on the shapes of the mold cavity 94 and recess 105 via vacuuming and heating steps included in the thermoforming process. The bladder element 14 can then be cooled, inflated to a predetermined pressure, and sealed to retain pressure.
When the material of the component 120A of
When the material of the component 120B of
The TPU component 120C of
When the material of the component 120C of
When the material of the component 120D of
When the material of the component 120E of
When the material of the component 120F of
Next, the footwear upper 22 is attached to the outer surface 30 of the upper sheet 16 in the recess 32 in step 208 so that a portion of the upper 22 is visible through the outer wall portion 44. The attachment can be by adhesives, a hot melt of a TPU layer adhered to the upper 22, radio frequency welding, or other suitable manner.
In step 210, the outsole 24 is secured to the lower surface 72 of the lower sheet 18 by adhesives, hot melt, radio frequency welding, or other suitable manner. In step 212, the toe bumper 26 is secured to the outward-facing surface 78 of the outer wall portion 44 by adhesives, radio frequency welding, or other suitable manner. Steps 208-212 can be performed in any order.
Accordingly, under the method 200, the article of footwear 10 is manufactured having a sole assembly including a bladder element, and is configured to have an outer wall portion 44 surrounding a periphery 68 of the upper 22, and a substantially flat outsole 24 generally perpendicular to the outer wall portion 44. The article of footwear 10 thus has an overall shape substantially like that of an athletic shoe with a traditional rubber sole formed in an autoclave.
While the best modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims.
Claims
1. A sole assembly for an article of footwear comprising:
- a bladder element having: a first polymeric sheet having an outer surface defining a recess; wherein the outer surface has a heel region, a midfoot region, and a forefoot region in the recess; wherein the first polymeric sheet has a peripheral outer wall portion extending around the recess; and a second polymeric sheet attached to the first polymeric sheet at the outer wall portion such that the first and second polymeric sheets define an interior cavity.
2. The sole assembly of claim 1, wherein the first polymeric sheet defines a ridge between the recess and the outer wall portion; and wherein the outer wall portion is substantially perpendicular to a peripheral edge of the second polymeric sheet.
3. The sole assembly of claim 2, wherein the recess, the ridge, and the outer wall portion define an inverted channel at an inner surface of the first polymeric sheet; and wherein the inverted channel is a peripheral portion of the interior cavity.
4. The sole assembly of any of claim 3, wherein an inner surface of the first polymeric sheet is bonded to an inner surface of the second polymeric sheet at multiple bonds extending transversely and only partway across the interior cavity between a medial side of the outer wall portion and a lateral side of the outer wall portion.
5. The sole assembly of claim 1, wherein the first and second polymeric sheets are at least partially thermoplastic polyurethane (TPU).
6. The sole assembly of claim 5, wherein each of the first and second polymeric sheets is a multi-layer sheet having at least a first layer including polyurethane and at least a second layer including a copolymer of ethylene and vinyl alcohol.
7. The sole assembly of claim 1 in combination with a footwear upper secured to the first polymeric sheet in the recess so that the outer wall portion surrounds a periphery of the footwear upper.
8. The sole assembly and footwear upper of claim 7, wherein the first and second polymeric sheets are at least partially transparent so that a portion of the footwear upper in the recess is visible through the outer wall portion.
9. The sole assembly of claim 1, further comprising:
- an outsole secured to an outer surface of the second polymeric sheet; wherein the outsole is substantially perpendicular to the outer wall portion.
10. The sole assembly of claim 9, wherein the outsole is an at least partially transparent thermoplastic polyurethane material.
11. The sole assembly of claim 10, wherein the outsole is at least partially dyed.
12. The sole assembly of claim 9, wherein the outsole has an outer surface with an etched pattern.
13. The sole assembly of claim 9, further comprising:
- a polymeric film with a graphic appearing thereon; wherein the polymeric film is attached to the outsole.
14. The sole assembly of claim 9, wherein the outsole is rubber.
15. The sole assembly of claim 1, further comprising:
- a toe bumper secured to an outer surface of the outer wall portion adjacent the forefoot region.
16. The sole assembly of claim 15, wherein the toe bumper is an at least partially transparent thermoplastic material.
17. The sole assembly of claim 16, wherein the toe bumper is at least partially dyed.
18. The sole assembly of claim 16, wherein the toe bumper has an outer surface with an etched pattern.
19. The sole assembly of claim 16, further comprising:
- a polymeric film with a graphic appearing thereon; wherein the polymeric film is attached to the toe bumper.
20. The sole assembly of claim 15, wherein the toe bumper is rubber.
21. The sole assembly of claim 1, wherein the sole assembly is configured without foam or rubber.
22. A sole assembly comprising:
- a midsole formed from a bladder element having a heel region, a midfoot region, and a forefoot region;
- wherein the bladder element has a first polymeric sheet forming a recess and a peripheral outer wall portion extending around the recess;
- wherein the bladder element has a second polymeric sheet extending underneath the first polymeric sheet and below the recess; and wherein the second polymeric sheet is bonded to the first polymeric sheet to thereby define a fluid-tight cavity between the first polymeric sheet and the second polymeric sheet;
- wherein the first polymeric sheet defines a ridge between the recess and the outer wall portion; and wherein the outer wall portion is substantially perpendicular to a peripheral edge of the second polymeric sheet; and
- wherein an inner surface of the first polymeric sheet is bonded to an inner surface of the second polymeric sheet at multiple bonds extending transversely and only partway across the interior cavity between a medial side of the outer wall portion and a lateral side of the outer wall portion.
23. The sole assembly of claim 22, wherein the recess, the ridge, and the outer wall portion define an inverted channel at an inner surface of the first polymeric sheet; and wherein the inverted channel is a peripheral portion of the interior cavity.
24. The sole assembly of claim 22, wherein the first and second polymeric sheets are at least partially thermoplastic polyurethane (TPU).
25. The sole assembly of claim 24, wherein each of the first and second polymeric sheets is a multi-layer sheet having at least a first layer including polyurethane and at least a second layer including a copolymer of ethylene and vinyl alcohol.
26. The sole assembly of claim 22 in combination with a footwear upper having a lower surface secured to the first polymeric sheet in the recess so that the outer wall portion surrounds a periphery of the footwear upper.
27. The sole assembly and footwear upper of claim 26, wherein the first and second polymeric sheets are at least partially transparent so that a portion of the footwear upper in the recess is visible through the outer wall portion.
28. The sole assembly of claim 22, further comprising:
- an outsole secured to an outer surface of the second polymeric sheet; wherein the outsole is substantially perpendicular to the outer wall portion; wherein the outsole is an at least partially transparent thermoplastic polyurethane material.
29. The sole assembly of claim 22, further comprising:
- an outsole secured to an outer surface of the second polymeric sheet; wherein the outsole is substantially perpendicular to the outer wall portion; wherein the outsole is rubber.
30. The sole assembly of claim 22, further comprising:
- a toe bumper secured to an outer surface of the outer wall portion adjacent the forefoot region; wherein the toe bumper is an at least partially transparent thermoplastic material.
31. The sole assembly of claim 22, further comprising:
- a toe bumper secured to an outer surface of the outer wall portion adjacent the forefoot region; wherein the toe bumper is rubber.
32. The sole assembly of claim 22, wherein the sole assembly is configured without foam or rubber.
33. A method of manufacturing an article of footwear comprising:
- providing a bladder element formed from a first polymeric sheet and a second polymeric sheet;
- wherein the first polymeric sheet has an outer surface defining a recess; wherein the outer surface has a heel region, a midfoot region, and a forefoot region in the recess; wherein the first polymeric sheet has a peripheral outer wall portion extending around the recess; and
- wherein the second polymeric sheet is attached to the first polymeric sheet at the outer wall portion such that the first and second polymeric sheets define an interior cavity.
34. The method of claim 33, further comprising:
- thermoforming the first and second polymeric sheets in a mold assembly to thereby form the bladder element.
35. The method of claim 34, wherein said thermoforming includes compressing peripheries of the first polymeric sheet and the second polymeric sheet together during said thermoforming to attach the first polymeric sheet to the second polymeric sheet.
36. The method of claim 35, further comprising:
- trimming the attached first polymeric sheet and second polymeric sheet at a peripheral flange.
37. The method of claim 34, wherein said thermoforming includes vacuuming the first polymeric sheet to conform to the mold assembly.
38. The method of any of claim 33, further comprising:
- attaching a footwear upper to the outer surface of the first polymeric sheet at the recess so that the footwear upper is visible through the outer wall portion.
39. The method of claim 33, further comprising:
- securing an outsole to an outer surface of the second polymeric sheet.
40. The method of claim 39, wherein said securing is so that the outsole is substantially perpendicular to the outer wall portion.
41. The method of claim 33, further comprising:
- securing a toe bumper to an outer surface of the outer wall portion.
Type: Application
Filed: Mar 19, 2014
Publication Date: Sep 24, 2015
Applicant: NIKE, Inc. (Beaverton, OR)
Inventors: Eric Joseph Marshall (Tualatin, OR), Douglas A. Beye (Beaverton, OR), Charles R. Edwards (Portland, OR)
Application Number: 14/219,113