Footwear Uppers Including Bladders, Articles of Footwear Including Bladders in the Upper, and Methods of Forming Such Uppers and/or Articles of Footwear
Footwear upper components include a fabric element having a first thermoplastic polyurethane component and a bladder component that defines a sealed interior chamber for containing a fluid. The bladder component includes an outer perimeter seam that extends at least partially around the sealed interior chamber, and at least a portion of this outer perimeter seam is engaged with the first thermoplastic polyurethane component of the fabric element. The outer perimeter seam seals two thermoplastic sheets together to form the bladder component. At least a portion of a major exterior surface of one thermoplastic sheet that defines the sealed interior chamber may be bonded to the thermoplastic polyurethane component of the fabric element in an adhesive free manner, and/or the portion of the outer perimeter seam that is bonded to the first thermoplastic polyurethane component of the fabric element may be bonded in an adhesive free manner.
This application is a U.S. Non-Provisional Application based on (a) U.S. Provisional Patent Appln. No. 63/277,916 filed Nov. 10, 2021 and entitled “Footwear Uppers Including Bladders and Articles of Footwear Including Bladders in the Upper” and (b) U.S. Provisional Patent Appln. No. 63/277,932 filed Nov. 10, 2021 and entitled “Footwear Uppers Including Bladders and Articles of Footwear Including Bladders in the Upper.” Each of U.S. Provisional Patent Appln. No. 63/277,916 and U.S. Provisional Patent Appln. No. 63/277,932 is entirely incorporated herein by reference.
FIELD OF THE INVENTIONThe present invention relates to bladders for footwear uppers, footwear uppers including the bladders, articles of footwear including the bladders, and/or methods of making and using such bladders, uppers, and/or articles of footwear. In some aspects of this technology, the bladders will be engaged with a footwear upper component in an adhesive free manner or with an adhesive based bond. Additionally or alternatively, in some aspects of this technology, the bladders will include texturing, e.g., imprinted by surface contour features of the attached footwear upper component and/or imprinted from a mold surface during molding or during another process. The present technology may be used to create footwear upper components and articles of footwear of the types described in concurrently filed U.S. Provisional Patent Appln. No. 63/277,903, filed Nov. 10, 2021 and entitled “Bladders, Footwear Uppers Including Bladders, and Articles of Footwear Including Bladders in the Upper” and U.S. Provisional Patent Appln. No. 63/277,941, filed Nov. 10, 2021 and entitled “Bladders, Footwear Uppers Including Bladders, and Articles of Footwear Including Bladders in the Upper,” each of which is entirely incorporated herein by reference.
BACKGROUNDConventional articles of athletic footwear include two primary elements, an upper and a sole structure. The upper may provide a covering for the foot that securely receives and positions the foot with respect to the sole structure. In addition, the upper may have a configuration that protects the foot and provides ventilation, thereby cooling the foot and removing perspiration. The sole structure may be secured to a lower surface of the upper and generally is positioned between the foot and any contact surface. In addition to attenuating ground reaction forces and absorbing energy, the sole structure may provide traction and control potentially harmful foot motion, such as over pronation.
The upper forms a void on the interior of the footwear for receiving the foot. The void has the general shape of the foot, and access to the void is provided at an ankle opening. Accordingly, the upper extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. A lacing system often is incorporated into the upper to allow users to selectively change the size of the ankle opening and to permit the user to modify certain dimensions of the upper, particularly girth, to accommodate feet with varying proportions. In addition, the upper may include a tongue that extends under the lacing system to enhance the comfort of the footwear (e.g., to moderate pressure applied to the foot by the laces). The upper also may include a heel counter to limit or control movement of the heel.
SUMMARYThis Summary is provided to introduce some general concepts relating to this technology in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the invention.
Aspects of this technology relate to bladders for footwear uppers, footwear uppers including the bladders, articles of footwear including the bladders, and/or methods of making and using such bladders, uppers, and/or articles of footwear, e.g., of the types described and/or claimed below and/or of the types illustrated in the appended drawings. The bladders may be engaged with a fabric component of the upper in any desired manner. In some aspects of this technology, the bladders will be engaged with a fabric component of the upper in an adhesive free manner (e.g., by melt bonding, by welding techniques (e.g., RF welding, ultrasonic welding, etc.), etc.) or with an adhesive based bond. Additionally or alternatively, in some aspects of this technology, the bladder (e.g., its perimeter seam surface and/or its bladder chamber surface) will include texturing formed thereon, e.g., imprinted by the surface of the fabric material with which it is engaged, imprinted from a mold surface, applied in a different manner, etc. Such bladders, uppers, and/or articles of footwear may include any one or more structures, parts, features, properties, and/or combination(s) of structures, parts, features, and/or properties of the examples described and/or claimed below and/or of the examples illustrated in the appended drawings.
The foregoing Summary, as well as the following Detailed Description, will be better understood when considered in conjunction with the accompanying drawings in which like reference numerals refer to the same or similar elements in all of the various views in which that reference number appears.
In the following description of various examples of bladders, footwear uppers, and/or articles of footwear according to the present technology, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example structures and environments in which aspects of this technology may be practiced. It is to be understood that other structures and environments may be utilized and that structural and functional modifications may be made to the specifically described structures, functions, and methods without departing from the scope of the present disclosure.
I. General Description of Aspects of this Technology
As noted above, aspects of this technology relate to bladders, footwear uppers including such bladders, and articles of footwear including such bladders, e.g., of the types described and/or claimed below and/or of the types illustrated in the appended drawings. Such bladders, footwear uppers, and articles of footwear may include any one or more structures, parts, features, properties, and/or combination(s) of structures, parts, features, and/or properties of the examples described and/or claimed below and/or of the examples illustrated in the appended drawings.
This application and/or claims use the adjectives, e.g., “first,” “second,” “third,” and the like, to identify certain components and/or features relating to this technology. These adjectives are used merely for convenience, e.g., to assist in maintaining a distinction between components and/or features of a specific structure. Use of these adjectives should not be construed as requiring a specific order or arrangement of the components and/or features being discussed. Also, use of these specific adjectives in the specification for a specific structure does not require that the same adjective be used in the claims to refer to the same part (e.g., a component or feature referred to as the “third” in the specification may correspond to any numerical adjective used for that component or feature in the claims).
This application describes footwear components (e.g., upper components (including fabric components), bladder components, sole structures, etc.) that are “bonded” together. The term “bonded” (and derivatives thereof) means that the components are joined securely to one another. The term “bonded” encompasses bonds formed using adhesives or cements (including hot melt adhesives) as well as bonds formed in an “adhesive free” manner, i.e., without use of a separate adhesive component. “Adhesive free” bonds include bonds formed by fusing or melting components together (e.g., if the components include compositions that are compatible to mix and join together to form a bond, such as two components including a thermoplastic polyurethane component); bonds formed by welding techniques (e.g., RF welding, ultrasonic welding, high-frequency welding, laser welding, impulse welding, etc.); bonds formed by heat sealing; etc. Some adhesive free bonds may form a seamless joint between the two previously separate components (e.g., the materials mix and join together and then re-harden with no discernible junction). The term “melt bond” and variations thereof, as used herein, mean bonds formed where localized melting of each component occurs (e.g., melting of the thermoplastic polymer present in each component), the melted components combine together, and then the combined components harden to thereby “fuse” and “bond” the two components together. Such melt bonded joints are adhesive free and may be seamless. The term “engaged with” is used herein as a generic term and includes both adhesive based bonds and adhesive free bonds within its scope as well as other potential types of engagement that fix two (or more) components together in a “non-bonded” manner (including through the use of mechanical connectors or fasteners, through the use of sewing or stitching, etc.).
The term “bladder precursor” as used herein means at least some portion of a final bladder structure (e.g., a portion of bladder 200), such as one of a first sheet or layer of thermoplastic polymer material 200A and/or a second sheet or layer of thermoplastic polymer material 200B discussed in more detail below. A “bladder precursor” also may be considered all bladder components in an unsealed condition (e.g., before seam 200S is formed) or a completely sealed bladder before it is inflated and/or fully inflated.
Some aspects or examples of this technology relate to footwear uppers that include: (a) a first fabric element (e.g., a first knit fabric element) that includes a first thermoplastic polyurethane component; and (b) a bladder component that defines a sealed interior chamber for containing a fluid. This bladder component includes an outer perimeter seam that extends at least partially around the sealed interior chamber. At least a portion of the outer perimeter seam is engaged (e.g., bonded, melt bonded, etc.) to the first thermoplastic polyurethane component of the first fabric element. The bladder component may include a first thermoplastic sheet and a second thermoplastic sheet facing the first thermoplastic sheet, wherein the outer perimeter seam fixes the first thermoplastic sheet to the second thermoplastic sheet. In such structures, a first major interior surface of the first thermoplastic sheet, a first major interior surface of the second thermoplastic sheet, and the outer perimeter seam define the sealed interior chamber. Additionally, in some examples of this technology, the first thermoplastic sheet will include a first major exterior surface opposite its first major interior surface, and at least a portion of this first major exterior surface of the first thermoplastic sheet will be engaged (e.g., bonded, melt bonded, etc.) to the first fabric element (e.g., the first thermoplastic polyurethane component of the first fabric element). In some aspects of this technology, the first fabric element and the bladder component (the outer perimeter seam and/or the first major exterior surface) will be joined together, optionally in an adhesive free manner (e.g., by melt bonding).
Additionally or alternatively, some aspects of this technology relate to footwear upper components that include: (a) a first fabric element (e.g., a first knit fabric element) that includes a first surface having texturing; and (b) a bladder component that defines a sealed interior chamber for containing a fluid. In this aspect of this technology, the bladder component will include: (a) a first major surface engaged with (e.g., bonded to) the first surface of the first fabric element, wherein the first major surface defines at least part of a first perimeter seam surface and at least part of a first surface of the sealed interior chamber, (b) a second major surface opposite the first major surface, wherein the second major surface defines at least part of a second perimeter seam surface opposite the first perimeter seam surface and at least part of a second surface of the sealed interior chamber opposite the first surface of the sealed interior chamber, and (c) a fluid chamber located between the first major surface and the second major surface. At least a portion of the first major surface (e.g., at least part of the first perimeter seam surface and/or at least part of the first surface of the sealed interior chamber) will include texturing having surface contour features corresponding to (e.g., imprinted by) the texturing present on the first surface of the first fabric element.
Additional aspects of this technology relate to methods of forming footwear upper components that include: (a) placing a bladder or a bladder precursor on a first fabric element (e.g., a first knit fabric element), wherein the first fabric element includes a first thermoplastic polyurethane component (the bladder or the bladder precursor includes at least a first thermoplastic polymer layer and optionally a second thermoplastic polymer layer overlapping the first thermoplastic polymer layer); and (b) applying heat and pressure to form a seam to engage (e.g., bond) the first thermoplastic polymer layer with the second thermoplastic polymer layer (if a second thermoplastic polymer layer is present) and/or to engage (e.g., bond) at least a portion of the first thermoplastic polymer layer with the first thermoplastic polyurethane component of the first fabric element. Alternatively, the second thermoplastic polymer layer may be bonded to the first thermoplastic polymer layer after the first fabric element and the first thermoplastic polymer layer are bonded together. The seam, the first thermoplastic polymer layer, and the second thermoplastic polymer layer define a sealed interior chamber for containing a fluid (e.g., a gas). Once the bladder is fully formed, the sealed interior chamber may be filled with fluid (e.g., inflated with a gas). In at least some examples of this technology, the first fabric element and the bladder or bladder precursor (the seam and/or at least some portion of the first thermoplastic polymer layer) will be joined together in an adhesive free manner (e.g., by melt bonding the first thermoplastic polyurethane component of the first fabric element with the first thermoplastic polymer layer of the bladder or bladder precursor).
Still additional aspects of this technology relate to methods of forming footwear upper components that include: (a) placing a bladder or a bladder precursor on a first fabric element, wherein the first fabric element includes a first surface having texturing, and wherein the bladder or the bladder precursor includes at least a first thermoplastic polymer layer, and optionally a second thermoplastic polymer layer overlapping the first thermoplastic polymer layer; and (b) forming texturing on at least a portion of the first thermoplastic polymer layer by applying heat and pressure to form at least one of: (i) a seam that engages (e.g., bonds) the first thermoplastic polymer layer with the second thermoplastic polymer layer (if present) and/or (ii) an engagement of (e.g., a bond between) at least the portion of the first thermoplastic polymer layer with the first fabric element. The second thermoplastic polymer layer may be bonded to the first thermoplastic polymer layer after the first fabric element and the first thermoplastic polymer layer are bonded. The bladder (or the bladder precursor) defines a sealed interior chamber for containing a fluid such as a gas (in a volume inside the seam and between the first and second thermoplastic polymer layers). The texturing formed on at least the portion of the first thermoplastic polymer layer corresponds in surface contour features to (and is imprinted by) the texturing included on the first surface of the first fabric element.
Still additional aspects of this technology relate to footwear upper components that include: (a) a first fabric element; and (b) a bladder component that defines a sealed interior chamber for containing a fluid (e.g., as gas). This example bladder component includes: (i) a first major surface engaged with the first fabric element, wherein the first major surface defines at least part of a first perimeter seam surface and at least part of a first surface of the sealed interior chamber, (ii) a second major surface opposite the first major surface, wherein the second major surface defines at least part of a second perimeter seam surface opposite the first perimeter seam surface and at least part of a second surface of the sealed interior chamber opposite the first surface of the sealed interior chamber, and (iii) and a fluid chamber located between the first major surface and the second major surface, and wherein at least a portion of the second major surface includes molded-in texturing (e.g., a plurality of raised ridges, a plurality of raised grid elements, a plurality of recessed grid elements, a herringbone pattern, a plurality of rounded elements (e.g., with raised rounded elements, recessed rounded elements, a combination of both, circular elements, oval elements, elliptical elements, teardrop shaped elements, etc.), etc.). Texturing may be different in different areas of the bladder (e.g., the molded-in texturing may include a first portion having a first pattern, a second portion having a second pattern different from the first pattern, etc.). The term “molded-in” texturing means texturing applied using a mold component irrespective of the particular process used (e.g., molding a bladder alone, molding a bladder while attaching to a fabric, formed in a vacuum forming process, forming in a thermoforming process, etc.). The term “molded-in” texturing, unless otherwise noted, includes texturing applied during an embossing or calendering process or a rolling process using a textured roller.
Further aspects of this technology relate to articles of footwear including the bladders and/or footwear uppers of the various types described above and described in more detail below. Still additional aspects of this technology relate to methods of making the bladders, footwear upper components, footwear uppers, and/or articles of footwear described above and described in more detail below.
Given the general description of features, examples, aspects, structures, and methods according to examples of the technology provided above, a more detailed description of specific example bladders, footwear upper components, footwear uppers, articles of footwear, and methods in accordance with this technology follows.
II. Detailed Description of Example Bladders, Footwear Uppers, Articles ofFootwear, and Other Components/Features According to this Technology
As described above, aspects of the present technology relate to footwear upper components that include a bladder engaged with a fabric component that will form a portion of the footwear upper (e.g., a tongue portion, an instep portion, a heel and/or ankle support portion, etc.).
The example footwear upper component 100 of
The adhesive free bonds in the structure of
The example footwear upper component 100 of
The bonds in the structure of
The example footwear upper component 100 structures of
The bonds in the structures of
As an alternative, the hot melt material 210A may be omitted from the example of
The bonds in the structures of
Bladder 200 structures may include various features to control the shape of the bladder 200 once it is inflated or filled and/or to control bladder expansion features when fluid pressure and/or volume changes. For example, internal welds (e.g., spot welds, straight and/or curved weld lines, etc.) joining the interior surface 200AI of the first sheet or layer of thermoplastic polymer material 200A with the interior surface 200BI of the second sheet or layer of thermoplastic polymer material 200B may be used control the inflated or filled bladder shape 200. Additionally or alternatively, interior components may be included within the interior chamber 2001 and engaged with the interior surfaces 200AI, 200BI of the first sheet or layer of thermoplastic polymer material 200A and the second sheet or layer of thermoplastic polymer material 200B. The interior component(s) may limit the distance that the interior surfaces 200AI, 200BI of the first sheet or layer of thermoplastic polymer material 200A and the second sheet or layer of thermoplastic polymer material 200B can separate from one another when the bladder 200 is inflated or filled. Such interior component structures, shape control methods, and shape control structures may be used with bladder components 200 in accordance with at least some examples of this technology.
Other shape control and/or bladder expansion control structures and methods also may be used with this technology.
In the examples of
In a similar manner, the material of fabric component 120 may be used in place of fabric component 110 in any of the various footwear upper component 100 structures shown in
Heat and pressure may be applied to: (a) engage (adhesively bond) fabric component 120 to the first sheet or layer of thermoplastic polymer material 200A and (b) engage (adhesively bond or adhesive free bond) fabric component 110 to the second sheet or layer of thermoplastic polymer material 200B. The application of heat and pressure to bond these components may take place simultaneously or separately. Further, the application of heat and pressure to bond these components may take place simultaneously or separately from the steps used to form the bladder 200 (e.g., the steps to form seam 200S between the interior surfaces 200AI, 200BI of layers 200A, 200B). Additionally, the application of heat and pressure to bond the fabric components 110, 120 to the sheets or layers of thermoplastic polymer material 200A, 200B may take place before or after the interior bladder chamber 2001 is inflated.
As shown in the examples of
As mentioned above (e.g., in conjunction with
When the example footwear upper 300 of
In some examples of this technology, features of the footwear upper component 100 may be controlled to allow for “two way” expansion.
Thus, in this illustrated example, at least some portions of the bladder 200's first sheet or layer of thermoplastic polymer material 200A and second sheet or layer of thermoplastic material 200B will be exposed in the footwear upper 300 in areas defining the sealed interior chamber 2001. In this manner, as shown in
The structure of
In the illustrated examples of
As described above, the bladder 200 and fabric components 110, 120 may be engaged together (e.g., by an adhesive based bond, by an adhesive free bond, etc.) using heat and pressure (e.g., to activate a hot melt adhesive, to perform localized melting, etc.).
Under any of the pressing techniques described above in conjunction with
A denser chenille fabric component 702B is engaged with the front and midfoot-to-forefoot sides of fabric component 702A in this example. This denser fabric component 702B provides enhanced durability and abrasion resistance and provides a stable and/or strong base for engaging one or more components of a sole structure. Another dense chenille fabric component 702C with small mesh openings is engaged with fabric component 702A at the heel-containing region 102H of the footwear upper base 102. Fabric component 702C also may provide durability, abrasion resistance, and/or a stable and/or strong base for engaging one or more sole structure 104 components.
Fabric component 702D of this example comprises a thermoplastic polyurethane (“TPU”) containing fabric component, e.g., a fabric component, optionally a knit fabric component, including at least one yarn formed from a TPU material and/or coated with a TPU material. This fabric component 702D forms a base for engaging components of a bladder 200, e.g., in an adhesive free manner (e.g., in melt bonded or welded manners, using heat and pressure, or the like, as described above). Fabric component 702D may be formed as a mesh with relatively large openings, e.g., to enhance breathability.
Fabric component 702E of this example upper blank 700 is located at a medial side of the upper blank 700. Fabric component 702E may comprise an elastic or elastomeric component, such as a stretchable chenille fabric, that helps provide comfort, stretches to enable easy donning and doffing, and/or helps hold the overall footwear upper to a wearer's foot.
The first thermoplastic sheet 200A, the second thermoplastic sheet 200B (not shown in FIG.
9C but shown in other figures), and the continuous outer perimeter seam 200S define a sealed interior volume 2001 for containing a gas or other fluid. The continuous outer perimeter seam 200S forms the outermost exterior perimeter of the bladder 200 in this example. As illustrated in
As further shown in
As previously described,
Examples of methods of making footwear upper components 100 now will be described in more detail. As an initial step, the bladder 200 (in an inflated or uninflated condition) or a bladder precursor is placed on a fabric component 110 or 120. In some examples, the fabric component 110 (e.g., a knit fabric element such as component 702D) will include a first thermoplastic polyurethane component that is capable of forming an adhesive free bond with the first sheet or layer of thermoplastic material (e.g., thermoplastic elastomer material) in the bladder 200 or the bladder precursor. In other examples, the fabric component 120 (e.g., a knit fabric element) will not be capable of forming an adhesive free bond with the first sheet or layer of thermoplastic material (e.g., thermoplastic elastomer material) in the bladder 200 or the bladder precursor under the pressing conditions, and thus an adhesive material (e.g., a hot melt adhesive) may be applied to at least one of the fabric component 120 and the bladder 200 (or bladder precursor).
Heat and pressure then are applied, in one step or in multiple steps: (a) to form a seam 200S to engage the first sheet or layer of thermoplastic polymer material 200A with the second sheet or layer of thermoplastic polymer material 200B and (b) to engage at least a portion of the first sheet or layer of thermoplastic polymer material 200A with fabric component 110, 120, e.g., in an adhesive free manner, in an adhesive based bond, etc. The seam 200S, the first sheet or layer of thermoplastic polymer material 200A, and the second sheet or layer of thermoplastic polymer material 200B define a sealed interior chamber 2001 for containing a fluid (e.g., a gas, such as air, nitrogen, etc.).
Once the bladder 200 or bladder precursor is attached to the fabric component 110/120, the sealed interior chamber 2001 may be inflated (if it was not already inflated). If necessary, the inflation port may be sealed after inflation is complete, and the port may be trimmed off. Footwear upper components 100 formed by these methods may have any of the specific structures, properties, features, and/or options described above in conjunction with
In some examples of these methods, a second fabric component will be engaged with the bladder 200 or bladder precursor, e.g., to make a structure like that shown in
Once the footwear upper component 100 is formed, it may be combined with other footwear upper component parts (if needed, e.g., a strobel or other bottom member) and/or other footwear parts (e.g., a strap system), to form an overall upper 800 like that shown in
The texturing may help provide feel differential when contacted by a user, e.g., to help locate the bladder 200 and/or to provide proprioceptive feedback. In addition, the texturing may provide an interesting aesthetic, as texturing may create different lighting, reflecting, and/or shadowing effects. Also, in some examples of this technology, at least one of the first sheet or layer of thermoplastic polymer material 200A and/or the second sheet or layer of thermoplastic polymer material 200B (e.g., at least the second sheet or layer 200B in
As some more specific examples, texturing may be applied to a bladder 200 surface 200BX using molding processes (e.g., when the bladder 200 is formed, when the bladder 200 is inflated, and/or when the bladder 200 or a bladder precursor is engaged with a fabric component 110, 120), using a thermoforming process, using a vacuum forming process, using an embossing process, etc.
In this illustrated example, the mold plates 1400A, 1400B are pressed together (shown by arrows 1410) with sufficient heating to soften the thermoplastic sheets 200A, 200B, form the outer perimeter seam 200S (e.g., by an adhesive free bond or by an adhesive based bond (if an adhesive has been applied to one or both of sheets 200A, 200B)), and engage thermoplastic sheet 200A with fabric component 110, 120 (e.g., by an adhesive free bond or by an adhesive based bond (if an adhesive has been applied to one or both of sheet 200A and fabric component 110, 120)). Because of the cavity 1400C in top mold plate 1400A in this example, the thermoplastic sheets 200A, 200B will not bond in the area adjacent and within the cavity 1400C (as no compressive force is applied to the sheets 200A, 200B in the cavity 1400C area).
As shown in
Alternatively, if desired, the cavity 1400C could be omitted such that the applied force 1410 from pressing the mold plates 1400A, 1400B together also presses mold surface 1400S (with its texturing 1400T) against surface 200BX of the second thermoplastic sheet 200B. In such examples, the vacuum force 1400V may not be present and/or needed to apply texturing to surface 200BX. In such examples, texturing may be applied to thermoplastic sheet 200A as well.
Any type of texturing pattern may be applied to the bladder 200.
The texturing 220R may help provide feel differential when contacted by a user, e.g., to help locate the bladder 200 with one's fingers and/or to provide proprioceptive feedback. The texturing 220R may face toward the interior of the shoe (e.g., to contact the wearer's foot or leg at least in the heel and/or ankle support area 200H), toward the exterior of the shoe (e.g., to enable easy location of the bladder 200 parts by feel), or in both directions in all or part of the bladder 200 (e.g., in one direction in one area of the bladder 200 and in the other direction in another area of the bladder 200). In addition, the texturing 220R may provide an interesting aesthetic, as texturing may create different lighting, reflecting, and/or shadowing effects. The bladder 200 also may have any of the transparency and/or other properties of the bladders described above in conjunction with
As other alternatives, if desired, texturing may be applied to one or more bladder surfaces (e.g., 200AX, 200BX) in other processes. For example, with one or both of the first and/or second thermoplastic sheets 200A, 200B softened (e.g., by application of heat), the sheet(s) 200A, 200B could be pressed by one or more rollers having a textured surface (e.g., passed between rollers, one of which may have a textured surface), e.g., in an embossing, calendaring, or rolling process.
While
The present invention is disclosed above and in the accompanying drawings with reference to a variety of example structures. The purpose served by the disclosure, however, is to provide examples of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention, as defined by the appended claims.
For the avoidance of doubt, the present application includes at least the subject matter described in the following numbered Clauses:
Clause 1. A footwear upper component, comprising:
-
- a first knit fabric element that includes a first thermoplastic polyurethane component; and
- a bladder component that defines a sealed interior chamber for containing a fluid, wherein the bladder component includes an outer perimeter seam that extends at least partially around the sealed interior chamber, and wherein at least a portion of the outer perimeter seam is bonded to or otherwise engaged with the first thermoplastic polyurethane component of the first knit fabric element.
Clause 2. The footwear upper component according to Clause 1, wherein the bladder component includes a first thermoplastic sheet and a second thermoplastic sheet facing the first thermoplastic sheet, wherein the outer perimeter seam fixes the first thermoplastic sheet to the second thermoplastic sheet, and wherein a first major interior surface of the first thermoplastic sheet, a first major interior surface of the second thermoplastic sheet, and the outer perimeter seam define the sealed interior chamber.
Clause 3. The footwear upper component according to Clause 2, wherein the first thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the first thermoplastic sheet, wherein at least a portion of the first major exterior surface of the first thermoplastic sheet that defines the sealed interior chamber is bonded to the first thermoplastic polyurethane component of the first knit fabric element in an adhesive free manner, and wherein the portion of the outer perimeter seam that is bonded to the first thermoplastic polyurethane component of the first knit fabric element is bonded in an adhesive free manner.
Clause 4. The footwear upper component according to Clause 3, wherein the outer perimeter seam includes a first seam portion engaging a first side of the first thermoplastic sheet with a first side of the second thermoplastic sheet and a second seam portion engaging a second side of the first thermoplastic sheet with a second side of the second thermoplastic sheet, wherein the first seam portion is located on an opposite side of the sealed interior chamber from the second seam portion, and wherein the portion of the first major exterior surface of the first thermoplastic sheet that is bonded to the first thermoplastic polyurethane component of the first knit fabric element extends continuously from the first seam portion to the second seam portion.
Clause 5. The footwear upper component according to Clause 2, wherein the first thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the first thermoplastic sheet, and wherein at least 50% of a surface area of the first major exterior surface of the first thermoplastic sheet is bonded to the first thermoplastic polyurethane component of the first knit fabric element in an adhesive free manner.
Clause 6. The footwear upper component according to Clause 2, wherein the first thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the first thermoplastic sheet, and wherein at least 80% of a surface area of the first major exterior surface of the first thermoplastic sheet is bonded to the first thermoplastic polyurethane component of the first knit fabric element in an adhesive free manner.
Clause 7. The footwear upper component according to any one of Clauses 2 to 6, further comprising: a second knit fabric element engaged with at least one of the first knit fabric element or the bladder component.
Clause 8. The footwear upper component according to Clause 7, wherein the second knit fabric element includes a second thermoplastic polyurethane component, wherein the second thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the second thermoplastic sheet, and wherein at least a portion of the first major exterior surface of the second thermoplastic sheet is bonded to the second thermoplastic polyurethane component of the second knit fabric element in an adhesive free manner.
Clause 9. The footwear upper component according to Clause 8, wherein at least 50% of a surface area of the first major exterior surface of the second thermoplastic sheet is bonded to the second thermoplastic polyurethane component of the second knit fabric element in an adhesive free manner.
Clause 10. The footwear upper component according to Clause 8, wherein at least 80% of a surface area of the first major exterior surface of the second thermoplastic sheet is bonded to the second thermoplastic polyurethane component of the second knit fabric element in an adhesive free manner.
Clause 11. The footwear upper component according to any one of Clauses 7 to 10, wherein the second knit fabric element includes an opening defined through it, and wherein at least a portion of an exterior surface of the sealed interior chamber is exposed through the opening.
Clause 12. The footwear upper component according to any one of Clauses 2 to 6, further comprising: a fabric component engaged with the second thermoplastic sheet.
Clause 13. The footwear upper component according to Clause 12, wherein the second thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the second thermoplastic sheet, and wherein at least a portion of the first major exterior surface of the second thermoplastic sheet is fixedly bonded to the fabric component.
Clause 14. The footwear upper component according to Clause 13, wherein at least 50% of a surface area of the first major exterior surface of the second thermoplastic sheet is fixedly bonded to the fabric component.
Clause 15. The footwear upper component according to Clause 13, wherein at least 80% of a surface area of the first major exterior surface of the second thermoplastic sheet is fixedly bonded to the fabric component.
Clause 16. The footwear upper component according to any one of Clauses 12 to 15, wherein the fabric component includes an opening defined through it, and wherein at least a portion of an exterior surface of the sealed interior chamber is exposed through the opening.
Clause 17. The footwear upper component according to any one of Clauses 12 to 15, wherein a portion of the fabric component partially covers an exterior surface of the sealed interior chamber.
Clause 18. The footwear upper component according to any one of Clauses 1 to 17, wherein the outer perimeter seam extends continuously and completely around the sealed interior chamber.
Clause 19. The footwear upper component according to Clause 18, wherein at least 90% of a surface area of one surface of the outer perimeter seam is bonded to the first thermoplastic polyurethane component of the first knit fabric element.
Clause 20. The footwear upper component according to any one of Clauses 1 to 19, wherein the outer perimeter seam includes a thermoplastic polyurethane material that melts under heat and pressure to bond with melted material of the first thermoplastic polyurethane component of the first knit fabric element.
Clause 21. The footwear upper component according to any one of Clauses 1 to 11 or
Clauses 18 to 20, further comprising: a fabric component engaged with the bladder component.
Clause 22. The footwear upper component according to Clause 21, wherein at least a portion of an exterior major surface of the bladder component forming the sealed interior chamber is fixedly bonded to the fabric component.
Clause 23. The footwear upper component according to Clause 22, wherein at least 50% of a surface area of the exterior major surface of the bladder component is fixedly bonded to the fabric component.
Clause 24. The footwear upper component according to Clause 22, wherein at least 80% of a surface area of the exterior major surface of the bladder component is fixedly bonded to the fabric component.
Clause 25. The footwear upper component according to any one of Clauses 21 to 24, wherein the fabric component includes an opening defined through it, and wherein at least a portion of an exterior major surface of the sealed interior chamber is exposed through the opening.
Clause 26. The footwear upper component according to Clause 25, wherein a portion of the fabric component is dissolved to form the opening.
Clause 27. The footwear upper component according to any one of Clauses 21 to 26, wherein a portion of the fabric component partially covers an exterior surface of the sealed interior chamber.
Clause 28. The footwear upper component according to Clause 27, wherein at least a portion of an exterior major surface of the sealed interior chamber is exposed at an exterior surface of the footwear upper component.
Clause 29. The footwear upper component according to any one of Clauses 21 to 28, wherein at least a portion of the fabric component that engages the sealed interior chamber is formed from a dissolvable material.
Clause 30. The footwear upper component according to any one of Clauses 1 to 29, wherein the outer perimeter seam forms a closed loop, and wherein a perimeter of the closed loop encloses a single sealed interior chamber which consists of the sealed interior chamber.
Clause 31. An article of footwear, comprising:
a footwear upper component according to any one of Clauses 1 to 30; and a sole structure engaged with the footwear upper component.
Clause 32. A method of forming a footwear upper component, comprising:
-
- placing a bladder or a bladder precursor on a first knit fabric element, wherein the first knit fabric element includes a first thermoplastic polyurethane component, and wherein the bladder or the bladder precursor includes a first thermoplastic polymer layer and a second thermoplastic polymer layer overlapping the first thermoplastic polymer layer;
- applying heat and pressure to form a seam to engage the first thermoplastic polymer layer with the second thermoplastic polymer layer and to engage at least a portion of the first thermoplastic polymer layer with the first thermoplastic polyurethane component of the first knit fabric element, wherein the seam, the first thermoplastic polymer layer, and the second thermoplastic polymer layer define a sealed interior chamber for containing a fluid; and
- inflating the sealed interior chamber.
Clause 33. The method according to Clause 32, wherein the first thermoplastic polymer layer and the second thermoplastic polymer layer are formed as separate sheets.
Clause 34. The method according to Clause 32 or 33, wherein the sealed interior chamber includes a first major exterior surface formed from the first thermoplastic polymer layer and a second major exterior surface formed from the second thermoplastic polymer layer opposite the first major exterior surface, and wherein at least a portion of the first major exterior surface of the first thermoplastic polymer layer is bonded to the first thermoplastic polyurethane component of the first knit fabric element.
Clause 35. The method according to any one of Clauses 32 to 34, wherein the seam comprises an outer perimeter seam that completely surrounds the sealed interior chamber.
Clause 36. The method according to any one of Clauses 32 to 35, wherein the first thermoplastic polymer layer includes a first major interior surface and a first major exterior surface opposite the first major interior surface, and wherein at least 50% of a surface area of the first major exterior surface of the first thermoplastic polymer layer is bonded to the first thermoplastic polyurethane component of the first knit fabric element in an adhesive free manner.
Clause 37. The method according to any one of Clauses 32 to 35, wherein the first thermoplastic polymer layer includes a first major interior surface and a first major exterior surface opposite the first major interior surface, and wherein at least 80% of a surface area of the first major exterior surface of the first thermoplastic polymer layer is bonded to the first thermoplastic polyurethane component of the first knit fabric element in an adhesive free manner.
Clause 38. The method according to any one of Clauses 32 to 37, further comprising:
engaging a fabric component with the second thermoplastic polymer layer.
Clause 39. The method according to Clause 38, wherein the step of engaging the fabric component with the second thermoplastic polymer layer takes place simultaneous with the step of applying heat and pressure.
Clause 40. The method according to Clause 39, wherein the second thermoplastic polymer layer includes a first major interior surface and a first major exterior surface opposite the first major interior surface of the second thermoplastic polymer layer, and wherein at least a portion of the first major exterior surface of the second thermoplastic polymer layer is bonded to a thermoplastic polyurethane component included in the fabric component.
Clause 41. The method according to Clause 40, wherein at least 50% of a surface area of the first major exterior surface of the second thermoplastic polymer layer is bonded to the thermoplastic polyurethane component of the fabric component in an adhesive free manner.
Clause 42. The method according to Clause 40, wherein at least 80% of a surface area of the first major exterior surface of the second thermoplastic polymer layer is bonded to the thermoplastic polyurethane component of the fabric component in an adhesive free manner.
Clause 43. The method according to any one of Clauses 38 to 42, wherein the fabric component includes an opening defined through it, and wherein at least a portion of an exterior surface of the sealed interior chamber is exposed through the opening.
Clause 44. The method according to any one of Clauses 32 to 37, further comprising: (i) engaging a fabric component with the second thermoplastic polymer layer; and (ii) forming an opening through the fabric component, wherein a portion an exterior surface of the second thermoplastic polymer layer is exposed through the opening.
Clause 45. The method according to Clause 44, wherein the portion of the exterior surface of the second thermoplastic polymer layer exposed through the opening includes a portion that forms an exterior surface of the sealed interior chamber.
Clause 46. The method according to Clause 44 or 45, wherein the step of forming the opening includes dissolving a portion of the fabric component to form the opening.
Clause 47. The method according to any one of Clauses 32 to 46, wherein the step of applying heat and pressure to form the seam includes localized melting to bond the portion of the first thermoplastic polymer layer with the first thermoplastic polyurethane component of the first knit fabric element.
Clause 48. The method according to any one of Clauses 32 to 47, wherein the step of applying heat and pressure to form the seam includes localized melting to bond the first thermoplastic polymer layer with the second thermoplastic polymer layer.
Clause 49. The method according to any one of Clauses 32 to 48, wherein the step of inflating the sealed interior chamber takes place after the step of applying heat and pressure.
Clause 50. The method according to any one of Clauses 32 to 48, wherein the step of inflating the sealed interior chamber takes place before the step of applying heat and pressure.
Clause 51. A footwear upper component formed by the method according to any one of
Clauses 32 to 50.
Clause 52. A method of making an article of footwear, comprising:
-
- forming a footwear upper component using the method according to any one of Clauses 32 to 50; and
- engaging a sole structure with the footwear upper component.
Clause 53. An article of footwear formed by the method according to Clause 52.
Clause 54. A footwear upper component, comprising:
a first fabric element; and a bladder component that defines a sealed interior chamber for containing a fluid, wherein the bladder component includes an outer perimeter seam that extends at least partially around the sealed interior chamber, and wherein at least a portion of the outer perimeter seam is bonded to the first fabric element.
Clause 55. The footwear upper component according to Clause 54, wherein the bladder component includes a first thermoplastic sheet and a second thermoplastic sheet facing the first thermoplastic sheet, wherein the outer perimeter seam fixes the first thermoplastic sheet to the second thermoplastic sheet, and wherein a first major interior surface of the first thermoplastic sheet, a first major interior surface of the second thermoplastic sheet, and the outer perimeter seam define the sealed interior chamber.
Clause 56. The footwear upper component according to Clause 55, wherein the first thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the first thermoplastic sheet, wherein at least a portion of the first major exterior surface of the first thermoplastic sheet that defines the sealed interior chamber is bonded to the first fabric element in an adhesive free manner, and wherein the portion of the outer perimeter seam that is bonded to the first fabric element is bonded in an adhesive free manner.
Clause 57. The footwear upper component according to Clause 56, wherein the outer perimeter seam includes a first seam portion engaging a first side of the first thermoplastic sheet with a first side of the second thermoplastic sheet and a second seam portion engaging a second side of the first thermoplastic sheet with a second side of the second thermoplastic sheet, wherein the first seam portion is located on an opposite side of the sealed interior chamber from the second seam portion, and wherein the portion of the first major exterior surface of the first thermoplastic sheet that is bonded to the first fabric element extends continuously from the first seam portion to the second seam portion.
Clause 58. The footwear upper component according to Clause 55, wherein the first thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the first thermoplastic sheet, and wherein at least 50% of a surface area of the first major exterior surface of the first thermoplastic sheet is bonded to the first fabric element in an adhesive free manner.
Clause 59. The footwear upper component according to Clause 55, wherein the first thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the first thermoplastic sheet, and wherein at least 80% of a surface area of the first major exterior surface of the first thermoplastic sheet is bonded to the first fabric element in an adhesive free manner.
Clause 60. The footwear upper component according to any one of Clauses 55 to 59, further comprising: a second fabric element engaged with at least one of the first fabric element or the bladder component.
Clause 61. The footwear upper component according to Clause 60, wherein the second thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the second thermoplastic sheet, and wherein at least a portion of the first major exterior surface of the second thermoplastic sheet is bonded to the second fabric element in an adhesive free manner.
Clause 62. The footwear upper component according to Clause 61, wherein at least 50% of a surface area of the first major exterior surface of the second thermoplastic sheet is bonded to the second fabric element in an adhesive free manner.
Clause 63. The footwear upper component according to Clause 61, wherein at least 80% of a surface area of the first major exterior surface of the second thermoplastic sheet is bonded to the second fabric element in an adhesive free manner.
Clause 64. The footwear upper component according to any one of Clauses 60 to 63, wherein the second fabric element includes an opening defined through it, and wherein at least a portion of an exterior surface of the sealed interior chamber is exposed through the opening.
Clause 65. The footwear upper component according to any one of Clauses 54 to 64, wherein the outer perimeter seam extends continuously and completely around the sealed interior chamber.
Clause 66. The footwear upper component according to Clause 65, wherein at least 90% of a surface area of one surface of the outer perimeter seam is bonded to the first fabric element.
Clause 67. The footwear upper component according to any one of Clauses 54 to 66, wherein the outer perimeter seam includes a thermoplastic material that melts under heat and pressure to bond with melted material of the first fabric element.
Clause 68. The footwear upper component according to any one of Clauses 54 to 67, wherein the outer perimeter seam forms a closed loop, and wherein a perimeter of the closed loop encloses a single sealed interior chamber which consists of the sealed interior chamber.
Clause 69. An article of footwear, comprising:
-
- a footwear upper component according to any one of Clauses 54 to 68; and
- a sole structure engaged with the footwear upper component.
Clause 70. A method of forming a footwear upper component, comprising:
-
- placing a bladder or a bladder precursor on a first fabric element, wherein the bladder or the bladder precursor includes a first thermoplastic polymer layer and a second thermoplastic polymer layer overlapping the first thermoplastic polymer layer;
- applying heat and pressure to form a seam to engage the first thermoplastic polymer layer with the second thermoplastic polymer layer and to engage at least a portion of the first thermoplastic polymer layer with the first fabric element, wherein the seam, the first thermoplastic polymer layer, and the second thermoplastic polymer layer define a sealed interior chamber for containing a fluid; and
- inflating the sealed interior chamber.
Clause 71. The method according to Clause 70, wherein the first thermoplastic polymer layer and the second thermoplastic polymer layer are formed as separate sheets.
Clause 72. The method according to Clause 70 or 71, wherein the sealed interior chamber includes a first major exterior surface formed from the first thermoplastic polymer layer and a second major exterior surface formed from the second thermoplastic polymer layer opposite the first major exterior surface, and wherein at least a portion of the first major exterior surface of the first thermoplastic polymer layer is bonded to the first fabric element.
Clause 73. The method according to any one of Clauses 70 to 72, wherein the seam comprises an outer perimeter seam that completely surrounds the sealed interior chamber.
Clause 74. The method according to any one of Clauses 70 to 73, wherein the first thermoplastic polymer layer includes a first major interior surface and a first major exterior surface opposite the first major interior surface, and wherein at least 50% of a surface area of the first major exterior surface of the first thermoplastic polymer layer is bonded to the first fabric element in an adhesive free manner.
Clause 75. The method according to any one of Clauses 70 to 73, wherein the first thermoplastic polymer layer includes a first major interior surface and a first major exterior surface opposite the first major interior surface, and wherein at least 80% of a surface area of the first major exterior surface of the first thermoplastic polymer layer is bonded to the first fabric element in an adhesive free manner.
Clause 76. The method according to any one of Clauses 70 to 75, further comprising:
engaging a fabric component with the second thermoplastic polymer layer.
Clause 77. The method according to Clause 76, wherein the step of engaging the fabric component with the second thermoplastic polymer layer takes place simultaneous with the step of applying heat and pressure.
Clause 78. The method according to Clause 77, wherein the second thermoplastic polymer layer includes a first major interior surface and a first major exterior surface opposite the first major interior surface of the second thermoplastic polymer layer, and wherein at least a portion of the first major exterior surface of the second thermoplastic polymer layer is bonded to the fabric component.
Clause 79. The method according to Clause 78, wherein at least 50% of a surface area of the first major exterior surface of the second thermoplastic polymer layer is bonded to the fabric component in an adhesive free manner.
Clause 80. The method according to Clause 78, wherein at least 80% of a surface area of the first major exterior surface of the second thermoplastic polymer layer is bonded to the fabric component in an adhesive free manner.
Clause 81. The method according to any one of Clauses 76 to 80, wherein the fabric component includes an opening defined through it, and wherein at least a portion of an exterior surface of the sealed interior chamber is exposed through the opening.
Clause 82. The method according to any one of Clauses 70 to 75, further comprising: (i) engaging a fabric component with the second thermoplastic polymer layer; and (ii) forming an opening through the fabric component, wherein a portion an exterior surface of the second thermoplastic polymer layer is exposed through the opening.
Clause 83. The method according to Clause 82, wherein the portion of the exterior surface of the second thermoplastic polymer layer exposed through the opening includes a portion that forms an exterior surface of the sealed interior chamber.
Clause 84. The method according to Clause 82 or 83, wherein the step of forming the opening includes dissolving a portion of the fabric component to form the opening.
Clause 85. The method according to any one of Clauses 70 to 84, wherein the step of applying heat and pressure to form the seam includes localized melting to bond the portion of the first thermoplastic polymer layer with the first fabric element.
Clause 86. The method according to any one of Clauses 70 to 85, wherein the step of applying heat and pressure to form the seam includes localized melting to bond the first thermoplastic polymer layer with the second thermoplastic polymer layer.
Clause 87. The method according to any one of Clauses 70 to 86, wherein the step of inflating the sealed interior chamber takes place after the step of applying heat and pressure.
Clause 88. The method according to any one of Clauses 70 to 86, wherein the step of inflating the sealed interior chamber takes place before the step of applying heat and pressure.
Clause 89. A footwear upper component formed by the method according to any one of
Clauses 70 to 88.
Clause 90. A method of making an article of footwear, comprising:
-
- forming a footwear upper component using the method according to any one of Clauses 70 to 88; and
- engaging a sole structure with the footwear upper component.
Clause 91. An article of footwear formed by the method according to Clause 90.
Clause 92. A footwear upper component, comprising:
-
- a first fabric element that includes a first surface having texturing; and
- a bladder component that defines a sealed interior chamber for containing a fluid, wherein the bladder component includes: (a) a first major surface engaged with the first surface of the first fabric element, wherein the first major surface defines at least part of a first perimeter seam surface and at least part of a first surface of the sealed interior chamber, (b) a second major surface opposite the first major surface, wherein the second major surface defines at least part of a second perimeter seam surface opposite the first perimeter seam surface and at least part of a second surface of the sealed interior chamber opposite the first surface of the sealed interior chamber, and (c) and a fluid chamber located between the first major surface and the second major surface, and wherein at least a portion of the first major surface includes texturing having surface contour features corresponding to the texturing present on the first surface of the first fabric element.
Clause 93. The footwear upper component according to Clause 92, wherein the texturing on the first major surface of the bladder component includes texturing on the first surface of the sealed interior chamber.
Clause 94. The footwear upper component according to Clause 92 or 93, wherein the texturing on the first major surface of the bladder component includes texturing on the first perimeter seam surface.
Clause 95. The footwear upper component according to any one of Clauses 92 to 94, wherein at least a portion of the second major surface includes texturing corresponding to the texturing present on the first surface of the first fabric element.
Clause 96. The footwear upper component according to Clause 95, wherein the texturing on the second major surface of the bladder component includes texturing on the second surface of the sealed interior chamber.
Clause 97. The footwear upper component according to Clause 95 or 96, wherein the texturing on the second major surface of the bladder component includes texturing on the second perimeter seam surface.
Clause 98. The footwear upper component according to any one of Clauses 92 to 97, wherein the first major surface of the bladder component is formed from a first thermoplastic sheet and the second major surface of the bladder component is formed from a second thermoplastic sheet.
Clause 99. The footwear upper component according to Clause 98, wherein the second thermoplastic sheet is formed from an at least partially transparent or translucent material such that the texturing present on at least a portion of the first major surface is visible through the second thermoplastic sheet.
Clause 100. The footwear upper component according to any one of Clauses 92 to 99, wherein the first surface of the first fabric element has a mesh structure.
Clause 101. The footwear upper component according to any one of Clauses 92 to 99, wherein the first surface of the first fabric element has a mesh structure with openings defined within a matrix formed by the first fabric element, and wherein the mesh structure and openings produce the surface contour features on the first major surface of the bladder component.
Clause 102. The footwear upper component according to any one of Clauses 92 to 101, wherein the first fabric element is a knit fabric element.
Clause 103. An article of footwear, comprising:
-
- a footwear upper component according to any one of Clauses 92 to 102; and
- a sole structure engaged with the footwear upper component.
Clause 104. A method of forming a footwear upper component, comprising:
-
- placing a bladder or a bladder precursor on a first fabric element, wherein the first fabric element includes a first surface having texturing, and wherein the bladder or the bladder precursor includes a first thermoplastic polymer layer and a second thermoplastic polymer layer overlapping the first thermoplastic polymer layer; and
- forming texturing on at least a portion of the first thermoplastic polymer layer by applying heat and pressure to form at least one of: (a) a seam that engages the first thermoplastic polymer layer with the second thermoplastic polymer layer and (ii) an engagement of at least the portion of the first thermoplastic polymer layer with the first fabric element, wherein the bladder or the bladder precursor defines a sealed interior chamber for containing a fluid, and wherein the texturing formed on the portion of the first thermoplastic polymer layer corresponds in surface contour features to the texturing included on the first surface of the first fabric element.
Clause 105. The method according to Clause 104, wherein the first thermoplastic polymer layer and the second thermoplastic polymer layer are formed as separate sheets.
Clause 106. The method according to Clause 104 or 105, wherein the portion of the first thermoplastic polymer layer on which the texturing is formed comprises at least a portion of the seam.
Clause 107. The method according to any one of Clauses 104 to 106, wherein the sealed interior chamber includes a first major exterior surface formed by the first thermoplastic polymer layer and a second major exterior surface formed by the second thermoplastic polymer layer, and wherein the portion of the first thermoplastic polymer layer on which the texturing is formed comprises at least a portion of the first major exterior surface.
Clause 108. The method according to Clause 107, wherein the step of forming the texturing forms texturing on at least a portion of the second major exterior surface.
Clause 109. The method according to any one of Clauses 104 to 106, wherein the sealed interior chamber includes a first major exterior surface formed by the first thermoplastic polymer layer and a second major exterior surface formed by the second thermoplastic polymer layer, and wherein the step of forming the texturing forms texturing on at least a portion of the second major exterior surface.
Clause 110. The method according to any one of Clauses 104 to 109, wherein the seam comprises an outer perimeter seam that completely surrounds the sealed interior chamber.
Clause 111. The method according to any one of Clauses 104 to 110, further comprising:
engaging a second fabric element with the second thermoplastic polymer layer.
Clause 112. The method according to Clause 111, wherein the step of engaging the second fabric element with the second thermoplastic polymer layer takes place simultaneous with the step of applying heat and pressure to form the texturing on at least the portion of the first thermoplastic polymer layer.
Clause 113. The method according to any one of Clauses 104 to 112, wherein the step of forming the texturing further includes forming texturing on at least a portion of the second thermoplastic polymer layer by applying heat and pressure to the second thermoplastic polymer layer, and wherein the texturing formed on the portion of the second thermoplastic polymer layer corresponds in surface contour features to the texturing included on the first surface of the first fabric element.
Clause 114. The method according to any one of Clauses 104 to 113, wherein the second thermoplastic polymer layer is formed at least in part from an at least partially transparent or translucent material, and wherein the texturing present on at least a portion of the first thermoplastic polymer layer is visible through the second thermoplastic polymer layer.
Clause 115. The method according to any one of Clauses 104 to 114, further comprising: inflating the sealed interior chamber after the step of forming the texturing.
Clause 116. The method according to any one of Clauses 104 to 114, further comprising: inflating the sealed interior chamber before the step of forming the texturing.
Clause 117. The method according to any one of Clauses 104 to 116, wherein the first surface of the first fabric element has a mesh structure.
Clause 118. The method according to any one of Clauses 104 to 116, wherein the first surface of the first fabric element has a mesh structure with openings defined within a matrix formed by the first fabric element, and wherein the mesh structure and openings produce the surface contour features on the first thermoplastic polymer layer.
Clause 119. The method according to any one of Clauses 104 to 118, wherein the first fabric element is a knit fabric element.
Clause 120. A footwear upper component formed by the method according to any one of Clauses 104 to 119.
Clause 121. A method of making an article of footwear, comprising:
-
- forming a footwear upper component using the method according to any one of Clauses 104 to 119; and
- engaging a sole structure with the footwear upper component.
Clause 122. An article of footwear formed by the method according to Clause 121.
Clause 123. A footwear upper component, comprising:
-
- a first fabric element; and
- a bladder component that defines a sealed interior chamber for containing a fluid, wherein the bladder component includes: (a) a first major surface engaged with the first fabric element, wherein the first major surface defines at least part of a first perimeter seam surface and at least part of a first surface of the sealed interior chamber, (b) a second major surface opposite the first major surface, wherein the second major surface defines at least part of a second perimeter seam surface opposite the first perimeter seam surface and at least part of a second surface of the sealed interior chamber opposite the first surface of the sealed interior chamber, and (c) and a fluid chamber located between the first major surface and the second major surface, and wherein at least a portion of the second major surface includes molded-in texturing.
Clause 124. The footwear upper component according to Clause 123, wherein the molded-in texturing on the second major surface of the bladder component includes texturing on at least a portion of the second surface of the sealed interior chamber.
Clause 125. The footwear upper component according to Clause 123 or 124, wherein the molded-in texturing on the second major surface of the bladder component includes texturing on the second perimeter seam surface.
Clause 126. The footwear upper component according to any one of Clauses 123 to 125, wherein the first major surface of the bladder component is formed from a first thermoplastic sheet and the second major surface of the bladder component is formed from a second thermoplastic sheet.
Clause 127. The footwear upper component according to any one of Clauses 123 to 126, wherein the molded-in texturing includes a plurality of raised ridges.
Clause 128. The footwear upper component according to any one of Clauses 123 to 126, wherein the molded-in texturing includes a plurality of raised grid elements.
Clause 129. The footwear upper component according to any one of Clauses 123 to 126, wherein the molded-in texturing includes a plurality of recessed grid elements.
Clause 130. The footwear upper component according to any one of Clauses 123 to 126, wherein the molded-in texturing includes a herringbone pattern.
Clause 131. The footwear upper component according to any one of Clauses 123 to 126, wherein the molded-in texturing includes a plurality of rounded elements.
Clause 132. The footwear upper component according to any one of Clauses 123 to 126, wherein the molded-in texturing includes a first portion having a first pattern and a second portion having a second pattern different from the first pattern.
Clause 133. An article of footwear, comprising:
-
- a footwear upper component according to any one of Clauses 123 to 132; and
- a sole structure engaged with the footwear upper component.
Claims
1. A footwear upper component, comprising:
- a first knit fabric element that includes a first thermoplastic polyurethane component; and
- a bladder component that defines a sealed interior chamber for containing a fluid, wherein the bladder component includes an outer perimeter seam that extends at least partially around the sealed interior chamber, and wherein at least a portion of the outer perimeter seam is bonded to or otherwise engaged with the first thermoplastic polyurethane component of the first knit fabric element.
2. The footwear upper component according to claim 1, wherein the bladder component includes a first thermoplastic sheet and a second thermoplastic sheet facing the first thermoplastic sheet, wherein the outer perimeter seam fixes the first thermoplastic sheet to the second thermoplastic sheet, and wherein a first major interior surface of the first thermoplastic sheet, a first major interior surface of the second thermoplastic sheet, and the outer perimeter seam define the sealed interior chamber, wherein the first thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the first thermoplastic sheet, wherein at least a portion of the first major exterior surface of the first thermoplastic sheet that defines the sealed interior chamber is bonded to the first thermoplastic polyurethane component of the first knit fabric element in an adhesive free manner, and wherein the portion of the outer perimeter seam that is bonded to the first thermoplastic polyurethane component of the first knit fabric element is bonded in an adhesive free manner.
3. The footwear upper component according to claim 2, wherein the outer perimeter seam includes: (i) a first seam portion engaging a first side of the first thermoplastic sheet with a first side of the second thermoplastic sheet and (ii) a second seam portion engaging a second side of the first thermoplastic sheet with a second side of the second thermoplastic sheet, wherein the first seam portion is located on an opposite side of the sealed interior chamber from the second seam portion, and wherein the portion of the first major exterior surface of the first thermoplastic sheet that is bonded to the first thermoplastic polyurethane component of the first knit fabric element extends continuously from the first seam portion to the second seam portion.
4. The footwear upper component according to claim 2, wherein at least 50% of a surface area of the first major exterior surface of the first thermoplastic sheet is bonded to the first thermoplastic polyurethane component of the first knit fabric element in an adhesive free manner.
5. The footwear upper component according to claim 2, further comprising: a second knit fabric element engaged with at least one of the first knit fabric element or the bladder component, wherein the second knit fabric element includes a second thermoplastic polyurethane component, wherein the second thermoplastic sheet includes a first major exterior surface opposite the first major interior surface of the second thermoplastic sheet, and wherein at least a portion of the first major exterior surface of the second thermoplastic sheet is bonded to the second thermoplastic polyurethane component of the second knit fabric element in an adhesive free manner.
6. The footwear upper component according to claim 5, wherein the second knit fabric element includes an opening defined through it, and wherein at least a portion of an exterior surface of the sealed interior chamber is exposed through the opening.
7. The footwear upper component according to claim 1, wherein the outer perimeter seam extends continuously and completely around the sealed interior chamber, and wherein at least 90% of a surface area of one surface of the outer perimeter seam is bonded to the first thermoplastic polyurethane component of the first knit fabric element.
8. The footwear upper component according to claim 1, wherein the outer perimeter seam includes a thermoplastic polyurethane material that melts under heat and pressure to bond with melted material of the first thermoplastic polyurethane component of the first knit fabric element.
9. The footwear upper component according to claim 1, further comprising: a fabric component engaged with the bladder component, and wherein the fabric component includes an opening defined through it, and wherein at least a portion of an exterior major surface of the sealed interior chamber is exposed through the opening.
10. The footwear upper component according to claim 1, further comprising: a fabric component engaged with the bladder component, wherein at least a portion of the fabric component that engages the sealed interior chamber is formed from a dissolvable material.
11. A method of forming a footwear upper component, comprising:
- placing a bladder or a bladder precursor on a first knit fabric element, wherein the first knit fabric element includes a first thermoplastic polyurethane component, and wherein the bladder or the bladder precursor includes a first thermoplastic polymer layer and a second thermoplastic polymer layer overlapping the first thermoplastic polymer layer;
- applying heat and pressure to form a seam to engage the first thermoplastic polymer layer with the second thermoplastic polymer layer and to engage at least a portion of the first thermoplastic polymer layer with the first thermoplastic polyurethane component of the first knit fabric element, wherein the seam, the first thermoplastic polymer layer, and the second thermoplastic polymer layer define a sealed interior chamber for containing a fluid; and
- inflating the sealed interior chamber.
12. The method according to claim 11, wherein the sealed interior chamber includes a first major exterior surface formed from the first thermoplastic polymer layer and a second major exterior surface formed from the second thermoplastic polymer layer opposite the first major exterior surface, and wherein at least a portion of the first major exterior surface of the first thermoplastic polymer layer is bonded to the first thermoplastic polyurethane component of the first knit fabric element.
13. The method according to claim 11, further comprising: engaging a fabric component with the second thermoplastic polymer layer.
14. The method according to claim 13, wherein the step of engaging the fabric component with the second thermoplastic polymer layer takes place simultaneous with the step of applying heat and pressure.
15. The method according to claim 14, wherein the second thermoplastic polymer layer includes a first major interior surface and a first major exterior surface opposite the first major interior surface of the second thermoplastic polymer layer, and wherein at least a portion of the first major exterior surface of the second thermoplastic polymer layer is bonded to a thermoplastic polyurethane component included in the fabric component.
16. The method according to claim 11, further comprising: engaging a fabric component with the second thermoplastic polymer layer; and
- forming an opening through the fabric component, wherein a portion an exterior surface of the second thermoplastic polymer layer is exposed through the opening.
17. The method according to claim 16, wherein the portion of the exterior surface of the second thermoplastic polymer layer exposed through the opening includes a portion that forms an exterior surface of the sealed interior chamber.
18. The method according to claim 16, wherein the step of forming the opening includes dissolving a portion of the fabric component to form the opening.
19. The method according to claim 11, wherein the step of applying heat and pressure to form the seam includes (i) localized melting to bond the portion of the first thermoplastic polymer layer with the first thermoplastic polyurethane component of the first knit fabric element, and/or (ii) localized melting to bond the first thermoplastic polymer layer with the second thermoplastic polymer layer.
20. The method according to claim 11, wherein the step of inflating the sealed interior chamber takes place after the step of applying heat and pressure.
Type: Application
Filed: Oct 19, 2022
Publication Date: May 11, 2023
Inventors: Patrick R. Case (Portland, OR), Yoon Jeong Choi (Portland, OR), John S. MacGilbert (Tigard, OR), James Molyneux (Portland, OR), Colin Runkle (Portland, OR), Bryan K. Youngs (Beaverton, OR)
Application Number: 17/969,443