Patent Description:
The present disclosure relates generally to bladders for articles of footwear, and to methods of making bladders for articles of footwear.

<CIT> describes a fluid filled chamber with a tensile element.

Sole structures generally include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion-resistance and traction with the ground surface. The outsole may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhance traction with the ground surface. Another layer of the sole structure includes a midsole disposed between the outsole and the upper. The midsole provides cushioning for the foot and may be partially formed from a polymer foam material that compresses resiliently under an applied load to cushion the foot by attenuating ground-reaction forces. The midsole may additionally incorporate a fluid-filled chamber to increase durability of the sole structure, as well as to provide cushioning to the foot by compressing resiliently under an applied load to attenuate ground-reaction forces. Sole structures may also include a comfort-enhancing insole or a sockliner located within a void proximate to the bottom portion of the upper and a stroble attached to the upper and disposed between the midsole and the insole or sockliner.

Fluid-filled chambers for use in footwear are typically formed from two barrier layers of polymer material that are sealed or bonded together to form a chamber. Often, the chamber is pressurized with a fluid, such as air, and may incorporate tensile members to retain a desired shape of the chamber when pressurized. Generally, fluid-filled chambers are designed with an emphasis on balancing support for the foot and cushioning characteristics that relate to responsiveness as the fluid-filled chamber resiliently compresses under an applied load. The fluid-filled chamber as a whole, however, fails to adequately dampen oscillations by the foot as the fluid-filled chamber compresses to attenuate ground-reaction forces. Accordingly, creating a midsole from a fluid-filled chamber that dampens foot oscillation and provides acceptable cushioning for the foot while attenuating ground-reaction forces is difficult to achieve.

According to the claimed invention, a bladder for an article of footwear is provided and includes a plate, a first tensile layer disposed adjacent to a first side of the plate, and a second tensile layer disposed on an opposite side of the plate from the first tensile layer, an inner surface of the second tensile layer joined to an inner surface of the first tensile layer through the plate by a plurality of inner bonds. The bladder additionally includes a first barrier layer disposed adjacent to the first tensile layer and joined to the first tensile layer by a plurality of first outer bonds to form a first chamber, one or more of the first outer bonds interposed between adjacent ones of the inner bonds.

The bladder may include one or more of the following optional features. For example, the first tensile layer and the second tensile layer may be formed of a first elastomeric material and the first barrier layer may be formed of a second elastomeric material different from the first elastomeric material. Additionally or alternatively, the first elastomeric material may have a lower melting temperature than the second elastomeric material.

According to the claimed invention, a second barrier layer is disposed adjacent to the second tensile layer and is joined to the second tensile layer by a plurality of second outer bonds to form a second chamber on the opposite side of the plate than the first chamber. In this configuration, the first chamber may be fluidly isolated from the second chamber by at least one of the first tensile layer and the second tensile layer. Additionally or alternatively, the first chamber may have a different pressure than the second chamber.

The plate may include a plurality of apertures extending through the plate with each of the inner bonds being formed within one of the apertures.

In one configuration, the second tensile layer may be joined to the first tensile layer around a periphery of the plate. Additionally or alternatively, the first tensile layer and the second tensile layer may be detached from the plate between the inner bonds to form one or more tensile elements. Further, each of the first outer bonds may be formed with one of the tensile elements.

Referring to <FIG>, a bladder <NUM> formed according to the principles of the present disclosure is shown. Generally, the bladder <NUM> includes a first chamber 12a formed, at least in part, by a first pair of barrier layers 14a, 16a on a first side of the bladder <NUM>, and a second chamber 12b formed, at least in part, by a second pair of barrier layers 14b, 16b on an opposite side of the bladder <NUM> than the first chamber 12a. Particularly, the chambers 12a, 12b are formed on opposite sides of a plate <NUM>, where inner barrier layers or tensile layers 14a, 14b of each chamber 12a, 12b are joined to each other through the plate <NUM>, and outer barrier layers 16a, 16b cooperate with respective ones of the tensile layers 14a, 14b to form the chambers 12a, 12b. Thus, as discussed in greater detail below, one or both of the outer barrier layers 16a, 16b is tethered to the tensile layer 14b, 14a located on the opposite side of the plate <NUM> from the respective outer barrier layer 16a, 16b by the tensile layer 14a, 14b located on the same side of the plate <NUM> as the respective outer barrier layer 16a, 16b.

As illustrated in <FIG>, the bladder <NUM> is formed as a full-length bladder <NUM> configured to extend continuously from an anterior end to a posterior end of an article of footwear <NUM> having an upper <NUM> and an outsole <NUM> attached to the bladder <NUM>. As set forth below, the bladder <NUM> is illustrated with different configurations 10a-10d in each of a toe region <NUM>, a ball region <NUM>, a mid-foot region <NUM>, and a heel region <NUM>. Particularly, the example bladder <NUM> shows a first configuration 10a (<FIG>) in the toe region <NUM>, a second configuration 10b (<FIG>) in the ball region <NUM>, a third configuration 10c (<FIG>) in the mid-foot region <NUM>, and a fourth configuration 10d (<FIG>) in the heel region <NUM>.

While the configurations 10a-10d described in each of the regions <NUM>, <NUM>, <NUM>, <NUM> may all be incorporated into a single bladder <NUM> in the manner shown and described herein, it will be appreciated that bladders manufactured according to the principles of the present disclosure can include any combination of one or more of the configurations shown in <FIG>. For example, an entire bladder may be formed using the configuration 10a shown and described in <FIG>, or of a combination of the configurations 10b, 10c shown and described in <FIG> and <FIG>.

Referring now to <FIG>, the components of the bladder <NUM> are shown in an exploded view. As provided above, the bladder includes a plate <NUM>, a pair of tensile layers 14a, 14b respectively disposed adjacent to opposite sides of the plate <NUM>, and a pair of outer barrier layers 16a, 16b disposed adjacent to respective ones of the tensile layers 14a, 14b. Thus, each of the tensile layers 14a, 14b is interposed between a side of the plate <NUM> and a respective one of the outer barrier layers 16a, 16b.

With continued reference to <FIG>, the plate <NUM> includes a first side <NUM>, a second side <NUM> formed on an opposite side than the first side <NUM>, and an outer periphery <NUM> extending between the first side <NUM> and the second side <NUM>. A distance from the first side <NUM> to the second side <NUM> defines a thickness of the plate <NUM>. The plate <NUM> may be described as including a substantially planar interior portion <NUM>, and a peripheral portion <NUM> formed along the outer periphery <NUM> of the plate <NUM> and surrounding the interior region <NUM>. As shown, the plate <NUM> includes a plurality of apertures <NUM> formed entirely through the thickness of the plate <NUM>. The apertures <NUM> may be formed through the interior portion <NUM> and/or the peripheral portion <NUM>.

In some configurations (10a, 10b), the thickness of the plate <NUM> may be substantially constant, while in other configurations (10c, 10d), the plate <NUM> may have a variable thickness. Optionally, the peripheral portion <NUM> defines a peripheral flange <NUM> extending outwardly from the interior portion <NUM> at an oblique angle relative to the interior portion <NUM>. Additionally or alternatively, the interior portion <NUM> and/or the peripheral portion <NUM> may include protuberances <NUM> formed on the first side <NUM> and/or the second side <NUM> to provide the plate <NUM> with a variable thickness. In the illustrated example, the plate <NUM> includes a protuberance <NUM> formed as a rib <NUM> extending from the first side <NUM> of the peripheral flange <NUM>. However, in other examples, the plate <NUM> may include one or more projections formed in the interior region <NUM> and/or on the second side <NUM>.

The plate <NUM> is formed, at least in part, by a material having a greater stiffness than the barrier layers 14a, 14b, 16a, 16b, and forms an internal structure or skeleton of the bladder <NUM>. In some examples, the plate <NUM> includes one or more polymeric materials having a higher melting temperature than at least the tensile layers 14a, 14b. In other examples, the plate <NUM> may be formed of or include composite materials and/or metal materials. The first and second sides <NUM>, <NUM> of the plate <NUM> are configured to inhibit bonding between the plate <NUM> and the tensile layers 14a, 14b. Thus, the plate <NUM> itself may be formed of a material that is incompatible (i.e., resistant to bonding) with the material of the tensile layers 14a, 14b. Additionally or alternatively, the sides <NUM>, <NUM> of the plate <NUM> may be coated or covered with a bond inhibitor to prevent joining of the tensile layers 14a, 14b and the plate <NUM>.

With continued reference to <FIG>, the tensile layers 14a, 14b are arranged on opposite sides <NUM>, <NUM> of the plate <NUM> such that the plate <NUM> is interposed between the tensile layers 14a, 14b when the bladder <NUM> is assembled. The tensile layers 14a, 14b each include an inner surface 36a, 36b and an outer surface 38a, 38b formed on an opposite side of the tensile layer 14a, 14b than the inner surface 36a, 36b. Each of the tensile layers 14a, 14b includes an outer periphery 40a, 40b extending between the inner surface 36a, 36b and the outer surface 38a, 38b.

When the bladder <NUM> is assembled, the inner surfaces 36a, 36b of the tensile layers 14a, 14b face the plate <NUM> and are joined to each other by inner bonds <NUM> through one or more of the apertures <NUM> of the plate <NUM>. The inner surfaces 36a, 36b may also be joined to each other along the outer periphery of the plate <NUM>, such that at least a portion of the plate <NUM> is enclosed between the tensile layers 14a, 14b.

Referring still to <FIG>, the outer barrier layers 16a, 16b are also arranged on opposite sides <NUM>, <NUM> of the plate, such that the plate <NUM> and the tensile layers 14a, 14b are interposed between the outer barrier layers 16a, 16b. The outer barrier layers 16a, 16b each include an inner surface 44a, 44b and an outer surface 46a, 46b formed on an opposite side of the outer barrier layer 16a, 16b from the inner surface 44a, 44b. Each of the outer barrier layers 16a, 16b includes an outer periphery 48a, 48b extending between the inner surface 44a, 44b and the outer surface 46a, 46b.

When the bladder <NUM> is assembled, the inner surfaces 44a, 44b of the outer barrier layers 16a, 16b face the outer surfaces 38a, 38b of the tensile layers 14a, 14b. As described in greater detail below with respect to each of the configurations 10a-10d, the inner surfaces 44a, 44b of the outer barrier layers 16a, 16b may be joined to the outer surfaces 38a, 38b of the tensile layers 14a, 14b, respectively, to define a geometry (e.g., thicknesses, width, and lengths) of the bladder <NUM>. For example, the inner surfaces 44a, 44b of the outer barrier layers 16a, 16b may be joined to the outer surfaces 38a, 38b of the tensile layers 14a, 14b by a plurality of outer bonds <NUM> in the interior portion <NUM> to form first and second web areas 52a, 52b of the bladder <NUM>. Similarly, the outer peripheries of the barrier layers 14a, 14b, 16a, 16b may be joined together to form a peripheral seam <NUM> extending around the bladder <NUM> to seal the fluid (e.g., air) within the fluid-filled chamber chambers 12a, 12b. Thus, the chambers 12a, 12b are associated with areas of the bladder <NUM> where the inner surfaces 44a, 44b of the outer barrier layers 16a, 16b are not joined together and, therefore, are separated from the outer surfaces 38a, 38b of the tensile layers 14a, 14b. As shown in the figures, a space formed between opposing surfaces 38a, 38b, 44a, 44b of the tensile layers 14a, 14b and outer barrier layers 16a, 16b defines an interior void 56a, 56b of each of the chambers 12a, 12b.

The barrier layers 14a, 14b, 16a, 16b can each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like. The tensile layers 14a, 14b are formed of a first elastomeric material and the outer barrier layers 16a, 16b are formed of a second elastomeric material.

The first elastomeric material is selected with a first melting temperature suitable for allowing the tensile layers 14a, 14b to be melded to each other through the plate <NUM> without affecting the material properties of the plate <NUM>. For instance, the first melting temperature of the first elastomeric material is low enough that the plate <NUM> will not be melted, deformed, or weakened when subjected to the first melting temperature during assembly of the bladder <NUM>. Accordingly, elastomeric material having different melting temperatures can be selected as the tensile layer 14a, 14b depending on the material of the plate <NUM> (e.g., polymeric, composite, metal). In some examples, where the plate <NUM> is formed of a polymeric material having a relatively low melting point (compared to metals or composites), the first elastomeric material may be a low-melt TPU having a melting temperature that is less than a melting temperature of the material of the plate <NUM>.

The second elastomeric material of the outer barrier layers 16a, 16b may be different than the first elastomeric material of the tensile layers 14a, 14b. For example, where a low-melt TPU material is utilized as the first elastomeric material, a conventional TPU material having a higher melting temperature may be utilized as the second elastomeric material. Utilizing a conventional TPU having a higher melting temperature for the second elastomeric material provides the outer barrier layers 16a, 16b of the chambers 12a, 12b with improved durability.

One or more of the barrier layers 14a, 14b, 16a, 16b can independently be transparent, translucent, and/or opaque. As used herein, the term "transparent" for a barrier layer and/or a fluid-filled chamber means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.

As used herein, the term "barrier layer" (e.g., barrier layers 14a, 14b, 16a, 16b) encompasses both monolayer and multilayer films. In some embodiments, one or more of the barrier layers 14a, 14b, 16a, 16b is produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or more of the barrier layers 14a, 14b, 16a, 16b is produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either aspect, each layer or sublayer can have a film thickness ranging from about <NUM> micrometers to about be about <NUM> millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about <NUM> micrometers to about <NUM> micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about <NUM> micrometer to about <NUM> micrometers.

Examples of suitable isocyanates for producing the polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), TDI adducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene <NUM>,<NUM>-diisocyanate (NDI), <NUM>,<NUM>-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), <NUM>,<NUM>' - dimethyldipheny1-<NUM>, <NUM>' -diisocyanate (DDDI), <NUM>,<NUM> '-dibenzyl diisocyanate (DBDI), <NUM>-chloro-<NUM>,<NUM>-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.

In another aspect, the polymeric layer can be formed of one or more of the following: EVOH copolymers, poly(vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyether imides, polyacrylic imides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials, as well as with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers, are also suitable.

The barrier layers 14a, 14b, 16a, 16b may include two or more sublayers (multilayer film) such as shown in Mitchell et al. , <CIT> and Mitchell et al. In embodiments where the barrier layers 14a, 14b, 16a, 16b include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in Bonk et al. In further embodiments, the barrier layers 14a, 14b, 16a, 16b may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of the barrier layers 14a, 14b, 16a, 16b includes at least four (<NUM>) sublayers, at least ten (<NUM>) sublayers, at least twenty (<NUM>) sublayers, at least forty (<NUM>) sublayers, and/or at least sixty (<NUM>) sublayers.

The bladder <NUM> can be produced from the barrier layers 14a, 14b, 16a, 16b using any suitable technique, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In an aspect, the barrier layers 14a, 14b, 16a, 16b can be produced by co-extrusion followed by vacuum thermoforming to produce an inflatable chamber 12a, 12b, which can optionally include one or more valves (e.g., one way valves) that allows the chamber 12a, 12b to be filled with the fluid (e.g., gas).

The chambers 12a, 12b can be provided in a fluid-filled (e.g., as provided in bladder <NUM>) or in an unfilled state. The chambers 12a, 12b can be filled to include any suitable fluid, such as a gas or liquid. In an aspect, the gas can include air, nitrogen (N<NUM>), or any other suitable gas. In other aspects, the chambers 12a, 12b can alternatively include other media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads). The fluid provided to the chambers 12a, 12b can result in the chambers 12a, 12b being pressurized. Alternatively, the fluid provided to the chambers 12a, 12b can be at atmospheric pressure such that the chambers 12a, 12b are not pressurized but, rather, simply contain a volume of fluid at atmospheric pressure.

The chambers 12a, 12b desirably have a low gas transmission rate to preserve its retained gas pressure. In some embodiments, the chambers 12a, 12b have a gas transmission rate for nitrogen gas that is at least about ten (<NUM>) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an aspect, the chambers 12a, 12b have a nitrogen gas transmission rate of <NUM> cubic-centimeter/square-meter•atmosphere•day (cm<NUM>/m<NUM>•atm•day) or less for an average film thickness of <NUM> micrometers (based on thicknesses of barrier layers 14a, 14b, 16a, 16b). In further aspects, the transmission rate is <NUM><NUM>/m<NUM>•atm•day or less, <NUM><NUM>/m<NUM>•atm•day or less, or <NUM><NUM>/m<NUM>•atm•day or less, (SI-Unit: <NUM> atm = <NUM> MPa).

Turning now to <FIG>, systems 100a-100d and methods for forming the different configurations 10a-10d of the bladder <NUM> are shown. As discussed above, the different configurations 10a-10d are illustrated in distinct regions <NUM>-<NUM> of a single bladder <NUM>. However, one or more of the configurations 10a-10d may be utilized in any region of the bladder <NUM>, and/or the entire bladder <NUM> may be formed using a single one of the configurations 10a-10d.

With reference to <FIG>, a system 100a and method for forming the first configuration 10a of the bladder <NUM> are shown. As, shown, the system includes a first tool 102a (<FIG>) and a second tool 104a (<FIG> and <FIG>). The first tool 102a includes an upper mold 106a and a lower mold 108a each including a respective mold surface 110a, 112a. As shown, the upper and lower mold surfaces 110a, 112a face each other, and cooperate to define a mold cavity 114a for receiving each of the tensile layers 14a, 14b and the plate <NUM>. Accordingly, profiles of the mold surfaces 110a, 112a correspond to profiles of the first and second sides <NUM>, <NUM> of the plate <NUM>. As illustrated in <FIG>, the plate <NUM> and the tensile layers 14a, 14b are initially provided to the mold cavity 114a in a layered arrangement with the plate <NUM> disposed between the tensile layers 14a, 14b.

With the components 14a, 14b, <NUM> positioned within the mold cavity 114a, the first tool 102a is then moved to a closed position (<FIG>) to join the inner surfaces 36a, 36b of the first tensile layer 14a and the second tensile layer 14b together through and around the plate <NUM>. Particularly, the inner surfaces 36a, 36b of the tensile layers 14a, 14b are joined together within the apertures <NUM> of the plate <NUM> at respective inner bonds <NUM>. Similarly, the outer peripheries 40a, 40b of the tensile layers 14a, 14b may be at least partially joined to each other around the outer periphery <NUM> of the plate <NUM> to form a first portion of the peripheral seam <NUM>. Here, the plate <NUM> is at least partially encapsulated within the joined tensile layers 14a, 14b, such that the components 14a, 14b, <NUM> may be collectively referred to as forming a chassis <NUM> for incorporation within the bladder <NUM>.

The first tool 102a may be a thermoforming tool 102a configured to subject the components 14a, 14b, <NUM> to a combination of heat and pressure to join the tensile layers 14a, 14b together. However, in other examples, the tensile layers 14a, 14b may be chemically attached (e.g., adhesives) or may be joined together using ultrasonic welding. As discussed above, the sides <NUM>, <NUM> of the plate <NUM> are inhibited from bonding to the tensile layers 14a, 14b by forming the plate <NUM> of an incompatible material or by coating the sides <NUM>, <NUM> with a bond inhibitor. For example, where thermoforming (melding) is used, the plate <NUM> may have a higher melting temperature than the tensile layers 14a, 14b to prevent melding between the plate <NUM> and the tensile layers 14a, 14b at the melting temperature of the tensile layers 14a, 14b. In other examples, a chemical coating may prevent adhesion, or a mechanical barrier may prevent attachment. Thus, while the tensile layers 14a, 14b may be compressed directly or indirectly against the plate <NUM> during the second step (<FIG>), the tensile layers 14a, 14b will only bond to each other and will remain detached from the plate <NUM> at areas between the inner bonds <NUM> and the peripheral seam <NUM>.

Turning now to <FIG>, the chassis <NUM> is shown after removal from the first tool 102a. Here, the tensile layers 14a, 14b are attached to each other through and around the plate <NUM>, and are detached from the plate <NUM> between the inner bonds <NUM> and the peripheral seam <NUM>. These detached portions of the tensile layers 14a, 14b form tensile elements <NUM> of the chassis <NUM>, which, as described below, are ultimately attached to the outer barrier layers 16a, 16b to tether the outer barrier layers 16a, 16b to the chassis <NUM>.

At <FIG>, the chassis <NUM> and the outer barrier layers 16a, 16b are positioned within the second tool 104a. The second tool 104a includes an upper mold 116a and a lower mold 118a each including a respective mold surface 120a, 122a. As shown, the upper and lower mold surfaces 120a, 122a face each other, and cooperate to define a mold cavity 124a for receiving each of the outer barrier layers 16a, 16b and the chassis <NUM>. As illustrated in <FIG>, the plate <NUM> and the outer barrier layers 16a, 16b are initially provided to the mold cavity 124a in a layered arrangement with the chassis <NUM> disposed between the outer barrier layers 16a, 16b.

The profiles of the mold surfaces 120a, 122a of the second tool 104a respectively define the shapes of the first and second chambers 12a, 12b in the first configuration 10a of the bladder <NUM>. For instance, the mold surfaces 120a, 122a each include interior projections 126a corresponding to the web areas 52a, 52b and peripheral projections 126b corresponding to the peripheral seam <NUM>. The interior projections 126a of each mold surface 120a, 122a are aligned with the tensile elements <NUM> of the chassis <NUM>, between the inner bonds <NUM>. Thus, as discussed below, the interior projections 126a are configured to compress the outer barrier layers 16a, 16b against the tensile elements <NUM> formed by the tensile layers 14a, 14b. The peripheral projections 126b are positioned outwardly from the outer periphery <NUM> of the plate <NUM>, and are configured to compress the outer peripheries 48a, 48b of the outer layers 16a, 16b against the first portion of the peripheral seam <NUM> formed by the tensile layers 14a, 14b.

The mold surfaces 120a, 122a also include recesses 128a, 128b formed between the projections 126a, 126b, which correspond to the shapes of the chambers 12a, 12b. In the illustrated example, the upper and lower mold surfaces 120a, 122a each include interior recesses 128a corresponding to interior subchambers <NUM> and peripheral recesses 128b corresponding to peripheral subchambers <NUM>. Here, the interior recesses 126a of the upper mold 116a are shallower than the interior recesses 126a of the lower mold 118a, whereby the interior recesses 126a of the upper mold 116a form interior subchambers <NUM> in the first chamber 12a that have a lesser height than the interior subchambers <NUM> of the second chamber 12b.

Turning now to <FIG>, with the outer barrier layers 16a, 16b and the chassis <NUM> positioned within the mold cavity 124a, the second tool 104a is moved to the closed position. The second tool 104a may be configured as a vacuum forming tool 104a, which imparts a vacuum within the mold cavity 124a to draw each of the outer barrier layers 16a, 16b against the respective mold surface 120a, 122a, thereby forming the profile of each chamber 12a, 12b.

In the closed position, the interior projections 126a and the peripheral projections 126b of each mold 116a, 118a are aligned with each other across the barrier layers 16a, 16b and the chassis <NUM>, such that the barrier layers 16a, 16b and the chassis <NUM> are compressed between opposing (i.e., facing) distal ends of corresponding projections 126a, 126b. As shown, the interior projections 126a of each mold 116a, 118a are aligned with each other across the tensile elements <NUM> of the chassis <NUM> to form a first plurality of the outer bonds <NUM> between the first interior barrier layer 14a and the first outer barrier layer 16a on the first side <NUM> of the plate <NUM>, and a second plurality of the outer bonds <NUM> between the second tensile layer 14b and the second outer barrier layer 16b on the second side <NUM> of the plate <NUM>. The peripheral projections 126b are aligned with each other across the portion of the peripheral seam <NUM> formed by the tensile layers 14a, 14b, and are configured to compress the outer barrier layers 16a, 16b against the tensile layers 14a, 14b to join the outer barrier layers 16a, 16b to the peripheral seam <NUM>.

With the outer barrier layers 16a, 16b joined to the tensile layers 14a, 14b at the outer bonds <NUM> and the peripheral seam <NUM>, the bladder <NUM> can be removed from the second tool 104a, as shown in <FIG>. Optionally, the interior voids 56a, 56b of the first chamber 12a and the second chamber 12b may be pressurized prior to or following removal of the bladder <NUM> from the second tool 104a. As a reminder, the interior voids 56a, 56b are formed between respective pairs of the tensile layers 14a, 14b and the outer barrier layers 16a, 16b. Thus, upon pressurization, the portions of the outer barrier layers 16a, 16b extending between the outer bonds <NUM> and the peripheral seam <NUM> are biased apart from the respective tensile layers 14a, 14b to form the interior voids 56a, 56b.

As shown and discussed above, the different profiles imparted to the outer barrier layers 16a, 16b during the vacuum forming process result in the first chamber 12a and the second chamber 12b having different profiles. Additionally, the interior voids 56a, 56b of the chambers 12a, 12b may be provided with different pressures. For instance, the interior void 56a of the first chamber 12a may have a greater pressure than the interior void 56b of the second chamber 12b, or vice versa. Optionally, spaces <NUM> formed between the tensile elements <NUM> and the plate <NUM> may also be pressurized with same or different pressures than the pressures of the interior voids 56a, 56b.

With particular reference to <FIG>, a system 100b and method for forming the second configuration 10b of the bladder <NUM> are shown. In view of the substantial similarity in structure and function of the components associated with the system 100a and configuration 10a with respect to the system 100b and configuration 10b, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.

As shown in <FIG>, formation of the second configuration 10b of the bladder <NUM> includes initially forming the chassis <NUM> using the first tool 102a in the same manner as described above with respect to <FIG>. The chassis <NUM> and the outer barrier layers 16a, 16b are then positioned within a second tool 104b for forming the bladder <NUM>, as shown in <FIG>. Here, the second tool 104b is substantially similar to the second tool 104a described above, except that the upper mold surface 120b of the upper mold 116b has a topography corresponding to a topography of the first side <NUM> of the interior portion <NUM> of the plate <NUM>. Thus, the upper mold surface 120b is generally configured to compress the first outer barrier layer 16a and the first tensile layer 14a together against the first side <NUM> of the plate <NUM> and between the inner bonds <NUM>. In this particular example, each of the first side <NUM> of the plate <NUM> and the upper mold surface 120b are shown as being planar. Accordingly, the planar upper mold surface 120b compresses the first outer barrier layer 16a and the first tensile layer 14a together against the planar interior portion <NUM> of the plate <NUM>. However, in other examples, the interior portion <NUM> of the plate <NUM> may be contoured, and the upper mold surface 120b may have a corresponding or complementary contour.

Referring to <FIG>, when the system 100b is moved to the closed position, the planar portion of the upper mold surface 120b compresses the first outer barrier layer 16a against the first tensile layer 14a across the interior portion <NUM> of the plate <NUM> and the first outer barrier layer 16a is joined to the first tensile layer 14a in the compressed areas. Accordingly, not only is the first outer barrier layer 16a joined to the first tensile layer 14a along the tensile elements <NUM>, but the barrier layers 14a, 16a are also joined together across the first bonds <NUM> between the tensile layers 14a, 14b. Accordingly, in the second configuration 10b, the web area 52a of first chamber 12a extends continuously across at least one of the inner bonds <NUM>, as opposed to only extending between the inner bonds <NUM>, as was done in the first configuration. In the illustrated example, the web area 52a of the first chamber 12a is shown as extending across two of the inner bonds <NUM>.

Turning to <FIG>, when the first chamber 12a is inflated, no interior subchambers are formed in the first chamber 12a, as the first outer barrier layer 16a is continuously joined to the first tensile layer 14a along the interior portion <NUM> of the plate <NUM>. As shown, the first chamber 12a only includes the peripheral subchambers <NUM>. Here, the second chamber 12b is formed the same as described above with respect to the first configuration 10a, and includes interior subchambers <NUM> and the peripheral subchambers <NUM>. Again, the first chamber 12a and the second chamber 12b may have the same or different pressures.

With particular reference to <FIG>, a system 100c and method for forming the third configuration 10c of the bladder <NUM> are shown. In view of the substantial similarity in structure and function of the components associated with the system 100a and configuration 10a with respect to the system 100c and configuration 10c, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.

As shown in <FIG>, in the third configuration 10c, the plate <NUM> includes a protuberance <NUM> formed along the flange <NUM> on the first side <NUM> of the plate <NUM>. As discussed in greater detail below and shown in <FIG> and <FIG>, the height of the protuberance <NUM> in the third configuration corresponds to a height of the peripheral subchambers <NUM> of the first chamber 12a. Accordingly, when the bladder <NUM> is formed, the protuberance <NUM> will support the inner surface 44a of the first outer barrier layer 16a within the peripheral subchamber <NUM>, but will not impart a profile or deformation to the first outer barrier layer 16a when the bladder <NUM> is in a resting state (e.g., unaffected by external forces).

In <FIG>, the chassis <NUM> is formed for the third configuration 10c. Here, the chassis <NUM> is formed using a first tool 102c in the same manner as discussed above with respect to the first configuration 10a, except the upper mold surface 110c of the upper mold 106c has a profile corresponding to the profile of the first side <NUM> of the plate <NUM> in the third configuration 10c. Accordingly, the upper mold surface 110c has recesses 130c corresponding to the profile of the protuberances <NUM>. Here, the upper mold surface 110c and the lower mold surface 112a define a mold cavity 114c corresponding to the profile of the fourth configuration 10d. When the chassis <NUM> is formed, the first tensile layer 14a conforms to the shape of the protuberances <NUM>.

Referring to <FIG> and <FIG>, because the protuberances <NUM> are configured to be confined within the profile of the peripheral subchambers <NUM>, the third configuration 10c of the bladder <NUM> can be formed using either one of the second tools 104a, 104b used in forming the first and second configurations 10a, 10b of the bladder <NUM>. In the illustrated example, the second tool 104b is configured for forming the continuous web area 52a in the first chamber 12a. However, the third configuration 10c may also be formed with interior subchambers <NUM>.

With continued reference to <FIG>, when the system 100c is closed, the protuberance <NUM> and the first tensile layer 14a are contained within the portion of the peripheral subchamber <NUM>. In the illustrated example, the outer surface 38a of the first tensile layer 14a is held in contact with the inner surface 44a of the first outer barrier layer 16a by the protuberance <NUM>. Optionally, the first tensile layer 14a may be joined to the first outer barrier layer 16a at one or more points along the protuberance <NUM> within the peripheral subchamber <NUM>. Providing the protuberance <NUM> within the peripheral subchamber <NUM> serves to provide additional structural support to the bladder <NUM> around the outer periphery of the foot. However, similar concepts may be utilized in other regions of the bladder <NUM>. For example, the plate <NUM> may include protuberances extending into any one of the interior chambers <NUM> or peripheral chambers <NUM> of the first and/or second chamber 12a, 12b.

With particular reference to <FIG>, a system 100d and method for forming the fourth configuration 10d of the bladder <NUM> are shown. In view of the substantial similarity in structure and function of the components associated with the system 100a and configuration 10a with respect to the system 100d and configuration 10d, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.

The system 100d and method of <FIG> are substantially similar to those described above with respect to <FIG>, where the plate <NUM> includes the protuberance <NUM> extending from the first side <NUM> of the flange <NUM>. However, as best shown in <FIG> and <FIG>, the protuberance <NUM> has a height that protrudes beyond the first outer barrier layer 16a such that a portion of the first outer barrier layer 16a conforms to the protuberance <NUM> and forms a protrusion <NUM> extending from the peripheral chamber <NUM>. Accordingly, the system 100d is provided with a first tool 102d and a second tool 104d configured to accommodate the increased height of the protuberance <NUM>. For instance, the upper mold 106d of the first tool 102d is formed with an upper mold surface 110d including recesses 130d having a greater height or depth than the recesses 130d of the upper mold 106c described above. Likewise, the upper mold surface 120d of the upper mold 116d of the second tool 104d includes indentations 132c formed in the peripheral recesses 128b for accommodating the extended protuberances <NUM>. Accordingly, each of the first tool 102d and the second tool 104d define respective mold cavities 114d, 124d corresponding to the profile of the fourth configuration 10d.

Thus, in contrast to the first and second configurations 10a, 10b where the peripheral subchamber <NUM> is entirely filled with fluid, and the third configuration 10c where the protuberance <NUM> is contained within the natural profile of the peripheral chamber <NUM>, in the fourth configuration 10d, the protuberance <NUM> imparts an extended profile to the peripheral subchamber <NUM>. Again, while the illustrated example shows the protuberance <NUM> disposed in the peripheral portion <NUM> of the plate <NUM>, the plate <NUM> may additionally or alternatively include projections formed in the interior portion <NUM> on either side <NUM>, <NUM>.

The systems 100a-100d and methods for forming the different configurations 10a-10d of the bladder <NUM> described above provide several advantages. Initially, providing the plate <NUM> within the bladder <NUM> allows an overall stiffness of the bladder <NUM> to be tuned. For instance, plates formed of different materials, shapes, and thicknesses may be incorporated within the bladder to provide the bladder <NUM> with integrated stiffness and support. In addition to providing structural benefits, the plate <NUM> simplifies formation of the bladder <NUM> by defining bonding locations <NUM> for the tensile layers 14a, 14b, which ultimately results in the formation of the tensile elements <NUM> used to constrain expansion of the outer barrier layers 16a, 16b.

Claim 1:
A bladder (<NUM>) for an article of footwear (<NUM>), the bladder (<NUM>) comprising:
a plate (<NUM>);
a first tensile layer (14a, 14b) disposed adjacent to a first side (<NUM>) of the plate (<NUM>);
a second tensile (14a, 14b) layer disposed on an opposite side (<NUM>) of the plate (<NUM>) from the first tensile layer (14a, 14b), an inner surface (36a, 36b) of the second tensile layer (14a, 14b) joined to an inner surface (36a, 36b) of the first tensile layer (14a, 14b) through the plate (<NUM>) by a plurality of inner bonds (<NUM>);
a first barrier layer (16a, 16b) disposed adjacent to the first tensile layer (14a, 14b) and joined to the first tensile layer (14a, 14b) by a plurality of first outer bonds (<NUM>) to form a first chamber (12a, 12b), one or more of the first outer bonds (<NUM>) interposed between adjacent ones of the inner bonds (<NUM>); and
a second barrier layer (16a, 16b) disposed adjacent to the second tensile layer (14a, 14b) and joined to the second tensile layer (14a, 14b) by a plurality of second outer bonds (<NUM>) to form a second chamber (12a, 12b) on the opposite side of the plate (<NUM>) than the first chamber (12a, 12b).