United States Patent [191
`Rudy
`
`[54] PRESSURIZABLE ENVELOPE AND
`METHOD
`[75] Inventor:
`Marion F. Rudy, Northridge, Calif.
`[73] Assignee:
`Robert C. Bogert, Marina Del Rey,
`Calif. ; a part interest
`[21] Appl. No.: 680,428
`[22] Filed:
`Apr.4,1991
`
`[60]
`
`[56]
`
`Related US. Application Data
`Division of Ser. No. 297,910, Jan. 19, 1989, which is a
`continuation of Ser. No. 147,131, Feb. 5, 1988, Pat. No.
`4,906,502.
`[51] Int. Cl.5 .............................................. .. B32B 1/04
`[52] US. Cl. .................................... .. 29/454; 493/210;
`156/145
`[58] Field of Search ............. .. 36/28, 29, 44; 156/ 145,
`156/147; 428/69, 71; 53/432, 433; 493/189,
`210, 211, 220; 29/454
`References Cited
`U.S. PATENT DOCUMENTS
`2,743,510 5/1956 Mauney et a1. ............... .. 156/197 X
`4,261,776 4/1981 Lea et al. .......... ..
`156/182 X
`4,340,626 7/1982 Rudy . . . . . . .
`. . . . .. 428/69 X
`4,409,271 10/1983 Pehr ...... ..
`.. 428/69 X
`4,999,072 3/1991 Dischler ........................... .. 36/29 X
`Primary Examiner-William E. Terrell
`Assistant Examiner-John A. Marlott
`Attorney, Agent, or Firm-Beehler & Pavitt
`[57]
`ABSTRACT
`An internally pressurizable lightweight high tensile
`strength multi-layered structure with an outer barrier
`layer envelope of elastomeric semi-permeable material
`
`llllllllllllll!lllllllllllllllllllilllliill
`US005083361A
`[11] Patent Number:
`5,083,361
`[45] Date of Patent:
`Jan. 28, 1992
`
`for use as a cushioning device is provided. The outer
`barrier layer is bonded, at a multiplicity of sites, to
`substantially the entire distal surfaces of a double
`walled drop-thread linked fabric wherein the ?laments
`are comprised of a highly distorted, long chain, axially
`orientated crystalline molecular structure which has a
`low gas permeability. The bond between the barrier
`layer and the facing fabric is substantially increased by
`the presence of fibrils and texturizing. The drop threads
`which are likewise texturized, function as stress averag
`ing members to maintain the composite structure in
`either a substantially ?at or planar or contoured con?g
`uration without weldments within the select load-bear
`ing areas. This lightweight product is capable of with
`standing very substantial internal inflation pressures,
`under severe long-term steady state and cyclical com
`pression and ?exural fatigue conditions. The product is
`in?ated, pressurized and sealed and maintains the inter
`nal in?atant pressure for extended periods of time, gen
`erally in excess of the useful life of the overall product,
`by employing the diffusion pumping phenomenon of
`self-in?ation. The cushioning device can selectively
`control the rate of diffusion pumping phenomenon by
`varying the density relationship between the elasto
`meric semi-permeable material of the envelope and the
`essentially gas impermeable highly distorted crystalline
`?lament material of the fabric, thus improving the long
`term performance and durability and reducing the cost,
`and eliminating some of the disadvantages of the earlier
`cushioning products. In a limiting case, it is possible to
`permanently in?ate the device using readily available
`?uids as nitrogen or air.
`
`6 Claims, 18 Drawing Sheets
`
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`US. Patent
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`US. Patent
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`Jan. 28, 1992
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`Jan. 28, 1992
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`Jan. 28, 1992
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`

`

`1
`
`PRESSURIZABLE ENVELOPE AND METHOD
`
`RELATED APPLICATIONS
`This application is a divisional of application Ser. No.
`7/297,9l0 ?led Jan. 19, 1989 which is a continuation in
`part of application Ser. No. 07/147,131, ?led Feb. 5,
`1988. now US. Pat. No. 4,906,502.
`
`FIELD OF INVENTION
`This invention relates to internally pressurizable mul
`ti-layered envelopes, and more particularly, to an im
`proved multi-layered pressurized and gas containing
`envelope which is particularly adapted for use as a
`cushioning device such as an insole or other component
`in footwear.
`
`5
`
`10
`
`20
`
`25
`
`30
`
`35
`
`5,083,361
`2
`In addition to the above problems, one of the more
`dif?cult challenges was the provision of a sealed, per
`manently in?ated cushioning device with ?at surfaces,
`as contrasted to tubular or rounded chambers, and
`which could be made relatively thin so as to achieve
`100% air support and cushioning and which possessed
`suf?cient fatigue resistance to withstand millions of
`compression cycles in use. In the case of consumer
`items, especially footwear, a useful life of several years
`is essential. Furthermore this product must maintain the
`unique and bene?cial cushioning properties, without
`signi?cant degradation throughout its full lifetime. As is
`apparent, a signi?cant loss or gain of pressure over a
`period of time is not acceptable, especially in consumer
`products. It is also desirable to provide an in?ated prod
`uct capable of withstanding relatively high localized
`loads without bottoming out, such as the loads typically
`encountered in athletic activities.
`For example, in running or other sport events which
`involve running or jumping, there are substantial local
`ized loads during heel strike or push off. If the cushion
`ing device bottoms out, then the entire purpose of the
`cushion is compromised. For most conditions encoun
`tered, to prevent bottoming out, the in?ated product
`either may be made sufficiently thick or highly pressur
`ized or both. Another desirable approach is to use
`smaller chambers in?ated at lower pressures, and posi
`tioned under the load bearing surface so that there is
`little or no accumulator volume into which the gas may
`escape. Relatively high pressurization of the prior art
`in?ated devices with rounded tubular chambers pro
`duced an uncomfortable feel, unless encapsulated with
`foam, or used with some other type of surface/contour
`moderator element.
`The load/de?ection curve of this tensile product
`achieves totally new, unique and bene?cial cushioning
`characteristics never before possible with other prior
`art load cushioning devices.
`The load de?ection characteristics of my earlier in
`ventions, US. Pat. No. 4,183,156, provided a very soft
`cushioned support under light loads. Then, with pro
`gressively heavier loads, the supportive force increased
`either in a linear or in an exponential manner. This type
`of load/de?ection characteristic is suitable for many
`applications. However, there are other uses where it is
`very desirable that the pressurized pneumatic cushion
`ing device initially exhibit a very ?rm cushion support
`under light to moderate compression loads, a degree of
`support greater than the product of the area of the
`applied load times the internal working pressure. Then,
`when greater compression loads are applied, the device
`automatically, at a predetermined load, changes from
`the ?rm, board-like cushioning support and exhibits a
`soft, relatively consistent and gradual increasing level
`of cushioned support throughout the full, available
`displacement of the in?ated device.
`This type of cushioned support embraces substan
`tially different, new novel technology from the prior
`art. New, novel and highly useful products are now
`possible that were impossible using the prior art.
`Thus, a need exists for an improved essentially per
`manently pre-pressurized product which has advan
`tages over the prior art in?ated products. It is also ap
`parent that there are the practical considerations of
`being able to manufacture such products relatively inex
`pensively, at relatively high volume and of a very high
`quality which assures that the product will be free of
`leaks and have an acceptable service life even when
`
`60
`
`BACKGROUND OF THE INVENTION
`Previously, considerable dif?culty had been experi
`enced in providing internally pressurizable multi-lay
`ered envelopes wherein the envelope was a ?at or uni
`formly contoured supporting surface, with the, capacity
`of being pressurized to relatively high levels. Previ
`ously mush of the absorbed, re-distributed, and stored
`impact/shock energy was lost and not returned in a
`useful form because of the requirement to encapsulate
`the unit in a viscoelastic foam acting as a moderator to
`develop the desired smooth or contoured surface.
`It was simply not possible to provide a product
`wherein much (greater than 60%) of the load support
`ing material of the product was a gas under pressure.
`With the former product, less than 40% of the energy of
`impact on the structure was returned in a bene?cial,
`efficient and comfortable manner, the balance of the
`energy being absorbed and dissipated as heat. The pres
`ent design is capable of returning, in a useful form, up to
`92% of the otherwise wasted energy. In addition, supe
`rior cushioning and compliance are also provided,
`which signi?cantly reduces damaging impact shock
`loads to the foot and legs to levels under 12 G’s.
`The new product was developed because dif?culty
`had been experienced with the prior products in pro
`ducing light weight, long-life, high-pressure in?ated
`structures for use in foot wear and the like which pos
`sessed a high degree of resilience and compliance
`wherein the shock energy absorbed, redistributed and
`stored at impact is efficiently returned as useful energy
`in a smooth manner, at a rate equal to or greater than
`the rate at which the applied load is removed from the
`devices. Success of this new product depended upon
`solving several basic problems: 1) separation (delamina
`tion) between the tensile element (fabric layer with drop
`threads) and the gas containing barrier layer, when
`subjected to high loads with long-term cyclical fatigue
`conditions, 2) crushing, abrasion, and bending fatigue
`failure of the drop-threads, 3) hydrolytic degradation
`failure of the drop threads, 4) fungus, bacteria and hy
`drolytic stress fracture of the barrier material, 5) unrav
`elling of the tensile-elements immediately adjacent to
`the cut edges of the cloth, when subject to high loads
`and bending and ?exing, 6) puncture and abrasion fail
`ure of the barrier ?lm, 7) leakage of the pressurizing gas
`at the perimeter seal, caused by ?ber ?laments extend
`ing from the sides of the tensile cloth being trapped in,
`and bridging the perimeter barrier seal so as to create
`minute leakage paths through which pressurizing gas
`could slowly leak out.
`
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`5,083,361
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`3
`built as a permanent and integral part of the footwear. It
`is also an advantage to be able to provide a gas pressur-
`ized load bearing cushioning member which may be
`formed in various shapes, thicknesses, and contours.
`
`BRIEF DESCRIPTION OF THE INVENTION
`
`These and other difficulties of the prior art have been
`overcome according to the present invention. The pres-
`ent invention provides a gas pressurized and inflated
`structure which comprises an hermetically sealed outer
`covering barrier layer which is securely bonded, as will
`be described, substantially over the entire outer surfaces
`of a double walled interior fabric structure. The double
`walled fabric structure comprises first and second outer
`fabric layers which are normally spaced apart from one
`another at a predetermined distance. Drop-threads, (or
`more appropriately drop-yams) preferably in the form
`of multi-filament yarns comprised of many individual
`fibers extend internally between the proximal or facing
`surfaces of the respective fabric layers. The use of mul-
`ti-filament drop-yams is unique to this product. The
`filaments of the drop yarns form tensile restraining
`means and are anchored to the respective fabric layers.
`The restraining means or drop yarns may be arranged
`nominally perpendicular to the first and second fabric
`layers, or they may be arranged in a triangular arrange-
`ment. It is noted that the yarn comprising the drop
`threads or restraining means may be separate and dis-
`tinct from the yarn of the first and second fabric layers,
`i.e., the yarn used for the first and second fabric layers
`may be completely different from the yarn of the drop
`threads or restraining means, depending on the applica-
`tion and the use environment. These restraining means
`function to maintain the general flat or contoured pla-
`nar form of the pressurized and inflated structure, and
`the bonding of the outer covering to the distal sides or
`exposed outer surfaces of the respective fabric layer
`prevents the outer covering from peeling away or sepa-
`rating from the distal surfaces and forming an aneu-
`rysm. The drop yarns which extend from one fabric
`layer to the other, function in pure tension as the pre-
`ferred restraining means and are present in quantities
`sufficient to hold the structure in the desired planar
`form without offering substantial resistance to the com-
`pression of the two outer layers towards one another.
`That is, the restraining means have very little compres-
`sive strength and very substantial tensile strength and
`thus do not provide any significant compressive support
`to externally applied loads and thus exhibit a very con-
`siderable fatigue life. It is the pressurized gas compo-
`nent that provides 100% of the cushioned support for
`the very heavy, life-time cyclic compression loads. The
`pressurized gas has literally an infinite fatigue life. Thus,
`by separating the compression, and tension load carry-
`ing components of the device in this manner, a very
`unique and beneficial result is achieved. The resulting
`product has a fatigue life many times greater than is
`otherwise possible. The region between the proximal
`surfaces of the fabric layers is of sufficient openness to
`allow movement of the pressurizing gas throughout the
`pressurized chairiber.
`The hermetically sealed outer barrier layers, which
`operate to contain the gas, preferably are composed of
`a composite elastomeric semi-permeable material which
`is substantially impervious to those gases which are
`essentially non-polar and that may additionally have
`very large molecular sizes. The outer barrier layers also
`can control the rate of inward and outward diffusion of
`
`10
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`15
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`20
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`25
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`N2 and Oz and other component gases of the ambient air
`by means of the percentage composition of the crystal-
`line component within the elastomeric component of
`the barrier layer. Therefore,
`this outer barrier layer
`provides a very important secondary function of being
`slightly permeable to some other gases such as oxygen.
`With this material, a selective inward diffusion of oxy-
`gen occurs from the ambient air which, by means of
`partial pressures, tends to increase the total pressure
`within the already pressurized enclosure. This is de-
`scribed in some detail in, for example, Rudy U.S. Pat.
`No. 4,340,626 patented July 20, 1982; Rudy et al, U.S.
`Pat. No. 4,183,156 patented July 15, 1980; Rudy et al,
`U.S. Pat. No. 4,271,606 patented June 9, 1981; and Rudy
`et al, U.S. Pat. No. 4,219,945 patented Sept. 2, 1980.
`Attention is respectfully invited to these patents, which
`are hereby incorporated herein by reference, for a de-
`scription as to the barrier fill, the pressurizing gas and
`the physical phenomenon which are involved in diffu-
`sion pumping and the activated diffusion of gas through
`the semi-permeable barrier layer.
`The structures according to the present invention are
`particularly unique and suited for use where they are
`required to absorb and cushion an impact load within a
`limited space and then return this otherwise wasted
`energy in a useful manner. This structure has a further
`advantage because it has a substantially reduced mass as
`compared to the prior art structures, thus providing
`pressure containing walls or elements which have a low
`hysteresis energy loss when flexed. Gas(s) pressurized
`to at least 2 psi and preferably more than 15 psi, func-
`tions well to provide excellent and comfortable cush-
`ioning and then to return the stored energy in a resilient,
`efficient life-like and beneficial manner. When the struc-
`ture of the present invention is pressurized to a level in
`excess of 40 to 50 psi the structure gives back as much
`as 92% of the energy of an impact.
`Therefore, if a weight having the shape, mass, and
`velocity of a representative human foot at heel-strike, is
`dropped from approximately two feet height on to a
`properly designed structure in accordance with the
`present invention, which is pressurized to a level of
`approximately 55 psig., the weight will first be well
`cushioned from the force of impact, such that the G
`forces on the weight will be in the range of 9 to 12 GS.
`Then nearly all of the impact energy that is absorbed,
`redistributed and stored in the device during the down-
`ward compression portion of the cycle (i.e., about 92%)
`will be very efficiently returned to the weight, causing
`it to rebound to approximately 92% of the original drop
`height, or 22 inches. The word compliance is used to
`express the combination of these two factors: i.e., cush-
`ioning and resilience. A product simultaneously exhibit-
`ing maximum cushioning‘ and maximum useful energy
`return, or resilience, is considered to have good compli-
`ance. Poor compliance would, of course, be the oppo-
`site.
`
`The present invention is uniquely suited to footwear
`and other similar cushioning applications where high
`style and/or maximum cushion comfort, support and
`shock protection are to be achieved in a minimum of
`thickness and space (i.e., low profile). Thicker devices
`as disclosed in Rudy U.S. Pat. No. 4,183,156, were, in
`large measure, poorly suited for this type of application.
`The hills and valleys of the earlier product, coupled
`with the need for some type of foam encapsulation or
`moderator device to provide a smooth, comfortable
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`INTEX EXHIBIT 2015, Pg. 21
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`INTEX EXHIBIT 2015, Pg. 21
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`5,083,361
`
`5.
`support surface, created a product that was relatively
`thick and clumsy for this type of application.
`The flat or contoured planar load bearing surfaces of
`the present invention achieves a completely new and
`unique degree of 100% floating on air cushioned, resil-
`ient support, comfort and protection never before possi-
`ble.'This invention eliminates the need for foam encap-
`sulation. However, in certain circumstances it may be
`desirable to use foam in order to build the unit into a
`midsole, to absorb moisture and to increase further the
`service life of the gas pressurized product. The use of
`foam can also control or eliminate the tendency of the
`subject cushioning product from buckling, when bent in
`a sharp radius;
`In the present invention the formation of one or more
`aneurysms constitutes failure. Aneurysms can develop
`either when there is delamination of the barrier material
`from the distal or outer surfaces of the double-walled
`fabric, or by failure of the drop yarns. Such drop yarn
`failure can be caused by bending fatigue and/or abra-
`sion of the drop yarns, normally referred to as a fibrilla-
`tion-type failure. See FIG, 30 for an illustration of an‘
`electron microscope image of a typical fibrillation fail-
`ure of drop yarn tensile fibers under the ball of the foot
`after approximately six months of wear in high perfor-
`mance athletic shoes. As discussed later, the present
`invention solves these problems for the life of the prod-
`uct.
`
`The use of drop yarns in a double walled structure
`acting in tension to constrain and shape the barrier
`surfaces has been proposed previously. An example of
`the aneurysm which can develop when the drop yarns
`are of insufficient strength or are deliberately severed, is
`illustrated for example in Cross, U.S. Pat. No. 3,205,106
`patented Sept. 7, 1965. There the product functions
`completely as a structural device, it does not produce a
`cushioning function; nor does it solve the problems
`inherent in a cushioning product such as does the pres-
`ent invention. Cross does not address the problems that
`must be solved in order to achieve permanent inflation
`nor does he attempt to use or control diffusion pumping
`in a useful and unique manner as described in this pres-
`ent invention.
`
`The use of drop yarns and filaments as structural
`compressional cushioning or stiffening members in dou-
`ble walled structures has been proposed, for example,
`by Tungseth, U.S. Pat. No. 3,616,126 patented Oct. 26,
`1971 and Giese et al, U.S. Pat. No. 4,005,532 patented
`Feb. 1, 1977. These prior structures are comprised of a
`single heavy (i.e., large 0.003 to 0.025 inch diameter)
`plastic monofilament strand woven into a stiff three-di-
`mensional, compression load supportive mat. The
`Tungseth ’l26 patent describes a product of this type
`that relies completely on the buckling characteristics of
`select diameter plastic monofilaments in the woven
`structure and which are placed in compression in order
`to absorb compression shock loads. In Tungseth ‘I26,
`no pneumatic support is provided at all.
`The Giese patent ‘S32 likewise is a stiff compression
`load supporting mat woven from a 0.010 of an inch
`diameter plastic monofilament strand in order to form a
`thermal
`insulation insert
`for articles of footwear;
`wherein it is stated “The separating material” (i.e., plas-
`tic monofilaments) “are of such a strength as to prevent
`deformation of the mesh-like fabrics toward each other
`when subjected to the weight of the wearer of the
`shoes.” This is identical to Tungseth. The embodiment
`calls for the mat to be covered with a barrier material
`
`6
`and closed to form a hermetically sealed chamber. In
`one form, air may be left within the chamber to form an
`insulative dead-air space, while in other forms, the air
`may be evacuated from the chamber or, replaced with a
`gas such as CO2 in order to achieve a thermal coeffici-
`ent of heat transfer that is lower than the ambient air.
`These structures are very poor shock absorbing devices
`returning little, if any, of the impact energy to the user
`and thus wasting and dissipating the energy away as
`internal frictional heat. Our tests reveal rapid fatigue
`failure of these large diameter, compression load sup-
`porting plastic monofilaments which thus create sharp,
`protruding plastic splinters that easily puncture the
`envelope film, resulting in a loss of vacuum or loss of
`special low thermal conductive gas. The sharp splinters
`likewise penetrate, irritate and puncture the skin of the
`foot, resulting in pain, discomfort and possible infection.
`Other prior patents include U.S. Pat. No. 4,409,271
`issued to Pehr on Oct. ll, 1983 and which relates to a
`lightweight construction element. The Pehr structure is
`composed of an untiimmed velvet fabric having a verti-
`cal pile between the upper an lower webs. The fabric is
`rendered impermeable to air by a rubber coating which
`is vulcanized and the fabric is joined together by a seam.
`The Pehr product may be filled with a gas, liquid or
`foam. The Pehr product is not intended to be used as a
`cushioning or shock absorbing device, as is the case
`with the present invention.
`Similar to Pehr is U.S. Pat. No. 2,743,510 issued to
`Mauney et al on May 1, 1956. There, however, fabric is
`used which has not been tensilized so that when ex-
`posed to heat and tension, the fabric will stretch.
`U.S. Pat. No. 3,205,106 of Sept. 7, 1965 issued to
`Cross also discloses a structure in which drop cords are
`present. The drop cords are severed in order to increase
`stiffness in the product by providing a convex section.
`This effectively produces an aneurysm, the very situa-
`tion which the present invention seeks to avoid.
`Also of interest, but describing an entirely different
`product from that here disclosed is U.S. Pat. No.
`4,261,776 of Apr. 14, 1981, issued to Lea et al and the
`patents therein discussed. The Lea et al product is a
`self-inflating air mattress.
`In the present invention the drop yarns consist of
`many very fine, texturized or bulked separate filaments
`(not a single monofilament as in the above prior art)
`each having a high tensile strength and being of a very
`small cross-section diameter in comparison with the
`prior art such that they cannot act as Euler column
`compression members and are completely incapable of
`supporting any significant compression load by them-
`selves. Should filaments become broken, the resulting
`product does not create a sharp splinter that could
`puncture or otherwise damage the barrier envelope.
`Thus, the load supporting mechanism of the present
`invention is completely different from the prior art, and
`with greatly superior high pressure containment, load
`carrying capability, shock absorption, fatigue life, resil-
`iency,
`long term permanent
`inflation and beneficial
`life-like energy storage and return characteristics that
`are not even remotely possible with the above stated
`prior art.
`Various gas containing foam materials have previ-
`ously been sealed in flexible air-tight compartments, see
`for example, Rosenberg, U.S. Pat. No. 4,590,689 pa-
`tented May 27, 1986 and Striegel, U.S. Pat. No.
`3,914,881 patented Oct. 28, 1975. Foam products of this
`type pressurized even with supergas (Rudy U.S. Pat.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`45
`
`50
`
`55
`
`65
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`INTEX EXHIBIT 2015, Pg. 22
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`5,083,361
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`7
`No. 4,183,156) have not been successful because of
`several problems; (1) the tensile strength of even the
`best open-cell foam materials is not sufficiently strong
`and reliable to support the necessary inflation pressures
`over the life of a product to be used in this manner in
`footwear; (2) under heavy cyclic compression loads,
`typical of the foot strike when walking or rimning, the
`walls of the individual cells constituting the foam struc-
`ture abrade and tear as they move against one another
`and thus rapidly fail, resulting in an aneurysm and/or a
`subsequent loss of pressure.
`It is known that the highest possible quality foam,
`when used as a cushioning load supportive, compres-
`sion member (i.e., mid halfsole or insole) in athletic
`footwear such as running shoes, loses a substantial per-
`cent of its original cushioning properties within just a
`few miles of running, and at about 150 miles approxi-
`mately 75% of the initial cushioning properties have
`been lost. The loss of cushioning is the result of internal
`breakdown of the cell walls of the foam as described
`above. In this usage, the footwear does not become
`unusable because of the described breakdown of the
`foam. The user simply is exposed to reduced cushioning
`(and poorer foot support) and thus much greater shock
`forces. However, with a pressurized structure, break-
`down of the foam structure results in formation of a
`protruding aneurysm or bulge under the foot. Even the
`smallest failure of this type (i.e., diameter) makes the
`product painful under the foot and therefore unusable.
`The relatively high pressures which are required to
`provide the desired and necessary degree of support
`and springiness present very substantial problems with
`the peeling or delamination of the outer barrier film
`away from the distal or outer surfaces of the double-
`walled fabric. It is thus important, in accordance with
`this invention, to provide a strong bond between the
`outer surface of each of the layers of the fabric and the
`facing surface of the envelope or barrier layer. In other
`words, the peel strength or the force needed to delami-
`nate the bonded layers must be very high throughout
`the life of the product.
`It been found in accordance with this invention that if
`the yarn which is used to form the double-walled fabric
`and which creates the fiber interface reinforcement of
`the barrier layer, is in some way bulked, texturized or
`flannelized or made from at least 20% discontinuous
`filaments, so that there is a large degree of openness to
`the yarn and there are numerous loops and/or spirals of
`small diameter tendrils or other tendrils and projections
`of filamentary material extending slightly from the dis-
`tal surfaces of the fabric layers, greatly improved bond-
`ing can be achieved. Actually, the tendrils extend from
`the larger diameter yams from which the fabric mate-
`rial is formed. The texturizing can be provided for ex-
`ample, by abrading the distal surfaces of the double-
`walled fabric, by crimping the individual filaments
`which go to make up the yarn, by using a false twist or
`air bulk heat-set texturizing step in manufacturing the
`yarn, and the like. Such a surface or bulk treatment is
`referred herein as a FIRTEC (Fiber Interface Rein-
`forcement Technology) surface treatment. It
`is also
`desirable to use a yarn wherein the filament surfaces are
`dull or semi-bright, as contrasted to bright. Therefore,
`in a preferred embodiment, the yarn from which the
`double-walled fabric is constructed is treated so that in
`the final product there is a large degree of openness to
`the yarn, and the distal sides of the respective fabric
`layers present a great many