(12> Ulllted States Patent
`Sell, Jr. et al.
`
`US006385864B1
`(16) Patent N6.=
`US 6,385,864 B1
`(45) Date of Patent:
`May 14, 2002
`
`2,645,865 A
`2,677,906 A
`2,703,770 A
`27487401 A
`
`7/1953 Town
`5/1954 Reed
`3/1955 MelZer
`6/1956 Winstead
`
`AT
`AT
`CA
`DE
`DE
`EP
`
`(List continued on next page.)
`FOREIGN PATENT DOCUMENTS
`181938
`M1906
`200963
`12/1958
`727582
`2/1966
`32 34 086
`9/1982
`92 01 7584
`12/1992
`0 094 868
`5/1983
`_
`_
`(List continued on next page.)
`OTHER PUBLICATIONS
`Sports Research RevieW, Nike, Inc., Jan/Feb. 1990.
`Brooks Runmng Catalog’ Fan 1991'
`Primary Examiner—Ted Kavanaugh
`(74) Attorney, Agent or Firm—Bann9r & Witcoff, Ltd
`(57)
`ABSTRACT
`
`(54) FOOTWEAR BLADDER WITH
`CONTROLLED FLEX TENSILE MEMBER
`
`(75) Inventors: James C. Sell, Jr., Battle Ground, WA
`(US); Craig E. Santos, Portland, OR
`(Us) David B Herridge Mendota
`Heights, MN (US); Daniel R. Potter,
`Forest Grove, OR (US)
`.
`.
`(73) Asslgnee: Nike, Inc., Beaverton, OR (US)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`(21) Appl. NO.: 09/526,861
`(22) F?edi
`Mali 16, 2000
`(51) Int. c1.7 .............................................. .. A43B 13/20
`(52) US. Cl. .......................................... .. 36/29; 36/35 B
`(58) Field Of Search .......................... .. 36/29, 71, 35 B,
`36/153; 428/72, 178, 179, 76
`
`(56)
`
`References Cited
`
`U'S' PATENT DOCUMENTS
`900,867 A 10/1908 Miller
`1,069,001 A
`7/1913 Guy
`1:240:53 A
`9/ 1917 01$“
`2 13/
`lsnRmney
`/
`nee
`’
`’
`1,514,468 A 11/1924 Schopf
`1 584 034 A
`5/1926 KlOtZ
`17625582 A
`4/1927 Anderson
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`7/1933 Krichbaum
`1,970,803 A
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`27004906 A
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`230803469 A
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`
`7/1937 Pearson
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`1/1942 Johnson
`2,269,342 A
`2,365,807 A 12/1944 Dialynas
`2’488’382 A 11/1949 Davis
`2,546,827 A
`3/1951 Lavinthal
`2,600,239 A
`6/1952 Gilbert
`
`A bladder for a sole assembly of a shoe With three dimen
`sional controlled ?ex connecting/tensile members extending
`betWeen the top and bottom outer layers of bladder. The
`connecting/tensile members are formed during molding of
`the bladder and comprise top and bottom portions that come
`together at a juncture. Since the outer perimeter and the
`internal connecting/tensile members are formed at the same
`time and of the same material, bonding problems betWeen
`.
`.
`.
`.
`.
`.
`.
`layers is ehmlnated and manufacturing is simpli?ed. The
`connecting/tensile members are formed With a predeter
`mined ?ex point in at least a portion of each member to
`reduce random fatigue stress concentrations. Broadly, there
`are tWo con?gurations: one in Which the tensile member is
`constructed to collapse upon compressive loading, and one
`in Which the tensile member is constructed to bend or fold
`upon compressive loading in a predetermined location. The
`shape, relatlve mm, length and barrier material thickness are
`.
`.
`.
`1 t d t
`. t . ? 1
`t
`.
`th
`h.
`.
`manlpu ae o ass1s 1n ne y un1ng e cus 1on1ng prop
`erties Of the ?nal bladder.
`
`.
`
`.
`
`.
`
`21 Claims, 14 Drawing Sheets
`
`INTEX EXHIBIT 2017, Pg. 1
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 6,385,864 B1
`Page 2
`
`US. PATENT DOCUMENTS
`
`2,762,134 A
`9/1956 Town
`3,030,640 A
`4/1962 Gosman
`3,048,514 A
`8/1962 Bentele et 81.
`3,120,712 A
`2/1964 Menken
`3,121,430 A
`2/1964 O’Reilly
`3,204,678 A
`9/1965 Worcester
`3,251,076 A
`5/1966 Burke
`3,284,264 A 11/1966 O’Rourke
`8/1967 Post
`3,335,045 A
`3,366,525 A
`1/1968 Jackson
`3,469,576 A
`9/1969 Smith et al.
`3,568,227 A
`3/1971 Dunham
`3,589,037 A
`6/1971 Gallagher
`3,608,215 A
`9/1971 Fukuoka
`3,685,176 A
`8/1972 RPdY
`3,758,964 A
`9/1973 Nlshlmura
`3,765,422 A 10/1973 SIIllth
`4,017,931 A
`4/1977 Golden
`4,054,960 A 10/1977 Pettit et 81.
`4,115,934 A
`9/1978 Hall
`4,129,951 A 12/1978 Petrosky
`4,167,795 A
`9/1979 Lambert, Jr.
`4,183,156 A
`1/1980 Rudy
`4,187,620 A
`2/1980 seiner
`4,217,705 A
`8/1980 DOnZiS
`4,219,945 A
`9/1980 Rudy
`4,271,606 A
`6/1981 Rudy
`4,287,250 A
`9/1981 Rudy
`4292 702 A 10/1981 Phillips
`’
`’
`4297797 A 11 1981 M
`’
`’
`/
`eye“
`4305212 A 12/1981 Com“
`4328599 A
`5/1982 Momma
`4358902 A 11/1982 Cole “FL
`A
`SZtaIlCSlk
`4,446,634 A
`JOhIlSOIl 618.1.
`4,458,430 A
`7/1984 Peterson
`4,483,030 A 11/1984 PllCk 61 8.1.
`4,486,964 A 12/1984 Rudy
`4,506,460 A
`3/1985 Rudy _
`4,535,553 A
`Derderlan 618.1.
`4547919 A 10/1985 Wang
`4,662,087 A
`5/1987 Bench
`4,670,995 A
`6/1987 Huang
`4,686,130 A
`8/1987 KO“
`4,722,131 A
`2/1988 Huang
`4,744,157 A
`5/1988 Dubner
`4,779,359 A 10/1988 Farrlolare, Jr.
`4,782,602 A 11/1988 LaklC
`4,803,029 A
`2/1989 IVCISCII 618.1.
`4,817,304 A
`4/1989 Parker et 81.
`4,823,482 A
`4/1989 Lakie
`_
`4,845,338 A
`7/1989 Laklc
`4,845,861 A
`7/1989 Mourrlgdglan
`4,874,640 A 10/1989 DOHZIS
`4,891,855 A
`1/1990 Cheng-Chung
`4,906,502 A
`3/1990 Rudy
`4,912,861 A
`4/1990 Huang
`4,936,029 A
`6/1990 Rudy
`4,965,899 A 10/1990 Sekrdo et a1.
`4,991,317 A
`2/1991 Lakie
`4,999,931 A
`3/1991 Vermeulen
`4,999,932 A
`3/1991 Grim
`5,022,109 A
`6/1991 Pekar
`5,025,575 A
`6/1991 Lakie
`5,042,176 A
`8/1991 Rudy
`5,044,030 A
`9/1991 Balaton
`5,046,267 A
`9/1991 Kilgore et al.
`5,083,361 A
`1/1992 Rudy
`
`5,092,060 A * 3/1992 Frachey et 81.
`5,104,477 A
`4/1992 Williams et al.
`5,155,927 A 10/1992 Bates et al.
`5,158,767 A 10/1992 Cohen et a1.
`5,179,792 A
`1/1993 Brantingham
`5,193,246 A
`3/1993 Huang
`5,199,191 A
`4/1993 Moumdjian
`5,224,277 A
`7/1993 Sang D0
`5,224,278 A
`7/1993 Jeon
`A
`Z133; ‘gang
`OHZIS
`a
`a
`572387231 A
`8/1993 Huang
`5,245,766 A
`9/1993 Warren
`5,253,435 A 10/1993 Auger et 81.
`5,257,470 A 11/1993 Auger et 81.
`5297 349 A
`3/1994 K11 Ore
`5’335’382 A
`8/1994 Hufn
`5,337,492 A
`8/1994 Andergie et al.
`5,353,523 A 10/1994 Kilgore et al.
`5,355,552 A 1O/1994 Huang
`5,367,791 A 11/1994 Gross et al.
`5,406,719 A
`4/1995 Potter
`5,425,184 A
`6/1995 Lyden et al.
`5,493,791 A * 2/1996 Kramer
`5,543,194 A
`8/1996 Rudy
`5,558,395 A
`9/1996 Huang
`5,572,804 A * 11/1996 Skaja etal.
`5,595,004 A
`1/1997 Lyden et 81.
`5,625,964 A
`5/1997 Lyden et 81.
`5,669,161 A
`9/1997 Huang
`5,686,167 A 11/1997 Rudy
`5,713,141 A
`2/1998 Mitchell et al.
`5 741 568 A
`4/1998 Rudy
`7
`7
`5,753,061 A
`5/1998 Rudy
`5 755 001 A
`5/1998 Potter et al
`5,771,606 A
`6/1998 Litch?eld et al.
`5,802,739 A
`9/1998 Potter et al.
`A
`Huang
`5 832 630 A 11/1998 Potter
`5:846:063 A 12/1998 Lakic
`5,902,660 A
`Huang
`5,907,911 A
`6/1999 Huang
`5,916,664 A
`6/1999 Rudy
`5,925,306 A
`7/1999 Huang
`5,937,462 A
`8/1999 Huang
`5,952,065 A
`9/1999 Mitchell etal.
`5,976,451 A 11/1999 Skaja et al.
`5,979,078 A 11/1999 McLaughlin
`5,987,780 A 11/1999 Lyden et al.
`5,993,585 A 11/1999 Goodwin et al.
`6,103,340 A
`1/2000 Bonk et 81'
`6,027,683 A
`2/2000 Huang
`6,029,962 A * 2/2000 Shorten et 61'
`6,055,746 A
`5/2000 Lyden et aL
`6,065,150 A
`50000 Huang
`6,092,310 A * 7/2000 Schoesler
`6,098,313 A
`8/2000 Skaja
`6,119,371 A
`9/2000 Goodwin et al.
`6,127,010 A 10/2000 Rudy
`6,128,937 A 10/2000 Huang
`6,176,025 B1
`1/2001 Patterson et al.
`
`FOREIGN PATENT DOCUMENTS
`
`EP
`EP
`EP
`FR
`FR
`FR
`FR
`FR
`
`0 215 974 A1
`0 605 485 A1
`0 780 064 A2
`1195549
`1406610
`2144464
`2404413
`2407008
`
`9/1985
`9/1992
`6/1997
`11/1959
`11/1965
`1/1973
`4/1979
`5/1979
`
`INTEX EXHIBIT 2017, Pg. 2
`Bestway v. Intex; PGR2017-00003
`
`

`

`US 6,385,864 B1
`Page 3
`
`FR
`FR
`FR
`GB
`GB
`GB
`$5
`JP
`JP
`TW
`
`2483321
`2614510
`2639537
`14955
`7441
`233387
`332%:
`266718
`6-181802
`75100322
`
`4/1981
`4/1987
`11/1988
`8/1893
`3/1906
`1/1924
`£23
`7/1992
`7/1994
`1/1975
`
`TW
`WO
`WO
`WO
`W0
`W0
`W0
`W0
`
`54221
`WO89/10074
`WO90/10396
`W091/11928
`W091/11931
`W092/08384
`W095/20332
`W0 98/09546
`
`* Cited by examiner
`
`6/1978
`11/1989
`9/1990
`8/1991
`8/1991
`5/1992
`8/1995
`3/1998
`
`INTEX EXHIBIT 2017, Pg. 3
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 1 0f 14
`
`US 6,385,864 B1
`
`FIG. 1
`PRIOR ART
`
`FIG. 2
`PRIOR ART
`
`FIG. 3
`
`FIG. 4
`PRIOR ART
`
`24
`
`?m“\“
`IIIIIIlllllllllnunmnu ||||||||||||||||||||||||||||| mllllllllllllllllll!
`\
`
`INTEX EXHIBIT 2017, Pg. 4
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 2 0f 14
`
`US 6,385,864 B1
`
`25 -
`
`2O -
`
`FIG. 5
`
`PRIOR ART
`
`26
`
`15 _
`
`3O /
`10 ~ A 5 .
`O / 28!
`l
`l
`I
`O
`10
`2O
`3O
`40
`
`FIG. 6
`PRIOR ART
`
`K
`
`42%
`
`FIG. 7
`PRIOR ART
`
`FIG. 8
`PRIOR ART
`
`INTEX EXHIBIT 2017, Pg. 5
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`
`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 3 0f 14
`
`US 6,385,864 B1
`
`FIG. 9
`
`FIG. 10
`
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`
`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 4 0f 14
`
`US 6,385,864 B1
`
`INTEX EXHIBIT 2017, Pg. 7
`Bestway v. Intex; PGR2017-00003
`
`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 5 0f 14
`
`US 6,385,864 B1
`
`FIG. 14
`
`FIG. 15
`
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`
`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 6 6f 14
`
`US 6,385,864 B1
`
`FIG. 16
`
`FIG. 17
`
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`
`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 7 0f 14
`
`US 6,385,864 B1
`
`FIG. 18
`
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`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 8 0f 14
`
`US 6,385,864 B1
`
`FIG. 20A 106
`
`FIG. 20C
`
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`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 9 0f 14
`
`US 6,385,864 B1
`
`F|G.21A
`
`118
`1
`
`110
`
`F|G.21B
`
`[I]
`
`FIG. 21C
`
`1
`
`2 1
`
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`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 10 0f 14
`
`US 6,385,864 B1
`
`FIG. 24 ,
`
`124
`122/’
`
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`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 11 0f 14
`
`US 6,385,864 B1
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`INTEX EXHIBIT 2017, Pg. 14
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`
`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 12 0f 14
`
`US 6,385,864 B1
`
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`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 13 0f 14
`
`US 6,385,864 B1
`
`FIG. 35
`
`\
`I
`
`\\\ \
`
`FIG. 36
`
`140'
`
`150
`
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`

`

`U.S. Patent
`
`May 14, 2002
`
`Sheet 14 0f 14
`
`US 6,385,864 B1
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`

`

`US 6,385,864 B1
`
`1
`FOOTWEAR BLADDER WITH
`CONTROLLED FLEX TENSILE MEMBER
`
`FIELD OF THE INVENTION
`
`The present invention relates to an improved cushioning
`member and method of making the same, and more particu
`larly to a ?uid ?lled bladder having controlled ?ex tensile
`members Which alloWs for the formation of complex-curved
`contours and shapes While minimiZing the amount of sur
`rounding foam material. The present invention also relates to
`footWear Wherein the bladder With controlled ?ex tensile
`members is used as a cushioning device Within a sole.
`
`BACKGROUND OF THE INVENTION
`
`Considerable Work has been done to improve the con
`struction of cushioning members Which utiliZe ?uid ?lled
`bladders such as those used in shoe soles. Although With the
`recent developments in materials and manufacturing
`methods, ?uid ?lled bladder members have greatly
`improved in versatility, there remain problems associated
`With obtaining optimum performance and durability. Fluid
`?lled bladder members are commonly referred to as “air
`bladders,” and the ?uid is generally a gas Which is com
`monly referred to as “air” Without intending any limitation
`as to the actual gas composition used.
`Closed-celled foam is often used as a cushioning material
`in shoe soles and ethylene-vinyl acetate copolymer (EVA)
`foam is a common material. In many athletic shoes, the
`entire midsole is comprised of EVA. While EVA foam can
`easily be cut into desired shapes and contours, its cushioning
`characteristics are limited. One of the advantages of gas
`?lled bladders is that gas as a cushioning compound is
`generally more energy efficient than closed-cell foam. This
`means that a shoe sole comprising a gas ?lled bladder
`provides superior cushioning response to loads than a shoe
`sole comprising only foam. Cushioning generally is
`improved When the cushioning component, for a given
`impact force, spreads the impact force over a longer period
`of time, resulting in a smaller impact force being transmitted
`to the Wearer’s body. Even shoe soles comprising gas ?lled
`bladders include some foam, and a reduction in the amount
`of foam Will generally afford better cushioning characteris
`tics.
`Some major engineering problems associated With the
`design of air bladders formed of perimeter barrier layers
`include: (I) obtaining complex-curved, contoured shapes
`Without the formation of deep peaks and valleys in the cross
`section Which require ?lling in or moderating With foams or
`plates; (ii) ensuring that the means employed to give the air
`bladder its complex-curved, contoured shape does not sig
`ni?cantly compromise the cushioning bene?ts of air; and
`(iii) reducing fatigue failure of the bladders caused by cyclic
`folding of portions of the bladder.
`The prior art is replete With attempts to address these
`dif?culties, but often presenting neW obstacles in the process
`of addressing these problems. Most of the prior art discloses
`some type of tensile member. A tensile member is an
`element associated With the bladder Which ensures a ?xed,
`resting relation betWeen the top and bottom barrier layers
`When the air bladder is fully in?ated, and Which often is in
`a state of tension While acting as a restraining means to
`maintain the general form of the bladder.
`Some prior art constructions are composite structures of
`air bladders containing foam or fabric tensile members. One
`type of such composite construction prior art concerns air
`bladders employing an open-celled foam core as disclosed
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`US. Pat. Nos. 4,874,640 and 5,235,715 to DonZis. These
`cushioning elements do provide latitude in their design in
`that the open-celled foam cores alloW for complex-curved
`and contoured shapes of the bladder Without deep peaks and
`valleys. HoWever, bladders With foam core tensile members
`have the disadvantage of unreliable bonding of the core to
`the barrier layers. FIGS. 1 and 2 illustrate a cross section of
`a prior art bladder 10 employing an open-celled foam core
`12 as a tensile member. FIG. 2 illustrates the loaded condi
`tion of bladder 10 With load arroWs 14. One of the main
`disadvantages of bladder 10 is that foam core 12 gives the
`bladder its shape and thus must necessarily function as a
`cushioning member Which detracts from the superior cush
`ioning properties of air alone. One reason for this is that in
`order to Withstand the high in?ation pressures associated
`With air bladders, the foam core must be of a high strength
`Which requires the use of a higher density foam. The higher
`the density of the foam, the less the amount of available
`volume in the bladder for gas. Consequently, the reduction
`in the amount of gas in the bladder decreases the bene?ts of
`gas cushioning.
`Even if a loWer density foam is used, a signi?cant amount
`of available volume is sacri?ced Which means that the
`de?ection height of the bladder is reduced due to the
`presence of the foam, thus accelerating the effect of “bot
`toming out.” Bottoming out refers to the premature failure of
`a cushioning device to adequately decelerate an impact load.
`Most cushioning devices used in footWear are non-linear
`compression based systems, increasing in stiffness as they
`are loaded. Bottoming out is the point Where the cushioning
`system is unable to compress any further. Also, the elastic
`foam performs a signi?cant portion of the cushioning func
`tion and is subject to compression set. Compression set
`refers to the permanent compression of foam after repeated
`loads Which greatly diminishes its cushioning aspects. In
`foam core bladders, compression set occurs due to the
`internal breakdoWn of cell Walls under heavy cyclic com
`pression loads such as Walking or running. The Walls of
`individual cells constituting the foam structure abrade and
`tear as they move against one another and fail. The break
`doWn of the foam exposes the Wearer to greater shock
`forces.
`Another type of composite construction prior art concerns
`air bladders Which employ three dimensional fabric as
`tensile members such as those disclosed in US. Pat. Nos.
`4,906,502 and 5,083,361 to Rudy, Which are hereby incor
`porated by reference. The bladders described in the Rudy
`patents have enjoyed considerable commercial success in
`NIKE, Inc. brand footWear under the name Tensile-Air® and
`ZoomTM. Bladders using fabric tensile members virtually
`eliminate deep peaks and valleys, and the methods described
`in the Rudy patents have proven to provide an excellent
`bond betWeen the tensile ?bers and barrier layers. In
`addition, the individual tensile ?bers are small and de?ect
`easily under load so that the fabric does not interfere With the
`cushioning properties of air.
`One shortcoming of these bladders is that currently there
`is no knoWn manufacturing method for making complex
`curved, contoured shaped bladders using these fabric ?ber
`tensile members. The bladders may have different heights,
`but the top and bottom surfaces remain ?at With no contours
`and curves. FIGS. 3 and 4 illustrate a cross section of a prior
`art bladder 20 employing a three dimensional fabric 22 as a
`tensile member. FIG. 4 illustrates the loaded condition of
`bladder 20 With load arroWs 24. As can be seen in FIGS. 3
`and 4, the surfaces of bladder 20 are ?at With no contours or
`slopes.
`
`INTEX EXHIBIT 2017, Pg. 18
`Bestway v. Intex; PGR2017-00003
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`

`

`US 6,385,864 B1
`
`3
`Another disadvantage is the possibility of bottoming out.
`Although the fabric ?bers easily de?ect under load and are
`individually quite small, the sheer number of them necessary
`to maintain the shape of the bladder means that under high
`loads, a signi?cant amount of the total de?ection capability
`of the air bladder is reduced by the volume of ?bers inside
`the bladder and the bladder can bottom out.
`One of the primary problems experienced With the fabric
`?bers is that these bladders are initially stiffer during initial
`loading than conventional gas ?lled bladders. This results in
`a ?rmer feel at loW impact loads and a stiffer “point of
`purchase” feel than belies their actual cushioning ability.
`This is because the fabric ?bers have a relatively loW
`elongation to properly hold the shape of the bladder in
`tension, so that the cumulative effect of thousands of these
`relatively inelastic ?bers is a stiff effect. The tension of the
`outer surface caused by the loW elongation or inelastic
`properties of the tensile member results in initial greater
`stiffness in the air bladder until the tension in the ?bers is
`broken and the solitary effect of the gas in the bladder can
`come into play Which can affect the point of purchase feel of
`footWear incorporating bladder 20. The Peak G curve, Peak
`G v. time in milliseconds, shoWn in FIG. 5 re?ects the
`response of bladder 20 to an impact. The portion of the curve
`labeled 26 corresponds to the initial stiffness of the bladder
`due to the ?bers under tension, and the point labeled 28
`indicates the transition point in Which the tension in the
`?bers of fabric 22 are “broken” and give Way to more of the
`cushioning effects of the air. The area of the curve labeled 30
`corresponds to loads Which are cushioned With more com
`pliant gas. The Peak G curve is a plot generated by an impact
`test such as those described in the Sport Research Review,
`Physical Tests, published by NIKE, Inc. as a special adver
`tising section, J anuary/February 1990, the contents of Which
`is hereby incorporated by reference.
`Another category of prior art concerns air bladders Which
`are injection molded, bloW-molded or vacuum-molded such
`as those disclosed in US. Pat. No. 4,670,995 to Huang and
`US. Pat. No. 4,845,861 to Moumdjian, Which are incorpo
`rated herein by reference. These manufacturing techniques
`can produce bladders of any desired contour and shape While
`reducing deep peaks and valleys. The main draWback of
`these air bladders is in the formation of stiff, vertically
`aligned columns of elastomeric material Which form interior
`columns and interfere With the cushioning bene?ts of the air.
`These bladders are designed to support the Weight of the
`Wearer. FIGS. 6 and 7 illustrate cross sections of a prior art
`bladder 40 Which is made by injection molding, bloW
`molding or vacuum-forming With vertical columns 42. FIG.
`7 illustrates bladder 40 in the loaded condition With load
`arroWs 44. Since these interior columns are formed or
`molded in the vertical position, there is signi?cant resistance
`to compression upon loading Which can severely impede the
`cushioning properties of the air.
`In Huang ’995 it is taught to form strong vertical columns
`so that they form a substantially rectilinear cavity in cross
`section. This is intended to give substantial vertical support
`to the cushion so that the cushion can substantially support
`the Weight of the Wearer With no in?ation. Huang ’995 also
`teaches the formation of circular columns using bloW
`molding. In this prior art method, tWo symmetrical rod-like
`protrusions of the same Width, shape and length eXtend from
`the tWo opposite mold halves to meet in the middle and thus
`form a thin Web in the center of a circular column. These
`columns are formed of a Wall thickness and dimension
`sufficient to substantially support the Weight of a Wearer in
`the unin?ated condition. Further, no means are provided to
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`cause the columns to ?eX in a predetermined fashion Which
`Would reduce fatigue failures. Huang’s columns are also
`prone to fatigue failure due to compression loads Which
`force the columns to buckle and fold unpredictably. Under
`cyclic compression loads, the buckling can lead to fatigue
`failure of the columns.
`FIG. 8 shoWs a close-up vieW of a prior art column similar
`to those shoWn in Huang With a thin Web in the middle of the
`column halves formed by a center Weld W and a slight draft
`angle 0 to the column halves. While Huang’s columns do not
`appear to have a draft angle, the commercial embodiments
`of the bladder taught by Huang have shoWn a draft angle
`similar to that shoWn in FIG. 8.
`Included in this prior art category of molded bladders are
`bladders having inWardly directed indentations as disclosed
`in Us. Pat. No. 5,572,804 to Skaja et al, Which is hereby
`incorporated by reference. Skaja et al. disclose a shoe sole
`component comprising inWardly directed indentations in the
`top and bottom members of the sole components. Support
`members or inserts provide some controlled collapse of the
`material to create areas of cushioning and stability in the
`component. The inserts are con?gured to eXtend into the
`outWardly open surfaces of the indentations. The indenta
`tions can be formed in one or both of the top and bottom
`members. The indented portions are proximate to one
`another and can be engaged With one another in a ?Xed or
`non-?Xed relation. In the Skaja patent, indentations that are
`generally hemispherical in shape and symmetrical about a
`central orthogonal aXis are taught. The outside shape of the
`indentation, that is, the shape outlined at the surface of the
`bladder component is circular. The inserts have the same
`shape as the indentations. The hemispherical indentations
`and mating support members or inserts respond to compres
`sion by collapsing symmetrically about a center point. While
`the hemispherical indentations and inserts of Skaja provide
`for some variation in cushioning characteristics by
`placement, siZe and material, there is no provision for
`biasing or controlling the compression or collapse in a
`desired direction upon loading. The indentations and the
`mating inserts contribute to the cushioning response of the
`bladder Which is opposed to the goal of the present invention
`in Which the controlled collapse members are engineered
`speci?cally to not interfere With the cushioning response of
`gas or air.
`Yet another prior art category concerns bladders using a
`corrugated middle ?lm as an internal member as disclosed in
`US. Pat. No. 2,677,906 to Reed Which describes an insole
`of top and bottom sheets connected by lateral connection
`lines to a corrugated third sheet placed betWeen them. The
`top and bottom sheets are heat sealed around the perimeter
`and the middle third sheet is connected to the top and bottom
`sheets by lateral connection lines Which eXtend across the
`Width of the insole. An insole With a sloping shape is thus
`produced, hoWever, because only a single middle sheet is
`used, the contours obtained must be uniform across the
`Width of the insole. By use of the attachment lines, only the
`height of the insole from front to back may be controlled and
`no complex-curved, contoured shapes are possible. Another
`disadvantage of Reed is that because the third, middle sheet
`is a continuous sheet, all the various chambers are indepen
`dent of one another and must be in?ated individually Which
`is impractical for mass production.
`The alternative embodiment disclosed in the Reed patent
`uses just tWo sheets With the top sheet folded upon itself and
`attached to the bottom sheet at selected locations to provide
`rib portions and parallel pockets. The main disadvantage of
`this construction is that the ribs are vertically oriented and
`
`INTEX EXHIBIT 2017, Pg. 19
`Bestway v. Intex; PGR2017-00003
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`

`

`US 6,385,864 B1
`
`5
`similar to the columns described in the patents to Huang and
`Moumdjian, and Would resist compression and interfere
`With and decrease the cushioning bene?ts of air. As With the
`?rst embodiment of Reed, each parallel pocket thus formed
`must be separately in?ated.
`A prior bladder and method of construction using ?at
`?lms is disclosed in US. Pat. No. 5,755,001 to Potter et al,
`Which is hereby incorporated by reference. The interior ?lm
`layers are bonded to the envelope ?lm layers of the bladder
`Which de?nes a single pressure chamber. The interior ?lm
`layers act as tensile members Which are biased to compress
`upon loading. The biased construction reduces fatigue fail
`ures and resistance to compression. The bladder comprises
`a single chamber in?ated to a single pressure With the tensile
`member interposed to give the bladder a complex-contoured
`pro?le. There is, hoWever, no provision for multiple layers
`of ?uid in the bladder Which could be in?ated to different
`pressures providing improved cushioning characteristics and
`point of purchase feel.
`Another Well knoWn type of bladder is formed using bloW
`molding techniques such as those discussed in US. Pat. No.
`5,353,459 to Potter et al, Which is hereby incorporated by
`reference. These bladders are formed by placing a lique?ed
`elastomeric material in a mold having the desired overall
`shape and con?guration of the bladder. The mold has an
`opening at one location through Which pressuriZed gas is
`introduced. The pressuriZed gas forces the lique?ed elasto
`meric material against the inner surfaces of the mold and
`causes the material to harden in the mold to form a bladder
`having the preferred shape and con?guration.
`There exists a need for an air bladder With a suitable
`tensile member Which solves all of the problems listed
`above: complex-curved, contoured shapes; elimination of
`deep peaks and valleys; no interference With the cushioning
`bene?ts of air alone; and the provision of a reliable bond
`betWeen tensile member and outer barrier layers. As dis
`cussed above, While the prior art has been successful in
`addressing some of these problems, they each have their
`disadvantages and fall short of a complete solution.
`
`SUMMARY OF THE INVENTION
`
`The present invention pertains to a bladder With con
`trolled ?ex connecting members extending betWeen the top
`and bottom outer layers of bladder. The bladder of the
`present invention may be incorporated into a sole assembly
`of an article of footWear to provide cushioning. When
`pressuriZed, the outer layers are placed under tension, and
`the connecting members function as tension members. The
`bladder provides a reliable bond betWeen the tensile mem
`bers and the outer barrier layers, and can be constructed to
`have complex-curved, contoured shapes Without interfering
`With the cushioning properties of air. A complex-contoured
`shape refers to varying the surface of the bladder in more
`than one direction. The present invention overcomes the
`enumerated problems With the prior art While avoiding the
`design trade-offs associated With the prior art attempts.
`In accordance With one aspect of the present invention, a
`bladder is formed by bloW-molding or rotational molding.
`Both of these methods create internal connection/tensile
`members Which are integral With the outer perimeter layer.
`Since the outer perimeter and the internal tensile members
`are formed at the same time and of the same material,
`bonding problems betWeen layers is eliminated and manu
`facturing is simpli?ed. By utiliZing pins in the bloW-molded
`or rotational mold, tensile column members are formed
`Which can provide a ?nely contoured shape, but Which do
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`not signi?cantly interfere With the cushioning properties of
`the air, When the bladder contains air or another ?uid. It is
`desirable that the tensile members compress easily under
`relatively loW loads, those exceeding 1/2 body Weight (35 kg)
`and preferably beloW 25 kg. In order to prevent fatigue stress
`on the members, a predetermined ?ex point is molded into
`at least a portion of each column. This assures that the
`members Will ?ex under relatively loW loads and that the
`?exure Will occur in a predictable manner, eliminating the
`prior art problem of fatigue failure in the vertical columns.
`To ensure that the tensile members do not interfere With
`the cushioning properties of air they are con?gured to be
`suf?ciently ?exible to receive compressive loads but are
`durable even under repeated loading. Broadly, there are tWo
`con?gurations: one in Which the tensile member is con
`structed to collapse upon compressive loading, and one in
`Which the tensile member is constructed to bend or fold like
`a hinge upon compressive loading in a predetermined loca
`tion.
`In another aspect of the present invention the shape of the
`?exible tensile column members and the interface at the ?ex
`point are manipulated to assist in ?nely tuning the cushion
`ing properties of the ?nal bladder. Differently shaped cross
`sections of columns, e.g. circles, ovals, squares, rectangles,
`triangles, spirals, half-moons, helices, etc., impart different
`amounts of resistance to compression and exhibit varying
`?ex properties. Also, the placement, thickness and number
`of ?ex points can signi?cantly effect the bending, collapsing,
`or folding properties of the tensile members. For example,
`multiple accordion-like pleats molded into the columns
`impart more ?exibility than a single notch or pleat of the
`same thickness. Additionally, the columns need not be
`arranged perpendicular to the plane of the bladder surface.
`By forming the tensile members at various angles, the
`direction that the tensile member bends or folds can be
`further controlled.
`Yet another aspect of the invention is to vary the lengths
`of the opposing ends of the tensile columns by utiliZing pin
`or rod-like protrusions of different lengths in the mold, the
`joint or hinge in the tensile members can be formed off
`center. The longer of the tWo pin or rod-like protrusions
`forms a column portion of longer length than the shorter pin
`or rod-like protrusion. This variation in the tensile column’s
`length can be manipulated to direct the ?exing of the column
`under compression.
`In another embodiment, the ?ex point of the tensile
`column is manipulated by altering the cross-section siZe of
`the pin or rod-like protrusions in the mold, Whereby the pins
`or rod-like protrusions in one mold half are larger in
`cross-section than the ones in the opposing half. This
`produces a tensile column With one portion larger than the
`other Which alloWs the smaller portion of the column to
`telescope or nest into the larger portion upon loading. In
`such a construction, the larger portion collapses around the
`smaller portion, rather than acting as a hinge.
`In yet another embodiment, spring elements such as
`elastomeric sheets, may be insert-molded during the bloW
`molding process to direct the ?ex pro