US007070845B2
`
`(12)
`
`United States Patent
`Thomas et al.
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 7,070,845 B2
`Jul. 4, 2006
`
`(54) FLUID-FILLED BLADDER FOR AN
`ARTICLE OF FOOTWEAR
`(75) Inventors: Edward Thomas, Portland, OR
`(US); DaVld GOOdWln, Portland, OR
`(Us)
`(73) Assignee: 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 24 days.
`
`(21) Appl. No.: 10/642,262
`(22) Filed:
`Aug. 18, 2003
`
`(65)
`
`Prior Publication Data
`
`US 2005/0039346 A1
`(51) Int Cl
`
`Feb. 24, 2005
`
`(2006.01)
`3323 1/04
`(2006.01)
`A43B 13/20
`(52) us. Cl. .......................... .. 428/69; 428/71; 428/86;
`36/29
`(58) Field of Classi?cation Search .................. .. 36/28,
`36/29’ 71’ 3 5 R
`See application ?le for Complete Search history
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`3,583,081 A
`6/1971 Hayashi
`
`4,183,156 A
`1/1980 Rudy
`4,219,945 A
`9/1980 Rudy
`4,513,449 A
`4/1985 D '
`4,874,640 A 10/1989 D222:
`4,906,502 A
`3/1990 Rudy
`5,083,361 A
`1/1992 Rudy
`5,543,194 A
`8/1996 Rudy
`5,741,568 A *
`4/1998 Rudy ........................ .. 428/69
`i l
`googwfn et a1‘
`6’l27’010 A 10/2000 Rggywm e a'
`’
`’
`
`EP
`
`FOREIGN PATENT DOCUMENTS
`1371762
`12/2003
`
`* cited by examiner
`
`Primary ExamineriTed Kavanaugh
`(74) Attorney, Agent, or F irmiBanner & Witcoif, Ltd.
`
`(57)
`
`ABSTRACT
`
`The invention relates to a ?uid-?lled bladder and a method
`for making for making a ?uid-?lled bladder that include a
`eere having at least One fusing ?lament- A P0111011 ef the
`fusing ?lament is positioned adjacent to the exterior surface
`of the core such that it engages and fuses to barrier layers of
`the bladder, thereby securing the core to the barrier layers
`Without the need for an additional fusing agent therebe
`tWeen.
`
`25 Claims, 2 Drawing Sheets
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`INTEX EXHIBIT 2018, Pg. 1
`Bestway v. Intex; PGR2017-00003
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`INTEX EXHIBIT 2018, Pg. 2
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`Bestway v. Intex; PGR2017-00003
`
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`INTEX EXHIBIT 2018, Pg. 2
`Bestway v. Intex; PGR2017-00003
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`

`U.S. Patent
`
`Jul. 4, 2006
`
`Sheet 2 0f 2
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`US 7,070,845 B2
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`FIG. 4
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`INTEX EXHIBIT 2018, Pg. 3
`Bestway v. Intex; PGR2017-00003
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`

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`US 7,070,845 B2
`
`1
`FLUID-FILLED BLADDER FOR AN
`ARTICLE OF FOOTWEAR
`
`BACKGROUND OF THE INVENTION
`
`1. Field of the Invention
`This invention relates to a ?uid-?lled bladder suitable for
`footwear applications. More particularly, the invention is a
`?uid-?lled bladder having a core that includes strands of
`fusing agent to secure the core to outer layers of the bladder.
`2. Description of Background Art
`Footwear is divided into tWo general parts, an upper and
`a sole. The upper is designed to comfortably receive the foot
`and the sole provides traction, protection, and a durable
`Wear-resistant surface. The considerable forces generated
`during athletic activities require that the sole of footWear
`attenuate ground reaction forces and absorb energy, thereby
`providing protection to the foot and leg. Accordingly, the
`sole of athletic footWear typically has a layered structure that
`includes a comfort-enhancing insole, a resilient midsole, and
`a ground-contacting outsole that provides both durability
`and traction.
`Midsoles are traditionally formed of conventional foam
`materials such as ethylene vinyl acetate or polyurethane that
`compress resiliently under an applied load to attenuate
`ground reaction forces and absorb energy. Conventional
`foam materials are resiliently compressible, in part, due to
`the inclusion of a plurality of open or closed cells that de?ne
`an inner volume substantially displaced by gas. That is, the
`foam includes bubbles formed in the material that enclose
`gas. After repeated compressions, hoWever, the cell structure
`deteriorates, thereby resulting in decreased compressibility
`of the foam. Thus, the force attenuation and energy absorp
`tion characteristics of the midsole may decrease over the
`lifespan of the footWear.
`One Way to overcome the draWbacks of utilizing conven
`tional foam materials is disclosed in U.S. Pat. No. 4,183,156
`to Rudy, hereby incorporated by reference, in Which cush
`ioning is provided by in?atable inserts formed of elasto
`meric materials. The inserts include a plurality of tubular
`chambers that extend substantially longitudinally through
`out the length of the footWear. The chambers are in ?uid
`communication With each other and jointly extend across the
`Width of the footWear. U.S. Pat. No. 4,219,945 to Rudy,
`hereby incorporated by reference, discloses an in?ated insert
`encapsulated in a foam material. The combination of the
`insert and the encapsulating material functions as a midsole.
`An upper is attached to the upper surface of the encapsu
`lating material and an outsole or tread member is a?ixed to
`the loWer surface.
`Such bladders are generally formed of an elastomeric
`material and are structured to have an upper or loWer surface
`that encloses one or more chambers therebetWeen. The
`chambers are pressurized above ambient pressure by insert
`ing a nozzle or needle connected to a ?uid pressure source
`into a ?ll inlet formed in the bladder. After the chambers are
`pressurized, the ?ll inlet is sealed, for example, by Welding,
`and the nozzle is removed.
`Bladders of this type have been manufactured by the prior
`art tWo-?lm technique in Which tWo separate sheets of
`elastomeric ?lm are formed having the overall peripheral
`shape of the bladder. The sheets are Welded together along
`the periphery to form a bladder having upper, loWer, and side
`surfaces, and the sheets are Welded together at predeter
`mined interior areas to give the bladder a desired con?gu
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`ration. That is, the interior Welds provide the bladder With
`chambers having a predetermined shape and size at desired
`locations.
`Bladders have also been manufactured by the prior art
`bloW-molding technique, Wherein a lique?ed elastomeric
`material is placed 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 air is provided.
`The pressurized air forces the lique?ed elastomeric material
`against the inner surfaces of the mold and causes the
`material to harden in the mold, thereby forming a bladder
`With the desired shape and con?guration.
`Another type of prior art bladder used in soles of footWear
`is disclosed in U.S. Pat. Nos. 4,906,502 and 5,083,361, both
`to Rudy, and both hereby incorporated by reference. This
`type of bladder is formed as a ?uid pressurized and in?ated
`structure that comprises a hermetically sealed outer barrier
`layer Which is securely fused substantially over the entire
`outer surfaces of a double-Walled fabric core. The double
`Walled fabric core is comprised of ?rst and second outer
`fabric layers that are normally spaced apart from one another
`at a predetermined distance. Connecting or drop yarns,
`potentially in the form of multi-?lament yarns having many
`individual ?bers, extend internally betWeen the proximal or
`facing surfaces of the respective fabric layers. The ?laments
`of the drop yarns form tensile restraining means and are
`anchored to the respective fabric layers. A suitable method
`of manufacturing the double Walled fabric structure is
`double needle bar Raschel knitting.
`U.S. Pat. Nos. 5,993,585 and 6,119,371, both issued to
`GoodWin et al., and both hereby incorporated by reference,
`disclose a bladder utilizing a double-Walled fabric core, as
`With the ’502 and ’361 patents, but Without a peripheral
`seam located midWay betWeen the upper and loWer surfaces
`of the bladder. Instead, the seam is located adjacent to the
`upper surface of the bladder. Advantages in this design
`include removal of the seam from the area of maximum
`sideWall ?exing and increased visibility of the interior of the
`bladder, including the connecting yarns. The process utilized
`to form a bladder of this type involves the formation of a
`shell, Which includes a loWer surface and a sideWall, With a
`mold. A double-Walled fabric core is placed on top of a
`covering sheet, and the shell, folloWing removal from the
`mold, is placed over the covering sheet and core. The
`assembled shell, covering sheet, and core are then moved to
`a lamination station Where radio frequency energy fuses
`opposite sides of the core to the shell and covering sheet and
`fuses a periphery of the shell to the covering sheet. The
`bladder is then pressurized by inserting a ?uid so as to place
`the connecting yarns in tension.
`Another type of prior art bladder used in soles of footWear
`is disclosed in U.S. Pat. No. 4,874,640 to Donzis, and U.S.
`Pat. Nos. 5,741,568 and 6,127,010 to Rudy, all ofWhich are
`hereby incorporated by reference. This type of bladder
`utilizes a compressible insert encapsulated Within an elas
`tomeric barrier member. In the ’640 patent, the elastomeric
`barrier member is generally impermeable to air and gener
`ally ?lled With a ?uid that can be pressurized. The insert
`includes a compression, impact absorbing foam core glued
`or fused on its external surfaces to the elastomeric barrier
`member. The internal foam cushioning member can be
`reinforced by including ?laments, ?bers, or fabrics Within
`the foam core. The ’568 and ’101 patents suggest various
`materials can be used for the compressible insert, including
`cotton, rubber, foam, horsehair, plastic mesh, etc. A pre
`ferred material is identi?ed as at least partially open cell,
`?exible foam, such as polyurethane or ethylene-vinyl
`
`INTEX EXHIBIT 2018, Pg. 4
`Bestway v. Intex; PGR2017-00003
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`

`

`US 7,070,845 B2
`
`3
`acetate. Filaments are utilized to enhance the connection
`betWeen the compressible insert and the barrier member,
`With portions of the ?laments being imbedded in both the
`compressible insert and the barrier material. Examples of
`suitable ?laments are listed as polyesters, polyethylene
`terephthalate, polyamides, nylons, ?berglass, carbon, glass,
`silk, cotton, Wool, urethane, aramid, Dacron, cellulose,
`rayon, copra, acetate, polyvinyl alcohol, polyacrylics, and
`mixtures thereof.
`While the cushioning bene?ts of bladders in articles of
`footWear are Well documented, the prior art methods of
`manufacturing bladders utiliZing a double-Walled fabric core
`have made them costly and time consuming to manufacture.
`In particular, the double-Walled fabric core is typically
`secured Within the bladder by attaching a layer of thermally
`activated fusing agent to the outer surfaces of the core, and
`then heating the bladder components to cause the fusing
`agent to melt, thereby securing the core the outer layers of
`the bladder. In practice, it is time consuming to add the
`fusing agent to the outer surfaces of the core and requires
`additional manufacturing steps, thereby increasing overall
`cost. Accordingly, the art requires a simple, cost effective
`method for securing a double-Walled fabric core Within a
`bladder. In addition to other bene?ts that Will become
`apparent from the folloWing disclosure, the present inven
`tion ful?lls this need.
`
`SUMMARY OF THE INVENTION
`
`The present invention relates to a ?uid-?lled bladder, and
`a method for forming a ?uid-?lled bladder, that is suitable
`for use With an article of footWear. The bladder includes an
`outer barrier and a core. The outer barrier is substantially
`impermeable to a ?uid contained by the bladder. The core is
`located Within the outer barrier and includes at least one
`fusing ?lament that fuses With the outer barrier and secures
`the core to the outer barrier.
`Conventional cores Were formed through a double needle
`bar Raschel knitting process. A sheet of fusing agent Was
`then applied to the outer layers of the cores. The fusing
`?lament of the present invention, hoWever, may be inte
`grated into the structure of the Walls, through Weaving for
`example, thereby eliminating the manufacturing step of
`applying the fusing agent to the outer layers.
`The fusing ?lament and the barrier layers may be a
`thermoplastic material that is heated to a temperature that
`softens the material, but is beloW the melting point. Subse
`quent contact and cooling of the materials will effectively
`fuse the materials and secure the core to the barrier layers.
`The advantages and features of novelty characterizing the
`present invention are pointed out With particularity in the
`appended claims. To gain an improved understanding of the
`advantages and features of novelty, hoWever, reference may
`be made to the folloWing descriptive matter and accompa
`nying draWings that describe and illustrate various embodi
`ments and concepts related to the invention.
`
`DESCRIPTION OF THE DRAWINGS
`
`The foregoing Summary of the Invention, as Well as the
`folloWing Detailed Description of the Invention, Will be
`better understood When read in conjunction With the accom
`panying draWings.
`FIG. 1 is a lateral elevational vieW of an article of
`footWear having a bladder in accordance With the present
`invention.
`
`4
`FIG. 2 is a top plan vieW of a bladder in accordance With
`the present invention.
`FIG. 3 is a cross-sectional vieW of the bladder as de?ned
`by line 3i3 in FIG. 2.
`FIG. 4 is a perspective diagrammatic vieW of a material
`that forms a core in accordance With the present invention.
`FIG. 5 is a cross-sectional vieW of the bladder, as depicted
`in FIG. 3, but prior to attachment of the core to the outer
`layers of the bladder.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`Referring to the ?gures and folloWing discussion, Wherein
`like numerals indicate like elements, an article of footWear
`and a bladder in accordance With the present invention are
`disclosed. FIG. 1 depicts an article of footWear 100 having
`an upper 110 and a sole 120. A bladder 200 is located in a
`heel portion of sole 120 to provide enhanced ground reaction
`force attenuation and energy absorption. Article of footWear
`100 is depicted as an athletic shoe. Bladder 200 may,
`hoWever, be utiliZed in other types of footWear, including
`dress shoes, sandals, boots, and in-line skates.
`Bladder 200, depicted individually in FIGS. 2 and 3,
`includes an outer barrier, is formed of a ?rst barrier layer
`21011, a second barrier layer 210b, and a core 220 that is
`positioned betWeen barrier layers 210a and 21019. First
`barrier layer 21011 is attached to second barrier layer 2101)
`around their respective peripheries to form a peripheral bond
`212. Accordingly, barrier layers 210a and 21019 and periph
`eral bond 212 form a sealed, ?uid-?lled chamber that
`encloses core 220.
`Barrier layers 210a and 21019 are formed of a thermo
`plastic elastomer material that is substantially impermeable
`to the ?uid contained by bladder 200. The material forming
`barrier layers 210a and 2101) may be, for example, a ?lm
`formed of alternating layers of thermoplastic polyurethane
`and ethylene-vinyl alcohol copolymer, as disclosed in US.
`Pat. Nos. 5,713,141 and 5,952,065 to Mitchell et al, incor
`porated by reference. A variation upon this material Wherein
`the center layer is formed of ethylene-vinyl alcohol copoly
`mer; the tWo layers adjacent to the center layer are formed
`of thermoplastic polyurethane; and the outer layers are
`formed of a regrind material of thermoplastic polyurethane
`and ethylene-vinyl alcohol copolymer may also be utiliZed
`for barrier layers 210a and 2101). Another suitable material
`is a ?exible microlayer membrane that includes alternating
`layers of a gas barrier material and an elastomeric material,
`as disclosed in US. Pat. Nos. 6,082,025 and 6,127,026 to
`Bonk et al., hereby incorporated by reference. Other suitable
`thermoplastic elastomer materials or ?lms include polyure
`thane, polyester, polyester polyurethane, polyether polyure
`thane, such as cast or extruded ester-based polyurethane ?lm
`having a shore A hardness of 85490, e.g., Tetra Plastics
`TPW-250. Additional suitable materials are disclosed in
`US. Pat. Nos. 4,183,156 and 4,219,945 to Rudy. Among the
`numerous thermoplastic urethanes that are useful in forming
`the ?lm sheets are urethanes such as PELLETHANE, a
`product of the DoW Chemical Company; ELASTOLLAN, a
`product of the BASF Corporation; and ESTANE, a product
`of the BF. Goodrich Company, all of Which are either ester
`or ether based. Still other thermoplastic urethanes based on
`polyesters, polyethers, polycaprolactone, and polycarbonate
`macrogels may be employed. Nitrogen blocking barrier
`materials may also be utiliZed and include PVDC, also
`knoWn as SURAN; nylon; EVOH; and PVDF, also knoWn as
`KYNAR. Further suitable materials include thermoplastic
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`US 7,070,845 B2
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`5
`?lms containing a crystalline material, as disclosed in Us.
`Pat. Nos. 4,936,029 and 5,042,176 to Rudy, hereby incor
`porated by reference, and polyurethane including a polyester
`polyol, as disclosed in Us. Pat. Nos. 6,013,340; 6,203,868;
`and 6,321,465 to Bonk et al., hereby incorporated by refer
`ence.
`Core 220 includes a ?rst Wall 22211 that is normally spaced
`apart from a second Wall 2221) at a predetermined distance.
`A plurality of connecting members 224 extend betWeen ?rst
`Wall 222a and second Wall 2221). When a ?uid pressuriZes
`bladder 200, the ?uid places an outWard force on barrier
`layers 210a and 21019. The outWard force extends connecting
`members 224, thereby placing connecting members 224 in
`tension and restraining further outWard movement of barrier
`layers 210a and 21019. A material from Which core 220 may
`be cut is depicted in FIG. 4. Connecting members 224 may
`be comprised of drop yarns that each include multiple tensile
`?laments that are anchored to ?rst Wall 222a and second
`Wall 2221). One method of manufacturing core 220 is double
`needle bar Raschel knitting. A portion of ?rst Wall 222a and
`second Wall 2221) may be formed of air-bulked or otherWise
`texturiZed yarn, such as false tWist texturiZed yarn having a
`combination of Nylon 6,6 and Nylon 6. Connecting mem
`bers 224 may be formed of a similar material. As Will be
`discussed in detail beloW, ?rst Wall 222a and second Wall
`2221) also include fusing ?laments. Although the thickness
`of core 220, Which is measured When connecting members
`224 are in a tensile state betWeen ?rst Wall 222a and second
`Wall 222b, may vary signi?cantly Within the scope of the
`present invention, a thickness that is suitable for footWear
`applications may range from 8 to 15 millimeters.
`Connecting members 224 may have a denier per ?lament
`of approximately 1 to 20 With one suitable range being
`betWeen 2 and 5. The individual tensile ?laments that
`comprise connecting members 224 may exhibit a tensile
`strength of approximately 2 to 10 grams per denier and the
`number of tensile ?laments per yarn ranges from approxi
`mately 1 to 100 With one suitable range being betWeen 40
`and 60. In general, there are approximately 1 to 8 yarns per
`tuft or strand and core 200 is knitted With approximately 200
`to 1000 tufts or strands per square inch of fabric, With one
`suitable range being betWeen 400 to 500 strands per square
`inch. The bulk density of the fabric is, therefore, in the range
`of about 20,000 to 300,000 ?bers per square inch4denier.
`Connecting members 224 may be arranged in roWs that
`are separated by gaps. The use of gaps provides core 220
`With increased compressibility in comparison to cores
`formed of double-Walled fabrics that utiliZe continuous
`connecting yarns. The gaps may be formed during the
`double needle bar Raschel knitting process by omitting
`connecting yarns on certain predetermined needles in the
`Warp direction. Knitting With three needles in and three
`needles out produces a suitable fabric With roWs of connect
`ing members 224 being separated by gaps. Other knitting
`patterns of needles in and needles out can be used, such as
`tWo in and tWo out, four in and tWo out, tWo in and four out,
`or any combination thereof. Also, the gaps may be formed
`in both a longitudinal and transverse direction by omitting
`needles in the Warp direction or selectively knitting or not
`knitting on consecutive courses. Core 220, as depicted in
`FIG. 4, has relatively large gaps betWeen connecting mem
`bers 224. Alternatively, the gaps may be smaller or connect
`ing members 224 may extend throughout core 220. The
`above-mentioned ’585 and ’371 GoodWin, et al patents
`disclose fabric bladder cores With gaps betWeen roWs of
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`connecting members, While the ’502 and ’361 Rudy patents
`disclose fabric bladder cores With connecting members
`located throughout the core.
`As discussed in the Description of Background Art sec
`tion above, double-Walled fabric cores are typically secured
`Within an outer barrier of a bladder by attaching a layer of
`thermally activated fusing agent to the ?rst Wall and second
`Wall of the core, and then heating the outer barrier, core, and
`fusing agent to cause the fusing agent to fuse the Walls of the
`core to the outer barrier. The thermally activated fusing
`agent is typically a sheet of thermoplastic material that is
`heated and pressed into contact With the ?rst Wall and the
`second Wall prior to placing the core betWeen layers of the
`outer barrier. Although this process could be utiliZed to
`effectively secure core 220 and barrier layers 210a and 21019
`to each other, this process adds a manufacturing step and
`additional expense to the manufacturing process.
`In contrast With the method discussed above, the present
`invention utiliZes a plurality of fusing ?laments 230 that are
`integrated into ?rst Wall 222a and second Wall 222b, through
`Weaving for example. Fusing ?laments 230 are formed of a
`material that Will fuse, bond, or otherWise become secured
`to barrier layers 210a and 21019 When the various compo
`nents of bladder 200 are heated and compressed together.
`Suitable materials for fusing ?laments 230 include, there
`fore, thermoplastic polyurethane or any of the materials that
`are suitable for barrier layers 210a and 210b, as discussed
`above. Fusing ?laments 230 may be Woven or otherWise
`mechanically manipulated into Walls 222a and 2221) during
`the double needle bar Raschel knitting process or folloWing
`the knitting process. Accordingly, fusing ?laments 230 may
`be integrated into Walls 222a and 222b during the manu
`facturing process of core 220, or fusing ?laments 230 may
`be subsequently added to Walls 222a and 22219.
`The con?guration of fusing ?laments 230 and the manner
`in Which fusing ?laments 230 are integrated into Walls 222a
`and 2221) may vary greatly Within the scope of the present
`invention. Fusing ?laments 230 may be ?bers, ?laments,
`yarns, strips, or elements of material that are elongate and
`are integrated into ?rst and second Walls 222a and 22219. The
`term “fusing ?laments” is, therefore, intended to encompass
`a broad range of types of material and material geometries
`that permit the material to be integrated into Walls 222a and
`22219. In contrast With the fusing agent utiliZed in prior art
`bladders, hoWever, fusing ?laments 230 are not sheets of
`material that are heat fused to the exterior surfaces of the
`core. FIGS. 2 and 4 depict fusing ?laments as extending in
`a ?rst, longitudinal direction and in a second direction that
`is transverse to the ?rst direction. Fusing ?laments 230 may
`also extend in only one direction, extend in a plurality of
`directions, or extend in random directions, for example.
`Fusing ?laments can be incorporated into the ?rst and
`second Walls by any conventional mechanical manipulation
`technique such as interWeaving, intertWining, and tWisting
`or interlooping, With knitting being the most common
`method of interlooping. For example, as mentioned above,
`When core 220 is made by double needle bar Raschel
`knitting, ?laments 230 are knit into the Walls 220a and 22019.
`Thermoplastic polyurethane ?bers are one suitable type of
`fusing ?lament. Examples of such ?bers are Optimer Eco
`thane and BFG/Hualon manufactured by Optimer Perfor
`mance Materials, Inc. of Wilmington, Del.
`Amethod of attaching core 220 to barrier layers 210a and
`210b, and thereby forming bladder 200, Will noW be dis
`cussed. As depicted in FIG. 5, core 220 is positioned
`betWeen barrier layers 210a and 2101) such that portions of
`fusing ?laments 230 located along the outer surfaces of
`
`INTEX EXHIBIT 2018, Pg. 6
`Bestway v. Intex; PGR2017-00003
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`

`

`US 7,070,845 B2
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`Walls 220 are located adjacent to the inner surfaces of barrier
`layers 210a and 2101). At least barrier layers 210a and 21019
`and fusing ?laments 230 are then heated and brought into
`contact such that fusing occurs betWeen fusing ?laments 230
`and barrier layers 210a and 21019. Heating may be achieved
`through a variety of processes, including irradiating the
`components With radio frequency energy, compressing the
`components betWeen platens of a hot press, positioning the
`components in a conventional radiant heater oven, ultrasonic
`Welding, and UV direct heating, for example. Following
`heating, the components are cooled. In this manner, core 220
`becomes effectively fused to barrier layers 210a and 21019.
`The temperature to Which barrier layers 210a and 21019
`and ?laments 230 are heated depends upon the speci?c
`materials utiliZed for fusing ?laments 230 and barrier layers
`210a and 21019. In general, the materials of the barrier layers
`210a and 21019 and fusing ?laments 230 should be heated to
`a degree that exceeds the softening temperature, but is beloW
`the melting point, thereby ensuring proper fusing. As noted
`above, barrier layers 210a and 21019 and ?laments 230 may
`be formed from a variety of materials. In addition, barrier
`layers 210a and 21019 and ?laments 230 may be formed from
`different materials. One suitable material for barrier layers
`210a and 21019 is alternating layers of thermoplastic poly
`urethane and ethylene-vinyl alcohol copolymer, Which has a
`melting temperature betWeen 350 and 360 degrees Fahren
`heit. The temperature to Which the ?rst material should be
`heated is, therefore, betWeen 300 and 320 degrees Fahren
`heit. Another suitable material for barrier layers 210a and
`21019 is a ?exible microlayer membrane that includes alter
`nating layers of a gas barrier material and an elastomeric
`material, such as thermoplastic polyurethane, Which also has
`a melting temperature in the range of 350 to 360 degrees
`Fahrenheit. A suitable temperature to Which the second
`material may be heated is, hoWever, betWeen 320 and 335
`degrees Fahrenheit. One skilled in the relevant art Will
`recogniZe, therefore, that the proper heating temperature
`depends upon the materials that comprise barrier layers 210a
`and 21019 and ?laments 230.
`Peripheral bond 212 is also formed by compressing and
`heat sealing barrier layers 210a and 2101) together around
`substantially the entire periphery of core 220. Alternatively,
`barrier layer 2101) may be preshaped to the con?guration
`depicted in FIG. 3, and barrier layer 21011, which is in sheet
`form, may be attached to the peripheral edges and sealed, as
`45
`disclosed in Us. Pat. No. 5,993,585 to GoodWin et al. A
`?uid, preferably air, is then injected into the area encom
`passed by barrier layers 210a and 21019 at a relatively high
`pressure, for example betWeen 60 and 80 pounds per square
`inch, in order to pre-in?ate and expand the core. The
`pressuriZed air is expired from the bladder and the intended
`permanent in?ation gas is inserted at the desired pressure,
`for example from 5 to 30 pounds per square inch. Finally, the
`injection port is sealed, thereby pressuriZing bladder 200. As
`depicted in FIGS. 2 and 3, peripheral bond 212 is substan
`tially located on the plane of ?rst barrier layer 21011. This
`con?guration removes the seam from the are of maximum
`sideWall ?exing and provides a more aesthetic structure in
`that the sideWall of bladder 200 is not obscured by a seam.
`Peripheral bond 212 may, hoWever, be located on a plane
`that is located betWeen barrier layers 210a and 21019. To
`assure that connecting member 224 adequately connects ?rst
`and second Walls 222a and 222b, and that Walls 222a and
`22219 are adequately fused to barrier layers 210a and 210b,
`a peel test under ASTM T-Peel Test D1876 is performed.
`Peel strengths betWeen 25 and 40 pounds per square inch are
`su?icient. As an alternative to the general method discussed
`
`8
`above, a thermoforming technique may be utiliZed, as dis
`closed in Us. patent application Ser. No. 09/995,003,
`entitled Method of Thermoforming a Bladder Structure and
`?led Nov. 26, 2001.
`Bladder 200 gains a variety of advantages over prior art
`bladders. For example, the overall Weight and stiffness
`(resistance to bending) of bladder 200 are reduced; material
`costs Will decrease because a lesser quantity of fusing
`material is required; a more consistent bladder may be
`produced as a manufacturing step is eliminated; and process
`e?iciency Will increase due to the removal of the manufac
`turing step.
`The present invention is disclosed above and in the
`accompanying draWings With reference to a variety of
`embodiments. The purpose served by the disclosure, hoW
`ever, is to provide an example of the various features and
`concepts related to the invention, not to limit the scope of the
`invention. One skilled in the relevant art Will recogniZe that
`numerous variations and modi?cations may be made to the
`embodiments described above Without departing from the
`scope of the present invention, as de?ned by the appended
`claims.
`That Which is claimed is:
`1. A ?uid-?lled bladder for an article of footWear, the
`bladder comprising:
`a ?exible outer barrier that is substantially impermeable to
`a ?uid contained by the bladder; and
`a core located Within the outer barrier, the core including
`at least one fusing ?lament that is fused directly to the
`outer barrier and secures the core to the outer barrier,
`each of the outer barrier and the at least one fusing
`?lament including thermoplastic polyurethane materi
`als.
`2. The ?uid-?lled bladder of claim 1, Wherein the core
`includes a ?rst Wall structure that is spaced froth a second
`Wall structure, the Wall structures being joined by a plurality
`of connecting members.
`3. The ?uid-?lled bladder of claim 2, Wherein the core is
`manufactured through a double needle bar Raschel knitting
`process.
`4. The ?uid-?lled bladder of claim 2, Wherein the at least
`one fusing ?lament is integrated into the Wall structures.
`5. The ?uid-?lled bladder of claim 2, Wherein the at least
`one fusing ?lament is mechanically manipulated into the
`?rst and second Wall structures.
`6. The ?uid-?lled bladder of claim 1, Wherein the outer
`barrier is formed of a ?rst barrier layer and a second barrier
`layer that are fused together around a periphery of the core.
`7. A ?uid-?lled bladder for an article of footWear, the
`bladder comprising:
`a ?exible outer barrier that is substantially impermeable to
`a ?uid contained by the bladder; and
`a core located Within the outer barrier, the core including
`a ?rst Wall structure that is spaced from a second Wall
`structure, the Wall structures being joined by a plurality
`of connecting members, and the core including at least
`one fusing ?lament that is integrated into the Wall
`structures and is fused directly to the outer barrier to
`secure the core to the outer barrier, a material of the at
`least one fusing ?lament being the same as a material
`of the outer barrier.
`8. The ?uid-?lled bladder of claim 7, Wherein the at least
`one fusing ?lament is mechanically manipulated into the
`Wall structures.
`9. The ?uid-?lled bladder of claim 7, Wherein the core is
`manufactured through a double needle bar Raschel knitting
`process.
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