Hinged cushion with stretch component and method of manufacturing a cushion

Abstract

The cushion includes a bladder that encloses an interior cavity and retains a gas in the interior cavity. A stretch component is disposed in the interior cavity and includes a stretch layer and a plurality of tethers connected to the stretch layer. The stretch layer is connected to an inner surface of the bladder such that the tethers span the interior cavity. The bladder has an inwardly projecting tie that connects the inner surface of the bladder to the stretch component, projects inwardly into the interior cavity, and partially passes through the plurality of tethers such that the bladder is narrowed at the inwardly projecting tie and the gas in the interior cavity is in fluid communication through the inwardly projecting tie. A method of manufacturing the cushion is also disclosed.

Description

[0001] This application is a divisional application of the invention patent application filed on May 17, 2018, with application number 201880032834.7 and entitled "Hinged buffer pad with tension member and method of manufacturing buffer pad".

[0002] Cross-references to related applications

[0003] This application claims priority to U.S. Provisional Application No. 62 / 508035, filed May 18, 2017, the entire contents of which are incorporated herein by reference. Technical Field

[0004] This teaching generally includes a cushioning pad with a hinged tension member, and a method for manufacturing a cushioning pad with an inwardly projecting rib. Background Technology

[0005] Cushioning pads (such as sole components of footwear) are typically configured to provide cushioning, motion control, and / or elasticity. Some cushioning pads utilize a sealed internal cavity filled with gas that elastically resists compressive loads. Tensile components may be disposed within the internal cavity and may limit the outward expansion of the cushioning pad. Attached Figure Description

[0006] Figure 1 This is a planar schematic diagram of the cushioning pad according to this teaching;

[0007] Figure 2 yes Figure 1 A bottom view of the cushioning pad;

[0008] Figure 3 yes Figure 1 The cushioning pad is in Figure 1 A schematic diagram of the cross-section taken at line 3-3 in the diagram;

[0009] Figure 4 yes Figure 1 The cushioning pad is in Figure 1 A schematic diagram of the cross-section taken at line 4-4 in the diagram;

[0010] Figure 5 yes Figure 1 The cushioning pad is in Figure 1 A schematic diagram of the cross-section taken at line 5-5 in the diagram;

[0011] Figure 6 yes Figure 1 A schematic diagram of the inner side view of the cushioning pad;

[0012] Figure 7 This is an internal side view diagram of footwear, including the sole structure, which includes... Figure 1 The cushioning pad is shown as a dashed line.

[0013] Figure 8 In manufacturing Figure 1 An exploded diagram of the components of the buffer pad before it appears;

[0014] Figure 9 In manufacturing Figure 1 A slightly up-view schematic diagram of the first mold insert used in the method of cushioning pads;

[0015] Figure 10 yes Figure 1 Exploded cross-sectional view of the components of the cushioning pad and a schematic diagram of the mold used to manufacture the cushioning pad;

[0016] Figure 11 yes Figure 10 When the mold is in the closed position Figure 1 A schematic diagram of the components of the cushioning pad in the mold;

[0017] Figure 12 This is a perspective view of the mold portion used to manufacture the alternative cushioning pad according to the alternative aspects of this teaching;

[0018] Figure 13 The first mold insert is fixed in Figure 12 A perspective view of the mold portion on the mold part;

[0019] Figure 14 Is with Figure 12 A perspective view of the second mold insert used in conjunction with the mold portion;

[0020] Figure 15 This is a planar schematic diagram of the cushioning pad according to this teaching;

[0021] Figure 16 yes Figure 15 A bottom view of the cushioning pad;

[0022] Figure 17 yes Figure 15 The cushioning pad is in Figure 15 A schematic diagram of the cross-section taken at line 17-17 in the diagram;

[0023] Figure 18 This is a planar schematic diagram of a pair of shoe sole structures;

[0024] Figure 19 This is a flowchart of a method for manufacturing a cushioning pad. Detailed Implementation

[0025] A cushioning pad includes an airbag surrounding an internal cavity, the airbag retaining gas within the internal cavity. The cushioning pad also includes a tension member disposed within the internal cavity. The tension member includes a tension layer and a plurality of tethers connecting the tension layer. The tension layer is attached to an inner surface of the airbag such that the tethers cross the internal cavity. The airbag has an inwardly projecting ribbon connecting the inner surface of the airbag to the tension member, projecting inward into the internal cavity, and partially passing through the plurality of tethers, such that the airbag narrows at the inwardly projecting ribbon, and gas in the internal cavity is fluidly communicated through the inwardly projecting ribbon. In other words, the inwardly projecting ribbon is located directly outside some of the tethers. The inwardly projecting ribbon is spaced apart from a second polymer sheet such that the internal cavity narrows at the inwardly projecting ribbon, and gas in the internal cavity is fluidly communicated across the inwardly projecting ribbon.

[0026] In one or more embodiments, a portion of the internal cavity on a first side of the inwardly projecting sash is in fluid communication with a portion of the internal cavity on a second side of the inwardly projecting sash, the second side being opposite to the first side. Therefore, when the cushioning pad is included in the sole structure, for example during foot stomping or foot tilting in footwear, gas in the internal cavity can be displaced across the inwardly projecting sash.

[0027] In one or more embodiments, the expansion pressure of the gas in the internal chamber is sufficient to tension multiple tethers, and an inwardly projecting tassel defines a groove on the outer surface of the airbag, dividing the cushioning pad into a first pad portion located on one side of the groove and a second pad portion located on the other side of the groove. The groove can serve as a telescopic groove for connecting the cushioning pads. Thus, the adaptability and responsiveness of the tethers to restore the internal chamber to its original shape under dynamic compressive loads is combined with the flexibility of the articulated cushioning pad, which is aligned with the tethers passing through the inwardly projecting tassels.

[0028] In one or more embodiments, the stretch layer includes a first stretch layer spaced a first distance from a second stretch layer at a location adjacent to an inwardly projecting strap, and the inwardly projecting strap is spaced a second distance from the second stretch layer. The second distance can be between 50% and 80% of the first distance. Reducing the internal cavity by this ratio provides an optimal articulation range, contributing to the flexibility of the cushioning pad.

[0029] Because the inwardly projecting ties at least partially traverse multiple tethers, in one or more embodiments, the multiple tethers include tethers aligned with the inwardly projecting ties and tethers displaced from the inwardly projecting ties. The tethers aligned with the inwardly projecting ties are shorter and / or thicker than the tethers displaced from the inwardly projecting ties. The tethers initially all have the same length and width before the cushioning pad is manufactured and the inwardly projecting ties are formed. The deformation of the tethers occurring at the inwardly projecting ties during manufacturing contributes to the hinge and flexibility of the cushioning pad.

[0030] In one or more embodiments, the airbag includes a first polymer sheet and a second polymer sheet, which are joined together at a peripheral flange to enclose an internal cavity. A tension layer includes a first tension layer attached to the first polymer sheet and a second tension layer attached to the second polymer sheet. An inwardly projecting strap is spaced apart from the second polymer sheet. When the internal space expands due to the tension of the strap, the second polymer sheet can be recessed inward toward the inwardly projecting strap across a groove. Due to this groove, a first pad portion is hinged relative to a second pad portion along the groove. Therefore, the outer surface of the first polymer sheet on the first side of the inwardly projecting strap may not be planar with the outer surface of the first polymer sheet on the second side of the inwardly projecting strap, with the second side opposite to the first side.

[0031] In one or more embodiments, the inwardly projecting strap is a first inwardly projecting strap, and the cushioning pad also includes a second inwardly projecting strap that connects the first polymer sheet to the first stretch layer and projects inwardly from the first polymer sheet toward the second polymer sheet and partially passes through the stretching member. The second inwardly projecting strap intersects with the first inwardly projecting strap and is spaced apart from the second polymer sheet, such that the internal cavity narrows at the second inwardly projecting strap, and gas in the internal cavity is in fluid communication through the second inwardly projecting strap.

[0032] A first surface bond can bond the inner surface of the first polymer sheet to the first stretched layer, and a second surface bond can bond the inner surface of the second polymer sheet to the second stretched layer opposite the first stretched layer. An inwardly projecting bond extends further inward from the first polymer sheet towards the second polymer sheet than the first surface bond.

[0033] In one or more embodiments, the cushioning pad is a sole component of a footwear article, and the inwardly projecting strap forms the bending axis of the sole component. Therefore, the cushioning component can be hinged at the inwardly projecting strap, and the bending axis can be aligned with the desired bending area of ​​the foot (e.g., such as the metatarsophalangeal joint).

[0034] The cushioning pad may include a plurality of inwardly projecting straps arranged in a symmetrical pattern. This facilitates the use of cushioning pads with the same construction in both right and left footwear, and in both cases, has straps (and therefore flexible grooves) proximal to the air bladder. For example, the inwardly projecting straps may be one of a plurality of straps projecting inward from the proximal side of the air bladder, the plurality of inwardly projecting straps being arranged in a symmetrical pattern about the axis of symmetry of the air bladder. The plurality of inwardly projecting straps may include a first group and a second group of straps spaced apart from each other and having parallel segments. When the cushioning pad bends along an axis set counterclockwise at a first angle from the axis of symmetry, the first and second groups of straps form a hinge axis. The plurality of inwardly projecting straps may further include a third group and a fourth group of straps spaced apart from each other and having parallel segments. When the cushioning pad bends along an axis set clockwise at a first angle from the axis of symmetry, the third and fourth groups of straps form a hinge axis.

[0035] In one or more embodiments, the plurality of inwardly projecting bands may include: a first central band extending through an axis of symmetry, a pair of symmetrical forward bands extending from a first end and a second end of the first central band, and a pair of symmetrical backward bands extending from a first end and a second end of the first central band. The plurality of inwardly projecting bands may further include: a second central band extending through an axis of symmetry and spaced apart from the first central band, a pair of symmetrical forward bands extending from a first end and a second end of the second central band, and a pair of symmetrical backward bands extending from a first end and a second end of the second central band.

[0036] When the cushioning pad bends along an axis set counterclockwise at a first angle from the axis of symmetry, it can be hinged at the first and second bending axes, and when the cushioning pad bends along an axis set clockwise at a first angle from the axis of symmetry, it can be hinged at the third and fourth bending axes. The first and second bending axes extend along the first and second central ties, respectively, with a forward ties extending from the first ends of the first and second central ties and a backward ties extending from the second ends of the first and second central ties. The third and fourth bending axes extend along the first and second central ties, respectively, with a forward ties extending from the second ends of the first and second central ties and a backward ties extending from the first ends of the first and second central ties.

[0037] A method of manufacturing a cushioning pad includes adapting a first polymer sheet and a second polymer sheet to components of a mold. For example, the first and second polymer sheets can be adapted to the mold components by vacuum and / or compression. Adapting the first and second polymer sheets in this manner presses the first polymer sheet against the second polymer sheet at one or more protrusions on a component of the mold. A tensioning member is disposed between the first and second polymer sheets. The tensioning member includes a first tension layer located near the first polymer sheet, a second tension layer located near the second polymer sheet, and a plurality of tethers connecting the first and second tension layers. The protrusions may be directly outside the plurality of tethers. Adapting the first and second polymer sheets according to this method creates an inwardly projecting band at the protrusion, the band connecting the first polymer sheet and the first tension layer and partially traversing the plurality of tethers. The inwardly projecting band protrudes toward the second polymer sheet but is spaced apart from the second tension layer and the second polymer sheet.

[0038] In one or more embodiments, the method includes thermally bonding a first stretch layer to a first polymer sheet and thermally bonding a second stretch layer to a second polymer sheet opposite to the first stretch layer. The thermal bonding may include at least one of the following: heating the first and second polymer sheets before placing them into a mold cavity, radio frequency welding, or heating the mold.

[0039] In one or more embodiments, the method may further include bonding a first polymer sheet to a second polymer sheet at a peripheral ligature, such that the first and second polymer sheets form an air bladder that at least partially encloses an internal cavity containing a tension member. A plurality of tethers traverse the internal cavity from the first tension layer to the second tension layer, with inwardly projecting ligatures protruding inward, and the internal cavity narrowing at the inwardly projecting ligatures.

[0040] In one or more embodiments, the method may further include inflating and sealing the internal cavity. Inflating the internal cavity tensions a plurality of lacing straps and forms a groove at an inwardly projecting kink on the outer surface of the first polymer sheet, at which the cushioning pad is hinged. In one or more embodiments, the cushioning pad is a sole component of a footwear article, and the groove defines the bending axis of the sole component.

[0041] In one or more embodiments, the inwardly projecting strap is one of a plurality of inwardly projecting straps on the proximal side of the cushioning pad, the plurality of inwardly projecting straps being arranged in a symmetrical pattern about the air bladder's axis of symmetry. The method also includes securing a cushioning pad (referred to as a first cushioning pad) to a first sole structure configured for the right foot, wherein the axis of symmetry of the first cushioning pad is rotated clockwise or counterclockwise by a first angle relative to the longitudinal axis of the first sole structure, and securing a second cushioning pad of the same configuration to a second sole structure configured for the left foot, wherein the axis of symmetry of the second cushioning pad is rotated clockwise or counterclockwise by a first angle relative to the longitudinal axis of the second sole structure, opposite to that of the first cushioning pad. The first and second sole structures are mirror images of each other. In this arrangement, one set of bending axes will be correctly aligned with the joints of the right foot, while another set of bending axes will be correctly aligned with the joints of the left foot. Thus, the symmetrical pattern of the plurality of inwardly projecting straps is specifically designed to allow the same cushioning component to be used in both the sole structure with the right foot configuration and the sole structure with the left foot configuration.

[0042] In one or more embodiments, the mold component includes a first mold portion and a second mold portion, at least one of the first mold portion and the second mold portion being translatable relative to the other of the first mold portion and the second mold portion between an open position and a closed position. Joining the first polymer sheet and the second polymer sheet at the peripheral ligature includes compressing the first polymer sheet and the second polymer sheet between the first mold portion and the second mold portion in the closed position.

[0043] In one or more embodiments of the method, before adapting the first and second polymer sheets to components of the mold, the method may include securing a mold insert to a first mold portion of the mold. The mold component with protrusions may be a mold insert. This allows for easy modification of the webbing style of the cushioning pad manufactured according to the method by changing the mold insert to a mold insert with a different protrusion pattern. For example, in one or more embodiments, the mold insert is a first mold insert, the cushioning pad is a first cushioning pad, and the method further includes manufacturing a second cushioning pad by removing the first mold insert from the first mold portion, and securing a second mold insert with a second protrusion, wherein the shape or size of the second protrusion differs from that of the first protrusion. Subsequent first and second polymer sheets are then respectively bonded to the second mold insert and another mold assembly, with a subsequent stretching member between the subsequent first and second polymer sheets. This bonding of the subsequent first and second polymer sheets presses the subsequent first polymer sheet against the subsequent second polymer sheet at the second protrusion, wherein the second protrusion is directly outside the subsequent stretching member. This creates a second inwardly projecting band at the second protrusion, which partially traverses the subsequent stretching member. Due to the second mold insert, the mold provides a different band pattern for the second cushioning pad compared to the first cushioning pad.

[0044] The above features and advantages, as well as other features and advantages, of this teaching will become apparent when taken in conjunction with the accompanying drawings and the following detailed description of the model used to implement this teaching.

[0045] Referring to the accompanying drawings, the same reference numerals refer to the same components in all views. Figure 1 It shows that it can be based on Figure 19 The cushioning pad 10 manufactured by method 210 has the characteristics of providing an ideal combination of cushioning and flexibility. For example... Figure 7 As shown, cushioning pad 10 is illustrated and described as a cushioning pad used in the sole structure 12 of footwear article 14. For example, the cushioning pad 10 shown is at least partially enclosed in a foam insole 11, and the cushioning pad 10 and the insole 11 together serve as the midsole of the sole structure 12. Outsoles, insoles, and other sole components may also be included in the sole structure 12. Thus, cushioning pad 10 is a sole component. However, cushioning pad 10, cushioning pad 110, or other cushioning pads manufactured according to method 210 discussed in this invention can be used in other articles, such as sportswear, sports equipment, furniture, and carpets. For example, cushioning pad 10 or 110 can be used in backpack straps, helmet pads, gaiters, baseball gloves, cushions, or carpets.

[0046] The cushioning pad 10 includes an air bladder 13 formed of a first polymer sheet 16 and a second polymer sheet 18, which are joined together at a peripheral kink 20 positioned along a peripheral flange 21 to surround an internal cavity 22. When the sheets 16, 18 are joined together at the peripheral kink 20 and any inflation ports are sealed, the air bladder 13 retains fluid within the internal cavity 22. As used in this invention, the “fluid” filling the internal cavity 22 can be a gas, such as air, nitrogen, another gas, or a combination thereof. The first and second polymer sheets 16, 18 are a variety of polymer materials capable of resiliently retaining fluids such as nitrogen, air, or another gas. Examples of polymer materials used for the first and second polymer sheets 16, 18 include thermoplastic urethanes, polyurethanes, polyesters, polyester polyurethanes, and polyether polyurethanes. Moreover, each of the first and second polymer sheets 16, 18 can be formed from different material layers comprising polymer materials. In one embodiment, each of the first and second polymer sheets 16, 18 is formed of a film having one or more thermoplastic polyurethane layers having one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that are impermeable to pressurized fluids contained therein. The barrier layers comprise flexible microfilms comprising alternating layers of gas-barrier and elastic materials, as disclosed by Bonk et al. in U.S. Patent Nos. 6,082,025 and 6,127,026, all of which are incorporated herein by reference. Alternatively, these layers may comprise an ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a re-polished material of an ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. Other suitable materials for the first and second polymer sheets 16, 18 are disclosed in Rudy's U.S. Patent Nos. 4,183,156 and 4,219,945, the entire contents of which are incorporated herein by reference. Other suitable materials for the first and second polymer sheets 16, 18 include: thermoplastic films containing crystalline materials as described in U.S. Patents 4,936,029 and 5,042,176 to Rudy, and polyurethanes containing polyester polyols as disclosed in U.S. Patents 6,013,340, 6,203,868, and 6,321,465 to Bonk et al., which are incorporated herein by reference in their entirety. When selecting the material for the cushioning pad 10, engineering properties such as tensile strength, tensile characteristics, fatigue characteristics, dynamic modulus, and loss tangent can be considered. For example, the thickness of the first and second polymer sheets 16, 18 used to form the cushioning pad 10 can be selected to provide these properties.

[0047] like Figure 3As shown in the optimal configuration, the cushioning pad 10 includes a tension member 30 disposed within an internal cavity 22. The tension member 30 includes a first tension layer 32, a second tension layer 34, and a plurality of tethers 36 extending from the first tension layer 32 to the second tension layer 34 across the internal cavity 22. The tethers 36 connect the first tension layer 32 to the second tension layer 34. Figure 3 The reference numerals are used only to indicate portions of the tie rope 36. The tie rope may also be referred to as a fabric tension member or thread, and may be in the form of a falling thread connecting the first tension layer 32 and the second tension layer 34. The tension member 30 may be formed as an integral textile element with spaced woven textiles.

[0048] The first stretch layer 32 is bonded to the inner surface 42 of the first polymer sheet 16, and the second stretch layer 34 is bonded to the inner surface 46 of the second polymer sheet 18. More specifically, a first surface bond 40 connects the inner surface 42 of the first polymer sheet 16 to the outer surface of the first stretch layer 32. A second surface bond 44 connects the inner surface 46 of the second polymer sheet 18 to the outer surface of the second stretch layer 34 opposite to the first stretch layer 32. In one or more embodiments, no solder resist is used on the inner surface 42 of the first polymer sheet 16 or on the outer surface of the first stretch layer 32, or on the inner surface 46 of the second polymer sheet 18 or on the outer surface of the second stretch layer 34, because the entire interface portion of these surfaces is bonded to each other.

[0049] Under the given inflation pressure of the internal cavity 22, the tether 36 restricts the separation of the first and second polymer sheets. Figure 3 The maximum separation position is shown. The outward force of the pressurized gas in the internal cavity 22 keeps the tether 36 taut, and the tether 36 prevents the tension layers 32, 34 and the polymer sheets 16, 18 from moving further outward relative to each other. However, the tether 36 does not exhibit compression resistance under compressive load. When pressure is applied to the cushioning pad 10, for example due to the dynamic impact force of the wearer during running or other sports, the cushioning pad 10 is compressed, and the polymer sheets 16, 18 collapse (i.e., relax) along with the tether 36, moving proportionally to the pressure applied to the first and second polymer sheets 16, 18 adjacent to a particular tether 36.

[0050] Before connecting the first and second polymer sheets 16, 18 according to the method 210 disclosed in this invention, the tethers 36 of the tension member 30 may all be of initial length and may all be approximately the same length, and as Figure 10 As shown, the first and second tension layers 32 and 34, connected by the tether 36, may each have generally flat outer surfaces 45 and 47 directly above the tether 36. Figure 8 In the middle, rope 36 is shown in a slack state because... Figure 8The tension member 30 is not within the sealed internal cavity and is not subjected to tension. Figure 10 In the middle, rope 36 is also shown in a slack state because... Figure 10 This refers to the tensioning component 30 before it is fixed within the sealed, pressurized internal cavity 22.

[0051] According to the method 210 provided by the present invention, although the tethers 36 initially have the same length, and the outer surfaces 45, 47 of the first and second stretch layers 32, 34 and the outer surfaces 49, 57 of the first and second polymer sheets 16, 18 are substantially flat (i.e., without contour) directly above the tethers before the cushioning pad 10 is manufactured, the manufacturing method 210 produces an inwardly projecting kink 50 that connects the first polymer sheet 16 to the first stretch layer 32 and projects directly from the first polymer sheet 16 toward the second polymer sheet 18 into the cavity region occupied by some of the tethers 36. In fact, in Figure 3 There are multiple inwardly protruding ribbons 50. Each ribbon 50 protrudes further toward the second polymer sheet 18 than the first surface ribbon 40.

[0052] Each link 50 is generated by a corresponding protrusion 51 of the mold component 53 in contact with the first polymer sheet 16 during the manufacturing method 210 disclosed in this invention. Figure 9 A representative mold component 53 is shown, which has a first-pattern protrusion 51 that results in the formation of... Figure 1 The inwardly protruding strap 50 of the cushioning pad 10 shown is of strap style 55A. The mold component 53 is a mold insert and may also be referred to as such or as a gasket. Figure 1 In the top view, the ribbon 50 is indicated by a dashed line because the ribbon 50 protrudes inward from the outer surface 49 shown.

[0053] The reinforcing band 50 creates a recessed groove 52 on the outer surface 49 of the first polymer sheet 16. For clarity, in Figure 1 Only some of the straps 50 and some of the grooves 52 are shown. In the illustrated embodiment, the inwardly projecting straps 50 are only present at the first polymer sheet 16. In other embodiments, manufacturing method 210 may provide inwardly projecting straps at the second polymer sheet 18 as an alternative to or supplement to the inwardly projecting straps 50 at the first polymer sheet 16. When assembled in the sole structure 12, the outer surface 49 of the first polymer sheet 16 may be the proximal side (i.e., the side closest to the foot) of the air bladder 13, such as... Figure 7 As shown, the outer surface 57 of the second polymer sheet 18 can be the distal side of the cushioning pad 10 (i.e., the ground side of the airbag 13). Figure 1As shown, the air bladder 13 is asymmetrical and is used to construct the sole structure for the left foot. In other words, the shape of the air bladder 13 generally follows the shape of the forefoot portion of the left foot. Furthermore, since the first polymer sheet 16 is on the proximal side, it best achieves the desired effect. Figure 6 and Figure 7 The hinge shown is caused by the ligature 50 and the groove 52. However, if flipped so that the second piece 18 is on the proximal side, the cushioning pad 10 can be used in the sole structure constructed for the right foot.

[0054] like Figure 3 As shown, each inwardly projecting tie 50 partially traverses multiple tethers 36. In other words, the tie 50 is directly outside the different tethers 36 and projects inwardly onto those tethers 36. The tethers 36 can be arranged in rows, each row extending laterally between the tension layers 32, 34, or the tethers 36 can extend between the tension layers 32, 34 in any other pattern. Each different tether 36 is aligned with the tie 50. The inwardly projecting tie 50 can traverse different rows of tethers 36 such that different tethers from different rows are aligned with the inwardly projecting tie 50, or the inwardly projecting tie 50 can be directly aligned with a single row. Some inwardly projecting ties 50 can be present between the rows of tethers.

[0055] refer to Figure 3 The plurality of tethers 36 include tethers 36A aligned with the inwardly projecting sash 50 and tethers 36B displaced from the inwardly projecting sash 50. The tether 36A aligned with the inwardly projecting sash 50 deforms due to heat, compressing the cover material of the first tensile layer 32 and / or covering the tether 36A with the compressed cover material of the first tensile layer 32, such that the tether 36A is shorter and / or thicker at the inwardly projecting sash 50 than elsewhere. Such tethers... Figure 3 The tether is designated by reference numeral 36A in the accompanying drawings and may be referred to as an improved tether 36A. However, unless otherwise specified, references to tether 36 herein include both tether 36A and tether 36B.

[0056] like Figure 1 and Figure 3 As shown, when the internal cavity 22 is inflated, the modified tether 36A creates a recessed groove 52 in the outer surface 49 of the first polymer sheet 16. When the inflation pressure of the gas in the internal cavity 22 is sufficient to tension the multiple tethers 36, the inwardly protruding ties 50 define the groove 52 at the outer surface 49 of the first polymer sheet 16. Figure 4 As shown, at each groove 52, the cushioning pad 10 is divided into a first pad portion 61 on one side of the groove 52 and a second pad portion 62 on the other side of the groove 52. The first pad portion 61 is hinged along the groove 52 relative to the second pad portion 62. In other words, the first polymer sheet 16 is hinged on the first side of the inwardly protruding strap 50 ( Figure 4 The first side of the first polymer sheet is represented as part 49A of the outer surface 49, and the second side of the inwardly protruding tie 50 of the first polymer sheet is also represented by the outer surface 49. Figure 4 The second side is represented by part 49B of the outer surface 49. The outer surface 49 is not on the same plane, and the second side is opposite to the first side.

[0057] The tension of the improved tether 36A also creates grooves 56 in the outer surface 57 of the second polymer sheet 18. When the internal cavity 22 expands, the second polymer sheet 18 is recessed inward toward the corresponding grooves 52 and the inwardly protruding ties 50 at each groove 56.

[0058] The physical deformation of the first polymer sheet 16 and the first stretch layer 32, combined with the tension of the modified tether 36A, will result in the groove 52 being deeper than the groove 56, solely due to the tension of the shortened modified tether 36A. Therefore, as Figure 6 As shown, the buffer pad 10 can have a hinged shape, for example, when not under load at the groove 52. In addition, the grooves 52 and 56 together facilitate the hinge (i.e., bending) of the buffer pad 10 at the groove 52, because the total thickness of the buffer pad 10 is reduced at the groove 52, thereby reducing the bending stiffness of the buffer pad at the groove 52.

[0059] The groove 52 thus serves as the bending axis of the cushioning pad 10. For example, in Figure 7 When the sole structure 12 of the footwear article 14 includes a cushioning pad 10, the inwardly protruding strap 50 and the resulting groove 52 can form the bending axes F1, F2, F3, and F4 of the sole structure 12. These bending axes are aligned with the joints of the foot (e.g., metatarsophalangeal joints), thereby increasing the flexibility of the sole structure 12. The bending axes F1, F2, F3, and F4 are... Figure 1 and Figure 6 The additional bending shafts F5 and F6 are generated by the generally longitudinally extending ligature 50 and groove 52. The bending shafts F5 and F6 increase the lateral (i.e., side) flexibility of the cushioning pad 10.

[0060] Reference Figure 3 and Figure 4Each inwardly projecting strap 50 is spaced apart from the second polymer sheet 18, such that the internal cavity 22 narrows but is not closed at the inwardly projecting strap 50, and gas in the internal cavity 22 can still fluidly communicate through the inwardly projecting strap 50. Adjacent to the inwardly projecting strap 50, the first tension layer 32 is separated from the second tension layer 34 by a first distance D1, and the inwardly projecting strap 50 is separated from the second tension layer 34 by a second distance D2. The first distance D1 may be the distance between the tension layers 32, 34 at the tether 36 instead of the modified tether 36A. The second distance D2 may be the minimum distance between the inwardly projecting strap 50 and the second tension layer 34 (i.e., the distance at the narrowest point of the internal cavity 22 below the strap 50). In one embodiment, the manufacturing method 210 may be controlled such that the second distance D2 is between 50% and 80% of the first distance D1. Within this depth range, the ligament produces the most desired amount of joint flex while maintaining fluid communication within the airbag 13 (i.e., no closed sub-cavities are formed within the airbag). For example, factors that may affect the ligament 50 and its protrusion toward the second polymer sheet 18 can be controlled to provide this desired ratio of the second distance D2 to the first distance D1. These factors may include the depth of the protrusion 51 forming the ligament 50, the temperature of the mold insert 53 or other mold components, the temperature of the components of the cushioning pad 10, the vacuum and / or inflation pressure in the mold cavity during manufacturing, the welding frequency power when using radio frequency welding, and other factors.

[0061] Therefore, as Figure 4 As shown, portion 22A of the inner cavity 22 on the first side of the inwardly protruding strap 50 is in fluid communication with portion 22B of the inner cavity 22 on the second side of the inwardly protruding strap 50, the second side being opposite to the first side. The improved tether 36A shown extends below the strap 50 between the two portions 22A, 22B, with a narrow diameter allowing gas to flow around and between the tether 36A, from portion 22A to portion 22B, and vice versa. When compressive force is applied to the cushioning pad 10 (e.g., in contact with footwear 14), Figure 7 During the ground phase (G), gas is allowed to move from portion 22A to portion 22B and from portion 22B to portion 22A. For example, when the foot tilts forward from the heel to the toes during foot strike, gas can be displaced backward from the cushioning pad 10 to a more forward portion of the cushioning pad 10. Thus, during the use of the cushioning pad 10, support and cushioning provided by the internal cavity 22 can be provided in the areas most needed during the use of the cushioning pad 10.

[0062] exist Figure 3In this context, the ribbon 50 designated 50A can be referred to as the first inwardly projecting ribbon, while the ribbon 50 designated 50B can be referred to as the second inwardly projecting ribbon. Like ribbon 50A, ribbon 50B connects the first polymer sheet 16 to the first tension layer 32, projects inwardly from the first polymer sheet 16 toward the second polymer sheet 18, and at least partially passes through the tether 36A of the tension member 30. Figure 1 , 3 Combining with 4, it is clear that the second inwardly protruding link 50B is... Figure 5 The cross-section of the inner cavity 22 intersects with the first inwardly projecting ribbon 50A and is spaced apart from the second polymer sheet 18, causing the inner cavity 22 to narrow but not to be closed at the second inwardly projecting ribbon 50B. Therefore, the gas in the inner cavity 22 is in fluid communication across the second inwardly projecting ribbon 50B.

[0063] Figure 10 An exploded view shows the components of the buffer pad 10, which are located between the components of the mold 66. More specifically, the mold components of the mold 66 include a first mold portion 66A, a second mold portion 66B, and a mold insert 53. Figure 11 A component of a buffer pad 10 is shown in a mold cavity 68 of a mold 66 defined by mold components, wherein the mold 66 is in the closed position.

[0064] Figure 15 and Figure 16 An alternative embodiment of the cushioning pad 110 is shown, which has many of the same features as the cushioning pad 10 and is indicated by the same reference numerals. For example, first and second polymer sheets 16, 18 are joined together at a peripheral link 20 to form an air bladder 113, which surrounds the internal cavity 22 and retains gas within the internal cavity. Figure 17 As shown and as described with respect to cushioning pad 10, stretching member 30 is disposed in internal cavity 22 and fixed to the inner surface of polymer sheets 16, 18. Figure 15 As shown, when used in, for example Figure 7 In a sole structure such as 12, the outer surface 49 of the first polymer sheet 16 is proximal to the air bladder 113, while the outer surface 57 of the second polymer sheet 18 is distal to the air bladder 113. This results in the deeper groove 52 of the cushioning pad 110 (i.e., deeper than groove 56) and... Figure 7 The bending tendency at groove 52, as shown, matches the bending movement of the foot.

[0065] In contrast to cushioning pad 10 and airbag 13, cushioning pad 110 and airbag 113 are symmetrical in overall shape at their outer periphery (i.e., at the peripheral ligament 20), with multiple inwardly projecting ligaments 50 arranged in a symmetrical pattern 155A about the axis of symmetry 115 of airbag 113 near the airbag 113. Figure 16 The corresponding groove 56 on the far side shown is also arranged symmetrically around the axis of symmetry 115. Figure 16 Only some grooves 56 are marked in the text. (As for...) Figure 18 As described, the symmetrical pattern 155A of the ligature 50 allows the cushioning pad 110 to be used to construct either a sole structure for the right foot or a sole structure for the left foot without any difference in the feel of the wearer's foot.

[0066] The multiple inwardly projecting straps 50 of the airbag 113 are marked with alphanumeric identifiers (e.g., 50C1, etc.) to distinguish the straps 50. The straps 50 include a first central strap 50H and a second central strap 50L. The first central strap 50H extends across an axis of symmetry 115, and the second central strap 50L also extends across an axis of symmetry 115 and is positioned substantially parallel to and spaced apart from the first central strap 50H. Each central strap 50H and 50L is symmetrical with respect to the axis of symmetry 115. The ligature 50 also includes symmetrical ligature pairs, such as: ligatures 50C1 and 50C2; ligatures 50D1 and 50D2; ligatures 50E1 and 50E2; ligatures 50F1 and 50F2; ligatures 50G1 and 50G2; ligatures 50I1 and 50I2; ligatures 50J1 and 50J2; ligatures 50K1 and 50K2; ligatures 50M1 and 50M2; and ligatures 50N1 and 50N1.

[0067] The ligature 50 includes a first set of ligatures 50G1, 50H, 50F2 and a second set of ligatures 50K1, 50L, 50J2, which are spaced apart from each other and have parallel segments. For example, ligatures 50G1 and 50K1 are parallel segments, as are ligatures 50F2 and 50J2. The first set of ligatures 50G1, 50H, 50F2 forms a first hinge axis A1, and the second set of ligatures 50K1, 50L, 50J2 forms a second hinge axis A2. For example, when the cushioning pad 110 bends along its axis at an angle 117B (i.e., counterclockwise) relative to the first axis of symmetry 115, axes A1 and A2 both act as bending axes. When the airbag 113 is rotated to this position, axes A1 and A2 will be substantially perpendicular to the first axis of symmetry 115. Figure 15 The original position of the axis of symmetry 115 is shown.

[0068] The ligature 50 also includes a third set of ligatures 50F1, 50H, 50G2 and a fourth set of ligatures 50J1, 50L, 50K2 spaced apart from the third set and having parallel segments. For example, ligatures 50G2 and 50K2 are parallel segments, as are ligatures 50F1 and 50J1. The third set of ligatures 50F1, 50H, 50G2 forms a third hinge axis A3, while the fourth set of ligatures 50J1, 50L, 50K2 forms a fourth hinge axis A4. For example, when the cushioning pad 110 flexes at an angle 117A relative to the axis of symmetry 115, axes A3 and A4 both serve as bending axes, with angle 117A having the same value as angle 117B, but in a different direction relative to the axis of symmetry 115 (i.e., clockwise). If the airbag 113 rotates in this direction, axes A3 and A4 will be substantially perpendicular to the ligature. Figure 15 The original position of the axis of symmetry 115 shown.

[0069] like Figure 15 As shown, the link 50 includes a first central link 50H extending on the axis of symmetry 115 and a pair of symmetrical forward links 50F1 and 50F2, which extend from a first end 118 and a second end 119 of the first central link 50H, respectively. The link 50 also includes a pair of symmetrical backward links 50G1 and 50G2, which extend from a first end 118 and a second end 119 of the first central link 50H, respectively.

[0070] The link 50 further includes: a second central link 50L extending across the axis of symmetry 115 and spaced apart from the first central link 50H; and a pair of symmetrical forward links 50J1, 50J2 extending from a first end 120 and a second end 121 of the second central link 50L, respectively. The link 50 also includes a pair of symmetrical backward links 50K1, 50K2 extending from a first end 120 and a second end 121 of the second central link 50L, respectively.

[0071] When the buffer pad 110 bends along an axis arranged counterclockwise from the axis of symmetry 115 at a first angle 117B, the buffer pad 110 is hinged at the first and second bending axes A1, A2; when the buffer pad 110 bends along an axis arranged clockwise from the axis of symmetry 115 at a first angle 117A, it is hinged at the third and fourth bending axes A3, A4. Therefore, referring to... Figure 18Cushioning pads 110A and 110B are identical to cushioning pad 110, except for their orientation relative to their respective sole structures 12R and 12L. By fixing cushioning pad 110A in a position within the sole structure 12R configured for the right foot, in which cushioning pad 110A is rotated clockwise by a first angle 117B relative to the longitudinal bending axis LA of the sole structure 12R, cushioning pad 110A will hinge (i.e., bend) along the first axis A1 and the second axis A2 when the right foot is dorsiflexed. By fixing cushioning pad 110B in a position within the sole structure 12L configured for the left foot, in which cushioning pad 110B is rotated counterclockwise by a first angle 117A relative to the longitudinal bending axis LA of the sole structure 12L, cushioning pad 110B will hinge along the third axis A3 and the fourth axis A4 when the left foot is dorsiflexed. Alternatively, when fixed to the right-foot sole structure 12R, the cushioning pad 110A can rotate counterclockwise, and when fixed to the left-foot sole structure 12L, the cushioning pad 110B can rotate clockwise. In this case, the cushioning pad 110A of the right-foot sole structure 12R will be hinged along bending axes A3 and A4, and the cushioning pad 110B of the left-foot sole structure 12L will be hinged along bending axes A1 and A2 during dorsiflexion of the right and left feet. In this way, by using the same construction of the cushioning pad 110 in both the right-foot and left-foot footwear, economies of scale can be achieved in manufacturing.

[0072] exist Figure 19 The flowchart illustrates a method 210 for manufacturing a cushioning pad such as cushioning pad 10, and refers to... Figure 10 and Figure 11 The following description is provided. Method 210 can begin at block 212, which secures a first mold insert 53 having a first protrusion pattern to a first mold portion 66A. For example, the first mold insert 53 has an opening 70 for receiving a fastener 72. The fastener 72 extends into an opening 74 in the first mold portion 66A to secure the first mold insert 53 to the first mold portion 66A. The opening 74 is in a recess 75 of the first mold portion 66A, and the insert 53 is fitted within the recess 75 such that surface 76 is flush with the adjacent surface 78 of the first mold portion 66A. The openings 70, 74 and the fastener 72 may be, for example, threaded. When arranged as described in block 212, the mold insert 53 is thus in and partially defines the mold cavity 68.

[0073] Next, in frame 214, before placing the component of the cushioning pad 10 into the open mold cavity 68, the component of the cushioning pad 10, the mold component, or both, can be preheated to help accelerate the subsequent thermoforming process via assembly frames 218, 220. In an embodiment of method 210, where the mold component having the protrusion that creates the inwardly projecting kink is one of mold portions 66A or 66B instead of the mold insert 53, method 210 may alternatively begin from frame 214.

[0074] Then, in frame 216, the first and second polymer sheets 16, 18 and the stretching member 30 are placed in the mold cavity 68, and the first stretching layer 32 is positioned near the first polymer sheet 16, the second stretching layer 34 is positioned near the second polymer sheet 18, and a plurality of tethers 36 connect the first stretching layer to the second stretching layer. Frame 216 may include placing the first and second polymer sheets 16, 18 and the stretching member 30 between open mold portions 66A, 66B. This can be achieved by using a shuttle frame (not shown) that keeps the respective components of the cushioning pad 10 aligned with each other and with the mold portions 66A, 66B, 53, as shown. Figure 10 As shown. In one embodiment, when placed in the mold cavity 68, one or both of the first and second polymer sheets 16, 18 may have already been bonded to the corresponding stretch layers 32, 34 of the stretch member 30, for example by lamination or by using an adhesive. In such an embodiment, the frame 220 is not necessary. If only one of the first and second polymer sheets 16, 18 is laminated to the corresponding stretch layers 32, 34 before the member is placed in the mold cavity 68 and thermoformed, the finished cushioning pad 10 will tend to curl along its longitudinal axis toward the unlaminated side. Alternatively, as Figure 10 As shown, when the first and second polymer sheets 16, 18 are placed in the mold cavity 68, they may not yet be bonded to the stretching member 30. Once the components of the cushioning pad 10 are positioned, one or both of the mold components 66A, 66B translate toward the other mold component to close the mold cavity 68.

[0075] Next, in box 218, as follows Figure 11As shown, the first polymer sheet 16 and the second polymer sheet 18 are adapted to components of the mold 66. For example, the outer surface 49 of the first polymer sheet 16 is adapted to the surface 76 of the mold insert 53. The surface 76 includes protrusions 51. A portion of the outer surface 49 of the first polymer sheet 16 is adapted directly to the mold surface 78 of the first mold portion 66A adjacent to the mold insert 53. In this way, the first polymer sheet 16 is adapted to the surface 76 including the protrusions 51, thereby pressing the first polymer sheet 16 against the second polymer sheet 18 at the protrusions 51, which are located directly outside some of the plurality of tethers 36. In frame 218, the outer surface 57 of the second polymer sheet 18 is also adapted to the mold surface 80 of the second mold portion 66B, as shown. Figure 11 As shown. Adapting polymer sheets 16, 18 to surfaces 76, 78, 80 may include evacuating the mold cavity 68 to pull the sheets 16, 18 toward the surfaces 76, 78, 80. Alternatively or additionally, adapting polymer sheets 16, 18 to surfaces 76, 78, 80 may include pressurizing the mold cavity 68 to press the polymer sheets 16, 18 toward the surfaces 76, 78, 80.

[0076] In frame 218, after or simultaneously with the first and second polymer sheets 16, 18 conforming to surfaces 76, 78, 80, in frame 220, the first stretch layer 32 can be thermally bonded to the first polymer sheet 16, and the second stretch layer 34 can be thermally bonded to the second polymer sheet 18, opposite to the first stretch layer 32. In addition to the vacuum and / or pressure of the mold cavity 68, heating of the polymer sheets 16, 18, stretch layers 32, 34, and / or mold components 53, 66A, 66B also enables thermal bonding at surface ties 40, 44 and inwardly projecting ties 50. When the components are cooled, the ties 40, 44, 50 remain. The conformation in frame 218 and the thermal bonding in frame 220 can be referred to as thermoforming, and inwardly projecting ties 50 are created at the protrusion 51 connecting the first polymer sheet 16 and the first stretch layer 32 and partially traversing the plurality of tethers 36, as shown. Figure 3 As shown, the inwardly projecting ribbon 50 protrudes toward the second polymer sheet 18, but remains spaced from the second stretch layer 34 and the second polymer sheet 18.

[0077] Thermal bonding of frame 220 may include heating the first polymer sheet 16 and the second polymer sheet 18 before placing them into mold cavity 68. Alternatively or additionally, thermal bonding may include heating one or more of mold assemblies 53, 66A, 66B, or performing radio frequency welding via mold 66.

[0078] Following or simultaneously with frame 220, method 210 may include frame 222, which joins the first polymer sheet 16 and the second polymer sheet 18 at the peripheral link 20 such that the first polymer sheet 16 and the second polymer sheet 18 at least partially surround the internal cavity 22 containing the stretching member 30. For example, joining the first polymer sheet 16 and the second polymer sheet 18 at the peripheral link 20 in frame 222 may include compressing the first polymer sheet 16 and the second polymer sheet 18 between the first mold portion 66A and the second mold portion 66B in a closed position, such as... Figure 11 As shown. A small portion of the periphery of the first and second polymer sheets 16, 18 may not be bonded, for example at the air inlet 82 of the sheet molded in frames 218 and 220.

[0079] Following frame 222, the mold cavity 68 can be opened in frame 224 by translating one or both of the mold portions 66A and 66B away from each other. The buffer pad 10 can then be removed from the mold cavity 68 in frame 226.

[0080] In box 228, it can be, for example, by... Figure 1 The inflation port 82 inflates the internal cavity 22 to the required inflation pressure. For example, a filling tube may be fitted into the inflation port 82, or it may be integrally formed from sheets 16, 18 at the inflation port 82. Excess material around the sheets 16, 18 surrounding the peripheral ties 20 may be trimmed before or after inflating the internal cavity 22 in frame 228. Gas, such as air, may be dispensed from a pressurization source or pumped from a pressurization source into the internal cavity 22 through the inflation port 82. In some embodiments, the internal cavity 22 does not expand but simply holds the gas at atmospheric pressure.

[0081] The internal cavity 22 is sealed within frame 230. In the illustrated embodiment, this can be achieved by sealing the inflation port 82, for example by thermally bonding pieces 16, 18 together at the inflation port 82, or by plugging the inflation port 82. Figure 1 In this configuration, sheets 16, 18 and any filling tubes have been trimmed, and the inflation port 82 has been sealed. Once frame 230 is complete, cushioning pad 10 is fully manufactured and ready to be assembled into footwear item 14. If the internal cavity 22 is inflated to sufficient pressure, the multiple lacing straps 36 will tighten, thereby forming a groove 52 on the outer surface 49 of the inwardly projecting laces 50 of the first polymer sheet 16, thus allowing the cushioning pad 10 to... Figure 6 It is hinged as shown, wherein the groove 52 forms a bending shaft.

[0082] Method 210 can be used to manufacture a cushioning pad 110 with a symmetrical construction. In such an embodiment, method 200 may include a block 232, which holds the cushioning pad 110 (in...) Figure 18 The method 210 is further comprising a frame 234 that attaches a second cushioning pad 110B, configured identically to the cushioning pad 110A (and as described in the invention with respect to the cushioning pad 110), to a second sole structure 12L configured for the left foot, such that the axis of symmetry 115 of the second cushioning pad 110B is rotated counterclockwise (or clockwise if the cushioning pad 110A of the first sole structure 12R is rotated counterclockwise) by a first angle 117A. The method 210 may also include a frame 234 that attaches a second cushioning pad 110B, configured identically to the cushioning pad 110A (and as described in the invention with respect to the cushioning pad 110), to a second sole structure 12L configured for the left foot, such that the axis of symmetry 115 of the second cushioning pad 110B is rotated counterclockwise (or clockwise if the cushioning pad 110A of the first sole structure 12R is rotated counterclockwise) by a first angle 117A. Figure 18 As shown in the construction, cushioning pad 110A is hinged along axes A1 and A2, and cushioning pad 110B is hinged along axes A3 and A4. Therefore, when the sole structures 12R and 12L are assembled in footwear worn on the right and left feet of the wearer, respectively, cushioning pads 110A and 110B are generally aligned with the joints of the right foot and the left foot in the same manner.

[0083] It should be understood that, despite Figure 10-11 In this design, the mold component having protrusions 51 forming inwardly projecting ribbons 50 is a mold insert 53. One or both of the mold portions 66A and 66B may have one or more protrusions, and a mold insert is not required. However, using a mold insert allows for the production of cushioning pads with different ribbon patterns, thereby reducing mold costs. For example, the same mold portions 66A and 66B can be used with different tool inserts to produce cushioning pads with different ribbon patterns. Figure 12 A mold portion 66AA for a cushioning pad used in a full-length sole structure is shown. Mold portion 66AA can be used in a mold similar to mold 66, located in the same position as mold portion 66A. Mold portion 66AA has a recess 75A similar to a groove 75, at which a mold insert can be secured by fasteners extending into an opening 74 similar to a mold insert 53. Figure 13 A first mold insert 53A with a first pattern of protrusion 51 is shown. The first mold insert 53A is fixed in a mold portion 66AA within a groove 75A. When the mold portion 66AA and the first mold insert 53A are used in a mold according to frames 212 to 230 of manufacturing method 210, a cushioning pad of a full-length sole component having a first ribbon pattern (i.e., a ribbon pattern generated by the pattern of the protrusion 51 of the mold insert 53A) will be manufactured according to method 210.

[0084] Figure 14A second mold insert 53B with a second pattern of protrusion 51 is shown. The shape or size of the protrusion 51 of the second mold insert 53B differs from that of the protrusion 51 of the first mold insert 53A, such that the second pattern of the protrusion 51 differs from the first pattern of the protrusion. After manufacturing a cushion with a first band pattern (i.e., a first pattern of an inwardly projecting band corresponding to the protruding first pattern of the first mold insert 53A), method 210 may include frame 236 for removing the first mold insert 53A from the mold cavity 68. Then, in frame 238, as described with respect to the mold insert 53A, the second mold insert 53B may be secured to the mold portion 66AA using fasteners 72 extending through openings 70, 74. Now, the second mold insert 53B is placed in the mold cavity 68. Steps 212 to 230 of method 210 can now be repeated to manufacture a second cushioning pad, which is a full-length sole component whose banding pattern differs from that of the first full-length sole component produced using the mold insert 53A. As described in the invention, the different banding pattern is the pattern of the inwardly projecting band 50, rather than a different pattern corresponding to the protrusion of the second mold insert 53B. For example, in repeating steps 212 to 230, step 216 is repeated by arranging subsequent first polymer sheets, subsequent second polymer sheets, and subsequent stretching members in the mold cavity 68, and by arranging the subsequent stretching members between the subsequent first polymer sheets and the subsequent second polymer sheets. Box 218 is repeated by adapting subsequent first and second polymer sheets to the second mold insert 53B and another mold component (e.g., a mold component similar to mold component 66B), pressing the subsequent first polymer sheet toward the subsequent second polymer sheet at a second protrusion 51 (i.e., at a protrusion 51 of the second mold portion 53B), the second protrusion being directly outside the subsequent stretching member. For example, box 220 is repeated by thermally bonding the first stretching layer of the subsequent stretching member to the subsequent first polymer sheet and thermally bonding the second stretching layer of the subsequent stretching member to the subsequent second polymer sheet, thereby creating a second inwardly projecting band at the second protrusion, thus partially traversing the subsequent stretching member. Due to the second mold insert 53B, the same mold portion and mold cavity thus provide a second cushioning pad with a banding pattern different from the first cushioning pad, and simply by removing the first mold insert 53A and replacing it with the second mold insert 53B.

[0085] To aid in and clarify the description of the various embodiments, various terms are defined herein. Unless otherwise stated, the following definitions apply throughout the specification (including the claims). Furthermore, all references cited are incorporated herein in their entirety.

[0086] "Footwear articles", "manufacturing footwear articles" and "footwear" can be considered as machines and articles. Assembled, wearable footwear articles (e.g., shoes, sandals, boots, etc.) and discrete components of footwear articles (e.g., midsoles, outsoles, uppers, etc.) are referred to in the present invention, in the singular or plural form, as "footwear articles" or "footwear".

[0087] The terms “a,” “single,” “the,” “at least one,” and “one or more” are used interchangeably to indicate the presence of at least one. Multiple such items may exist unless the context explicitly indicates otherwise. Unless explicitly stated otherwise or given by the context (including the appended claims), in all cases, all numerical values ​​(e.g., quantities or conditions) of parameters in this invention should be understood to be modified by the term “about,” regardless of whether “about” actually appears before the numerical value. “About” indicates that the numerical value allows for some slight imprecision (achieving accuracy in some way; approximating or reasonably approaching the value; close). If the imprecision provided by “about” is not otherwise understood in the art in this ordinary sense, then “about” as used in this invention indicates a variation that can at least be caused by ordinary methods of measuring and using such a parameter. As used in the specification and appended claims, unless otherwise stated, a value is considered “about” equal to the specified value if it is neither greater than five percent nor less than five percent of the specified value. Furthermore, the disclosure of a range should be understood to specifically disclose all values ​​within that range and further subdivisions of the range.

[0088] The terms “comprising,” “including,” and “having” are inclusive, thus specifying the presence of the stated feature, step, operation, element, or component, but not excluding the presence or addition of one or more other functions, steps, operations, elements, or components. Where possible, the order of steps, processes, and operations may be changed, and other or alternative steps may be employed. As used herein, the term “or” includes any and all combinations of the associated listed items. The term “any” should be understood to include any possible combination of the referenced items, including “any one” of the referenced items. The term “any” should be understood to include any possible combination of the claims referenced in the appended claims, including “any one” of the referenced claims.

[0089] For the sake of adaptability and convenience, directional adjectives corresponding to the indicated embodiments may be used throughout the detailed description. Those skilled in the art will recognize that terms such as “above,” “below,” “above,” “below,” “top,” and “bottom” may be used to describe graphic-related features without limiting the scope of the invention as defined in the claims.

[0090] The term "longitudinal" refers to the direction in which a component extends. For example, the longitudinal direction of a footwear item extends between the forefoot and heel areas. The terms "forward" or "front" are used to indicate the general direction from the heel area to the forefoot area, and the terms "backward" or "rear" are used to indicate the opposite direction, from the forefoot area to the heel area. In some cases, a component can be identified by its longitudinal axis and the longitudinal direction along that axis. The longitudinal direction or longitudinal axis can also be referred to as the front-back direction or front-back axis.

[0091] The term "lateral" refers to the direction in which the width of an extending component is measured. For example, the lateral aspect of footwear extends between the outer and inner sides of the footwear. Lateral or transverse axis can also be referred to as sideways or lateral axis, or mid-outer direction or mid-outer axis.

[0092] The term "vertical" refers to a direction that is generally perpendicular to both the horizontal and vertical directions. For example, when a sole structure is laid flat on the ground, the vertical direction can extend upwards from the ground. It will be understood that each of these directional adjectives can be applied to the various components of a sole structure. The term "upward" or "upper" refers to a vertical direction pointing towards the top of a component, which may include the instep, fastening area, and / or upper. The term "downward" or "downward" refers to a vertical direction opposite to the upward direction, pointing towards the bottom of the component, and typically may refer to the bottom of the sole structure of footwear articles.

[0093] The term "inside" in footwear, such as shoes, refers to the portion of the space occupied by the wearer's foot when the footwear is worn. The term "inner side" of a component refers to the side or surface of the assembled footwear that the component faces (or will face) the footwear. The term "outer side" or "outer side" of a component refers to the side or surface of the assembled footwear that the component is away from (or will be away from) the footwear. In some cases, other components may be located between the inner side of a component and the space between the inner side of the assembled footwear. Similarly, other components may be located between the outer side of a component and the space between the outer side of the assembled footwear. Furthermore, the terms "inward" and "inner" refer to a direction toward the interior of a footwear component or article, such as a shoe, while the terms "outward" and "outer" refer to a direction toward the exterior of a footwear component or article, such as a shoe. Additionally, the term "proximal" refers to the direction closer to the center of the footwear component or toward the foot when the user inserts their foot into the footwear. Similarly, the term "distal" refers to the direction away from the center of the footwear component or away from the foot when the user inserts their foot into the footwear. Therefore, the terms proximal and distal can be understood as opposing terms describing relative spatial positions.

[0094] Although various embodiments have been described, this description is intended to be exemplary and not restrictive, and it will be apparent to those skilled in the art that many more embodiments and implementations are possible within the scope of these embodiments. Unless specifically limited, any feature of any embodiment may be combined with or substituted with any other feature or element in any other embodiment. Therefore, the embodiments are not limited except by means of the appended claims and their equivalents. Similarly, various modifications and changes may be made within the scope of the appended claims.

[0095] Although several modes for implementing many aspects of this teaching have been described in detail, those skilled in the art to which this teaching relates will recognize that various alternative aspects for implementing this teaching are within the scope of the appended claims. All that is included in the foregoing description or shown in the accompanying drawings should be construed as illustration and example of the entire range of alternative embodiments, which will generally be recognized by those of ordinary skill in the art as being structurally and / or functionally equivalent or otherwise apparent based on the included content, and are not limited to those embodiments explicitly depicted and / or described.

Claims

1. A type of footwear, comprising: The sole structure includes a foam insole, an air bladder, and a stretching member, wherein the air bladder and the stretching member are at least partially enclosed in the foam insole, and the air bladder, the stretching member, and the foam insole together serve as the midsole of the sole structure. The airbag is fixed to the bottom of the foam shoe, surrounds the internal cavity, and retains gas in the internal cavity; The stretching component is disposed in the internal cavity and includes a stretching layer and a plurality of tethers connecting the stretching layer. The stretching layer is connected to the inner surface of the bladder, such that the tethers cross the internal cavity. The airbag has an inwardly protruding strap that connects the inner surface of the airbag to the tension member, protrudes inward into the internal cavity, and partially passes through the plurality of tethers, such that the airbag narrows at the inwardly protruding strap, and the gas in the internal cavity is in fluid communication across the inwardly protruding strap. The inwardly protruding rib establishes the bending axis of the sole structure; Among them, multiple inwardly protruding ribs are arranged in a symmetrical pattern about the axis of symmetry of the airbag near the airbag; The plurality of inwardly protruding straps include a first set of straps and a second set of straps, which are spaced apart from each other and have parallel segments. When the airbag is fixed to the foam shoe sole and the axis of symmetry is rotated counterclockwise by a first angle from the longitudinal bending axis of the footwear, the first set of straps and the second set of straps establish a hinge axis.

2. The footwear article according to claim 1, wherein: The airbag includes a first polymer sheet and a second polymer sheet, which are joined together at a peripheral flange to seal the internal cavity. The stretch layer includes a first stretch layer connected to the first polymer sheet and a second stretch layer connected to the second polymer sheet; The inwardly projecting ribbon protrudes inward from the first polymer sheet, and the inwardly projecting ribbon is spaced apart from the second polymer sheet; When the inflation pressure of the gas in the internal cavity is sufficient to tension the plurality of laces, the inwardly projecting laces define a groove on the outer surface of the first polymer sheet, and the sole structure is hinged at the groove.

3. The footwear article according to any one of claims 1-2, wherein, The airbag is fixed to the forefoot area of ​​the bottom layer of the foam shoe.

4. Footwear according to any one of claims 1-2, wherein: The outer flange forms the periphery of the airbag.

5. Footwear according to any one of claims 1-2, wherein, The outer flange forms the periphery of the airbag, and the airbag is symmetrical in overall shape around the periphery.

6. The footwear article according to claim 1 or 2, wherein, The plurality of inwardly projecting ligaments also include: A third set of straps and a fourth set of straps spaced apart from each other and having parallel segments; the third set and the fourth set establish a hinge axis when the airbag is fixed to the foam shoe sole and the axis of symmetry is rotated clockwise by a first angle from the longitudinal bending axis of the footwear.

7. The footwear article according to claim 2, wherein: The airbag has a plurality of inwardly protruding grooves on its distal side, and the plurality of inwardly protruding grooves on the distal side are arranged symmetrically around the axis of symmetry. and The groove defined by the inwardly projecting ligament is deeper than the inwardly projecting groove on the distal side.

8. The footwear article according to claim 7, wherein: The inner surface of the first polymer sheet and the entire interface portion of the first stretch layer are bonded to each other; The inner surface of the second polymer sheet and the entire interface portion of the second stretch layer are bonded to each other; The plurality of inwardly protruding ribbons are located at the first polymer sheet; and The plurality of inwardly protruding grooves are located at the second polymer sheet.

9. The footwear article according to claim 2, wherein: The inner surface of the first polymer sheet and the entire interface portion of the first stretched layer are bonded to each other; and The inner surface of the second polymer sheet and the entire interface portion of the second stretch layer are bonded to each other.

10. The footwear article according to claim 9, wherein: The second stretch layer is spaced a first distance from the first stretch layer at a location adjacent to the inwardly projecting ligature; The inwardly projecting ribbon is separated from the second stretch layer by a second distance; and The second distance is between 50% and 80% of the first distance.

11. The footwear article according to any one of claims 1-2, wherein, A portion of the internal cavity on the first side of the inwardly projecting ligament is in fluid communication with a portion of the internal cavity on the second side of the inwardly projecting ligament, the second side being opposite to the first side.

12. Footwear according to any one of claims 1-2, wherein: The plurality of tethers include tethers aligned with the inwardly projecting ties and tethers displaced from the inwardly projecting ties. and The tether aligned with the inwardly projecting ligature is shorter and thicker than the tether that has shifted away from the inwardly projecting ligature.

13. The footwear article according to claim 2, wherein, When the internal cavity expands, the second polymer sheet is recessed inward at each groove of the second polymer sheet toward the corresponding groove of the first polymer sheet and the inwardly projecting ribbon.

14. The footwear article according to claim 13, wherein, The groove defined by the inwardly projecting ribbon is deeper than the groove on the second polymer sheet.

15. The footwear article according to claim 1 or 2, wherein, The airbag extends in the forefoot area of ​​the foam shoe sole, but not in the heel area of ​​the foam shoe sole.

16. A method for manufacturing footwear, wherein, The footwear article is the footwear article according to any one of claims 1-15.

17. A type of footwear, comprising: The sole structure includes a foam insole, an air bladder, and a stretching component, wherein the air bladder, the stretching component, and the foam insole together serve as the midsole of the sole structure. The airbag is fixed to the bottom of the foam shoe, surrounds the internal cavity, and retains gas in the internal cavity; The stretching component is disposed in the internal cavity and includes a stretching layer and a plurality of tethers connecting the stretching layer. The stretching layer is connected to the inner surface of the bladder, such that the tethers cross the internal cavity. The airbag has an inwardly protruding strap that connects the inner surface of the airbag to the tension member, protrudes inward into the internal cavity, and partially passes through the plurality of tethers, such that the airbag narrows at the inwardly protruding strap, and the gas in the internal cavity is in fluid communication across the inwardly protruding strap. The inwardly protruding rib establishes the bending axis of the sole structure; The airbag includes a first polymer sheet and a second polymer sheet, which are joined together at a peripheral flange to seal the internal cavity. An inwardly protruding ribbon protrudes from the first polymer sheet and is spaced apart from the second polymer sheet. The stretching layer includes a first stretching layer and a second stretching layer; Wherein, the entire outer surface of the first stretch layer is bonded to the inner surface of the first polymer sheet; The entire outer surface of the second stretch layer is bonded to the inner surface of the second polymer sheet; Among them, multiple inwardly protruding ribs are arranged in a symmetrical pattern about the axis of symmetry of the airbag near the airbag; The plurality of inwardly protruding straps include a first set of straps and a second set of straps, which are spaced apart from each other and have parallel segments. When the airbag is fixed to the foam shoe sole and the axis of symmetry is rotated counterclockwise by a first angle from the longitudinal bending axis of the footwear, the first set of straps and the second set of straps establish a hinge axis.

18. The footwear article according to claim 17, wherein: The second stretch layer is spaced a first distance from the first stretch layer at a location adjacent to the inwardly projecting ligature; The inwardly protruding ribbon is separated from the second stretch layer by a second distance; The second distance is within 50% to 80% of the first distance.

19. Footwear articles according to any one of claims 17-18, wherein: When the internal cavity expands, the second polymer sheet is recessed inward at each groove of the second polymer sheet toward the corresponding groove of the first polymer sheet and the inwardly projecting ribbon; The groove defined by the inwardly projecting ribbon is deeper than the groove on the second polymer sheet.

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