Internal Bead-Layer Airbag Bladder for Visible Cushioning
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Solution Overview
Problem
Existing bladders in footwear and apparel lack the ability to provide both aesthetic and performance customization while maintaining structural integrity, particularly when exposed or partially visible.
Innovation Solution
A bladder system with an internal bead layer is produced using a manufacturing process that includes extrusion of a bead layer onto polymeric films, followed by thermoforming and recycling of excess material to form a bladder with a customizable pattern and performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bladders are concealed within a sole structure to provide cushioning, then structural integrity and cushioning performance are improved, but aesthetic customization and visibility are worsened
Solution Approach 1:
The bead layer is nested within the bladder structure, specifically positioned between the polymeric films and the compressible material, allowing aesthetic customization without compromising the structural integrity provided by the concealed bladder configuration
2Adaptability or versatility
If bladders are made visible through large openings in the midsole, then aesthetic customization and visibility are improved, but structural integrity and protection are worsened
Solution Approach 1:
The bladder is constructed as a composite structure with polymeric films forming the outer layer and a bead layer positioned internally, creating a composite material system that provides both aesthetic customization through visible patterns and structural integrity through the multi-layer construction
3Ease of manufacture
If bladders use traditional single-material construction, then manufacturing simplicity is improved, but performance customization and functionality are worsened
Solution Approach 1:
The bladder is segmented into distinct functional layers: an outer polymeric film layer providing structural integrity, an internal bead layer providing cushioning and aesthetic customization, and a compressible material layer providing additional cushioning. This segmentation allows independent optimization of each layer for its specific function while maintaining manufacturing feasibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system allows for bladders with customizable aesthetics and performance characteristics, enhancing structural integrity and recyclability, while maintaining visibility and functionality.
Implementation Method 1
an extrusion system configured to deposit a bead layer onto the first interior surface
Implementation Method 2
a vacuum forming press configured to form the first barrier sheet and the second barrier sheet into a three-dimensional chamber
Data Source
AI summary
A bladder for a wearable article, the bladder comprising a first barrier sheet including a first surface and a second surface disposed on an opposite side from the first surface, a second barrier sheet including a third surface and a fourth surface disposed on an opposite side from the third surface and attached to the second surface of the first barrier sheet to define a chamber, and a bead layer disposed on at least one of the second surface or the fourth surface within the chamber.