Fluid-Filled Chamber Tensile Bonding for Shape Retention
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Solution Overview
Problem
Existing methods for manufacturing fluid-filled chambers in footwear midsoles are inefficient and lack effective mechanisms to maintain the shape and integrity of the chambers under pressure.
Innovation Solution
A fluid-filled chamber configuration comprising a barrier and a tensile element, where the tensile element is secured to the barrier at discrete bond areas, with bond inhibitors preventing unwanted bonding, allowing the chamber to maintain its shape under pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods (two-film technique, thermoforming, blowmolding) are used to form fluid-filled chambers, then chambers can be produced, but the manufacturing process is inefficient and complex
Solution Approach 1:
The manufacturing process is segmented into distinct stages: forming the barrier with bonded portions, inserting the tensile element into the interior void, and sealing the chamber. This segmentation allows each component to be prepared independently and assembled systematically, improving manufacturing efficiency and reducing process complexity compared to traditional one-step methods.
Solution Approach 2:
The barrier is pre-formed with bonded portions created before the tensile element is inserted. This preliminary action allows the barrier structure to be established in advance, simplifying the subsequent assembly process and enabling more efficient manufacturing workflows.
2Strength
If fluid is pressurized inside the chamber, then cushioning performance is improved, but the chamber loses its shape and integrity
Solution Approach 1:
The tensile element acts as a counterbalancing structure that resists the outward pressure exerted by the pressurized fluid inside the chamber. This counteracting force maintains the chamber's shape and structural integrity while allowing the fluid to provide cushioning performance, effectively resolving the contradiction between strength and shape retention.
Solution Approach 2:
The barrier is formed as a flexible membrane with bonded portions that can contain pressurized fluid while maintaining structural integrity. The thin film structure allows the chamber to deform slightly under pressure for cushioning while the bonded portions prevent complete loss of shape, enabling both cushioning performance and shape retention.
3Strength
If the tensile element is secured to the barrier in continuous contact, then structural integrity is improved, but manufacturing complexity increases due to bonding requirements
Solution Approach 1:
The bonding between the tensile element and barrier is segmented into discrete bonded portions rather than continuous contact. This segmentation reduces the complexity of the bonding process by limiting it to specific areas, while still providing sufficient structural integrity through strategically placed bond zones.
Solution Approach 2:
The bonding between the tensile element and barrier is applied locally at specific portions rather than uniformly across the entire surface. This local quality approach maintains structural integrity at critical locations while simplifying the overall manufacturing process by reducing the extent of bonding required.
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 solution enables efficient manufacturing and maintains the chamber's shape and integrity by using a tensile element to counteract outward pressure, ensuring consistent performance and durability.
Implementation Method 1
The tensile element is spaced inward from the sidewall portion. The tensile element is (a) secured to the first portion of the barrier in a plurality of discrete first bond areas and (b) secured to the second portion of the barrier in a plurality of discrete second bond areas.
Data Source
AI summary
A fluid-filled chamber, which may be incorporated into articles of footwear and other products, may include an outer barrier and a tensile element. The outer barrier may have a first portion, an opposite second portion, and an interior surface defining an interior void. The tensile element may be secured to the first portion of the outer barrier in a plurality of first bond areas and may be secured to the second portion of the outer barrier in a plurality of second bond areas. Each of the bond areas may be connected to portions of the tensile element spaced from the interior surface.