U.S. patent application number 15/459165 was filed with the patent office on 2017-09-21 for fluid-filled body and method for forming the same.
This patent application is currently assigned to NIKE, Inc.. The applicant listed for this patent is NIKE, Inc.. Invention is credited to Taryn M. Hensley, Dervin A. James.
Application Number | 20170266938 15/459165 |
Document ID | / |
Family ID | 58410501 |
Filed Date | 2017-09-21 |
United States Patent
Application |
20170266938 |
Kind Code |
A1 |
Hensley; Taryn M. ; et
al. |
September 21, 2017 |
FLUID-FILLED BODY AND METHOD FOR FORMING THE SAME
Abstract
A fluid-filled chamber is provided and includes a first barrier
layer, a second barrier layer attached to the first barrier layer
and cooperating with the first barrier layer to define an interior
void, and a third layer attached to one of the first barrier layer
and the second barrier layer including mineral mica that provides
the one of the first barrier layer and the second barrier layer
with an iridescent appearance caused by differential refraction of
light waves.
Inventors: |
Hensley; Taryn M.;
(Portland, OR) ; James; Dervin A.; (Hillsboro,
OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Assignee: |
NIKE, Inc.
Beaverton
OR
|
Family ID: |
58410501 |
Appl. No.: |
15/459165 |
Filed: |
March 15, 2017 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62308796 |
Mar 15, 2016 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B 13/189 20130101;
A43B 13/20 20130101; B29D 35/08 20130101; B32B 2437/02 20130101;
A43B 13/186 20130101; B32B 19/045 20130101; B32B 27/40 20130101;
A43B 13/188 20130101; A43B 1/0027 20130101; B32B 3/26 20130101;
A43B 1/0072 20130101; A43B 13/04 20130101 |
International
Class: |
B32B 27/40 20060101
B32B027/40; B32B 3/26 20060101 B32B003/26; A43B 13/04 20060101
A43B013/04; A43B 13/18 20060101 A43B013/18; A43B 13/20 20060101
A43B013/20; A43B 1/00 20060101 A43B001/00; B32B 19/04 20060101
B32B019/04; B29D 35/08 20060101 B29D035/08 |
Claims
1. A fluid-filled chamber comprising: a first barrier layer; a
second barrier layer attached to the first barrier layer and
cooperating with the first barrier layer to define an interior
void; and a third layer attached to one of the first barrier layer
and the second barrier layer and including mineral mica operable to
provide the one of the first barrier layer and the second barrier
layer with an iridescent appearance caused by differential
refraction of light waves.
2. The fluid-filled chamber of claim 1, wherein the third layer is
formed from a polymer material.
3. The fluid-filled chamber of claim 1, wherein the third layer is
formed from a polyurethane material.
4. The fluid-filled chamber of claim 1, wherein the mica is at
least one of ground mica, built-up mica, and sheet mica.
5. The fluid-filled chamber of claim 1, wherein the mica is
deposited on an outer surface of the third layer.
6. The fluid-filled chamber of claim 1, wherein the third layer is
impregnated with mica.
7. The fluid-filled chamber of claim 1, wherein the third layer is
disposed within the interior void.
8. The fluid-filled chamber of claim 1, wherein the third layer is
attached to an exterior surface of at least one of the first
barrier layer and the second barrier layer.
9. The fluid-filled chamber of claim 1, wherein the third layer is
attached to an interior surface of at least one of the first
barrier layer and the second barrier layer within the interior
void.
10. An article of footwear incorporating the fluid-filled chamber
of claim 1.
11. A method comprising: attaching a first iridescent material to a
first barrier sheet; inserting the first barrier sheet into a mold;
inserting a second barrier sheet into the mold; applying at least
one of heat and pressure to at least one of the first barrier
sheet, the second barrier sheet, and the iridescent material via
the mold; joining the first barrier sheet and the second barrier
sheet together to define a chamber; and inflating the chamber.
12. The method of claim 11, wherein inserting the first barrier
sheet into the mold includes positioning the first iridescent
material between the first barrier sheet and the second barrier
sheet.
13. The method of claim 11, wherein inserting the first barrier
sheet into the mold includes positioning the first barrier sheet
between the first iridescent material and the second barrier
sheet.
14. The method of claim 11, further comprising attaching a second
iridescent material to the second barrier sheet.
15. The method of claim 14, wherein inserting the second barrier
sheet into the mold includes positioning the second iridescent
material between the second barrier sheet and the first barrier
sheet.
16. The method of claim 14, wherein inserting the second barrier
sheet into the mold includes positioning the second barrier sheet
between the second iridescent material and the first barrier
sheet.
17. The method of claim 11, wherein providing the first iridescent
material includes providing a polymer material having an iridescent
appearance caused by differential refraction of light waves.
18. The method of claim 11, wherein providing the first iridescent
material includes providing a material including mica.
19. The method of claim 18, wherein providing a material including
mica includes providing a material impregnated with mica.
20. The method of claim 11, further comprising incorporating the
chamber into an article of footwear.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional
Application Ser. No. 62/308,796, filed Mar. 15, 2016, the
disclosure of which is hereby incorporated by reference in its
entirety.
FIELD
[0002] The present disclosure relates generally to a fluid-filled
chamber and a method for forming the same.
BACKGROUND
[0003] This section provides background information related to the
present disclosure which is not necessarily prior art.
[0004] Articles of footwear are typically designed and constructed
with a particular purpose in mind. For example, an article of
footwear for use in an athletic event is typically designed to
provide a particular response to an athlete based on the
requirements of the event.
[0005] Articles of footwear for use during running, for example,
typically include an insole, a midsole, and an outsole that
cooperate to simultaneously provide an athlete with comfort,
support, and performance during forward movement (i.e., to help
propel the wearer forward). Similarly, articles of footwear for use
in other activities such as basketball and football are similarly
designed with the athlete in mind to provide comfort and support
during the particular activity. In basketball and football,
however, the article of footwear may be designed and constructed to
support a foot of the athlete during cutting and lateral movements
rather than primarily in forward movements, as with an article of
footwear specifically designed for running. Further, articles of
footwear intended for use during a football game likely also
include a series of cleats that protrude from an outsole to provide
the athlete with traction on a given playing surface.
[0006] While articles of footwear are typically designed with
performance in mind, more and more, articles of footwear are
designed to also provide a unique and distinctive aesthetic
appearance along with a desired level of performance.
DRAWINGS
[0007] The drawings described herein are for illustrative purposes
only of selected configurations and not all possible
implementations, and are not intended to limit the scope of the
present disclosure.
[0008] FIG. 1 is a lateral side view of an exemplary article of
footwear in accordance with the principles of the present
disclosure;
[0009] FIG. 2 is a medial side view of the article of footwear of
FIG. 1;
[0010] FIG. 3A is an exemplary cross-sectional view of a forefoot
portion of the article of footwear taken along Line 3A-3A of FIG.
1;
[0011] FIG. 3B is an exemplary cross-sectional view of a heel
portion of the article of footwear taken along Line 3B-3B of FIG.
1;
[0012] FIG. 4 is a perspective view of an exemplary forefoot
portion of the article of footwear of FIGS. 1-2;
[0013] FIG. 5 is a top plan view of the forefoot portion of FIG.
4;
[0014] FIG. 6 is a bottom plan view of the forefoot portion of FIG.
4;
[0015] FIG. 7A is a cross-sectional view of the forefoot portion
taken along Line 7A-7A of FIG. 5;
[0016] FIGS. 7B-7G illustrate cross-sectional views of alternative
forefoot portions;
[0017] FIG. 8 is a perspective view of an exemplary heel portion of
the article of footwear of FIGS. 1-2;
[0018] FIG. 9 is a top plan view of the heel portion of FIG. 8;
[0019] FIG. 10 is a bottom plan view of the heel portion of FIG.
8;
[0020] FIG. 11A is a cross-sectional view of the heel portion taken
along Line 11A-11A of FIG. 9;
[0021] FIGS. 11B-11G illustrate cross-sectional views of
alternative heel portions;
[0022] FIG. 12 is a bottom perspective view of a mold for forming
the forefoot portion of FIGS. 4-7A;
[0023] FIG. 13 is a top perspective view of the mold of FIG.
12;
[0024] FIGS. 14A-14E illustrate cross-sectional views taken along
Line 14-14 of FIG. 12 or FIG. 13 depicting a manufacturing process
for forming the forefoot portion of FIGS. 4-7A utilizing the mold
of FIG. 12;
[0025] FIG. 15 is a bottom perspective view of a mold for forming
the heel portion of FIGS. 8-11A;
[0026] FIG. 16 is a top perspective view of the mold of FIG. 15;
and
[0027] FIGS. 17A-17D illustrate cross-sectional views taken along
Line 17-17 of FIG. 15 or FIG. 16 depicting a manufacturing process
for forming the heel portion of FIGS. 8-11A utilizing the mold of
FIG. 15.
[0028] Corresponding reference numerals indicate corresponding
parts throughout the drawings.
DETAILED DESCRIPTION
[0029] Example configurations will now be described more fully with
reference to the accompanying drawings. Example configurations are
provided so that this disclosure will be thorough, and will fully
convey the scope of the disclosure to those of ordinary skill in
the art. Specific details are set forth such as examples of
specific components, devices, and methods, to provide a thorough
understanding of configurations of the present disclosure. It will
be apparent to those of ordinary skill in the art that specific
details need not be employed, that example configurations may be
embodied in many different forms, and that the specific details and
the example configurations should not be construed to limit the
scope of the disclosure.
[0030] The terminology used herein is for the purpose of describing
particular exemplary configurations only and is not intended to be
limiting. As used herein, the singular articles "a," "an," and
"the" may be intended to include the plural forms as well, unless
the context clearly indicates otherwise. The terms "comprises,"
"comprising," "including," and "having," are inclusive and
therefore specify the presence of features, steps, operations,
elements, and/or components, but do not preclude the presence or
addition of one or more other features, steps, operations,
elements, components, and/or groups thereof. The method steps,
processes, and operations described herein are not to be construed
as necessarily requiring their performance in the particular order
discussed or illustrated, unless specifically identified as an
order of performance. Additional or alternative steps may be
employed.
[0031] When an element or layer is referred to as being "on,"
"engaged to," "connected to," "attached to," or "coupled to"
another element or layer, it may be directly on, engaged,
connected, attached, or coupled to the other element or layer, or
intervening elements or layers may be present. In contrast, when an
element is referred to as being "directly on," "directly engaged
to," "directly connected to," "directly attached to," or "directly
coupled to" another element or layer, there may be no intervening
elements or layers present. Other words used to describe the
relationship between elements should be interpreted in a like
fashion (e.g., "between" versus "directly between," "adjacent"
versus "directly adjacent," etc.). As used herein, the term
"and/or" includes any and all combinations of one or more of the
associated listed items.
[0032] The terms first, second, third, etc. may be used herein to
describe various elements, components, regions, layers and/or
sections. These elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms do not imply a
sequence or order unless clearly indicated by the context. Thus, a
first element, component, region, layer or section discussed below
could be termed a second element, component, region, layer or
section without departing from the teachings of the example
configurations.
[0033] A fluid-filled chamber is provided and includes a first
barrier layer, a second barrier layer attached to the first barrier
layer and cooperating with the first barrier layer to define an
interior void, and a third layer attached to one of the first
barrier layer and the second barrier layer and including mineral
mica that provides the one of the first barrier layer and the
second barrier layer with an iridescent appearance caused by
differential refraction of light waves.
[0034] In one configuration, the third layer may be formed from a
polymer material such as a polyurethane material.
[0035] The mica may be deposited on an outer surface of the third
layer and/or is impregnated in the third layer and may be at least
one of ground mica, built-up mica, and sheet mica.
[0036] The third layer may be disposed within the interior void.
Alternatively, the third layer may be attached to an exterior
surface of at least one of the first barrier layer and the second
barrier layer.
[0037] In one configuration, the third layer may be attached to an
interior surface of at least one of the first barrier layer and the
second barrier layer within the interior void.
[0038] An article of footwear may be provided and may incorporate
the fluid-filled chamber described.
[0039] A method is provided and includes attaching a first
iridescent material to a first barrier sheet, inserting the first
barrier sheet into a mold, inserting a second barrier sheet into
the mold, and applying at least one of heat and pressure to at
least one of the first barrier sheet, the second barrier sheet, and
the iridescent material via the mold. The method also includes
joining the first barrier sheet and the second barrier sheet
together to define a chamber and inflating the chamber.
[0040] Inserting the first barrier sheet into the mold may include
positioning the first iridescent material between the first barrier
sheet and the second barrier sheet.
[0041] Inserting the first barrier sheet into the mold may include
positioning the first barrier sheet between the first iridescent
material and the second barrier sheet.
[0042] A second iridescent material may be attached to the second
barrier sheet. Inserting the second barrier sheet into the mold may
include positioning the second iridescent material between the
second barrier sheet and the first barrier sheet. Inserting the
second barrier sheet into the mold may include positioning the
second barrier sheet between the second iridescent material and the
first barrier sheet.
[0043] Providing the first iridescent material may include
providing a polymer material having an iridescent appearance caused
by differential refraction of light waves.
[0044] Providing the first iridescent material may include
providing a material including mica and/or providing a material
impregnated with mica.
[0045] The method may also include incorporating the chamber into
an article of footwear.
[0046] In another configuration, a method is provided and includes
inserting a first barrier sheet into a mold, inserting a second
barrier sheet into a mold, inserting a first iridescent sheet into
the mold, and applying at least one of heat and pressure to the
first barrier sheet, the second barrier sheet, and the iridescent
sheet via the mold. The method also includes joining the first
barrier sheet and the second barrier sheet together to define a
chamber, joining the iridescent sheet to at least one of the first
barrier sheet and the second barrier sheet, and inflating the
chamber.
[0047] Inserting the first barrier sheet into the mold may include
positioning the first iridescent material between the first barrier
sheet and the second barrier sheet.
[0048] Inserting the first barrier sheet into the mold may include
positioning the first barrier sheet between the first iridescent
material and the second barrier sheet.
[0049] The method may additionally include inserting a second
iridescent material into the mold. Inserting the second iridescent
material into the mold may include positioning the second
iridescent material between the second barrier sheet and the first
barrier sheet. Inserting the second iridescent material into the
mold may include positioning the second barrier sheet between the
second iridescent material and the first barrier sheet.
[0050] Providing the first iridescent material may include
providing a polymer material having an iridescent appearance caused
by differential refraction of light waves.
[0051] Providing the first iridescent material may include
providing a material including mica and/or providing a material
impregnated with mica.
[0052] The method may also include incorporating the chamber into
an article of footwear.
[0053] Referring to FIGS. 1-2, an article of footwear 10 is shown
and includes an upper portion 12 and a sole portion 14. The upper
portion 12 provides a comfortable and secure covering for a foot
(not shown) of a wearer. As such, the foot may be located within
upper portion 12 to effectively secure the foot within the article
of footwear 10 or otherwise unite the foot and the article of
footwear 10. The sole portion 14 is secured to a lower area of the
upper portion 12 and extends between the foot and a ground surface
G to, for example: (1) attenuate ground reaction forces (i.e., for
cushioning the foot); (2) provide traction; (3) enhance stability;
and (4) influence the motions of the foot. The sole portion 14 is
located under the foot for providing support to the foot.
[0054] The article of footwear 10 may be defined by three regions,
such as, for example: (1) a forefoot region 16, (2) a midfoot
region 18 and (3) a heel region 20. The forefoot region 16
generally includes portions of the article of footwear 10
corresponding with toes of the foot and the joints connecting the
metatarsals with the phalanges. The midfoot region 18 generally
includes portions of the article of footwear 10 corresponding with
an arch area of the foot. The heel region 20 generally corresponds
with rear portions of the foot, including the calcaneus bone.
[0055] The article of footwear 10 also includes a lateral side 22
(see, e.g., FIG. 1) and a medial side 24 (see, e.g., FIG. 2). The
lateral side 22 and the medial side 24 define opposite sides of the
article of footwear 10 and extend through each of forefoot region
16, the midfoot region 18 and the heel region 20. More
particularly, the lateral side 22 corresponds with an outside area
of the foot (i.e. the surface that faces away from the other foot),
and the medial side 24 corresponds with an inside area of the foot
(i.e., the surface that faces toward the other foot).
[0056] The forefoot region 16, the midfoot region 18 and the heel
region 20 and the lateral side 22 and the medial side 24 are not
intended to demarcate precise areas of the article of footwear 10.
Rather, the forefoot region 16, the midfoot region 18 and the heel
region 20 and the lateral side 22 and the medial side 24 are
intended to represent general areas of the article of footwear 10.
In addition to the article of footwear 10, the forefoot region 16,
the midfoot region 18 and the heel region 20 and the lateral side
22 and the medial side 24 may also be applied to upper portion 12,
sole portion 14 and individual elements thereof.
[0057] A majority of upper portion 12 may incorporate various
material elements that are stitched or adhesively bonded together
to form an interior void for securely and comfortably receiving a
foot. The material elements may be selected and located in upper
portion 12 to selectively impart properties of, for example: (1)
durability; air-permeability; wear-resistance; flexibility; and
comfort. The void in the upper portion 12 is shaped to accommodate
the foot. When the foot is located within the void, therefore, the
upper portion 12 extends along a lateral side of the foot, along a
medial side of the foot, over the foot, around the heel, and under
the foot.
[0058] An ankle opening 26 in heel region 20 provides the foot with
access to the void. A lace 28 extends over a tongue 30 and through
various lace apertures 32 or other lace-receiving elements in upper
portion 12. The lace 28 and the adjustability provided by tongue 30
may be utilized for modifying the dimensions of ankle opening 26
and the interior void, thereby securing the foot within the
interior void and facilitating entry and removal of the foot from
the interior void.
[0059] Referring to FIGS. 3A and 3B, the upper portion 12 may
optionally include an insole or sockliner 34 that is located within
the void and positioned to extend under a lower surface of the foot
to enhance the comfort of the article of footwear 10.
[0060] Referring to FIGS. 1-2, the sole portion 14 includes a
forefoot portion 100 and a heel portion 200. Optionally, an outsole
portion 36 (see, also, e.g., FIGS. 3A, 3B) may be disposed over at
least a portion of one or both of the forefoot portion 100 and the
heel portion 200. The outsole portion 36 may be secured to lower
areas of one or both of the forefoot portion 100 and the heel
portion 200 and may be formed from, for example, a wear-resistant
rubber material that is textured to impart traction.
[0061] Each of the forefoot portion 100 and the heel portion 200
may be directly secured to a lower area of upper portion 12 and may
be formed from a polymer material that encloses a fluid, such as,
for example: a gas, liquid, gel or the like. In an example, during
walking or running, one or both of the forefoot portion 100 and the
heel portion 200 compress between the foot and the ground G,
thereby attenuating ground-reaction forces (i.e., one or both of
the forefoot portion 100 and the heel portion 200 are inflated and
are generally pressurized by the fluid disposed therein for
cushioning the foot).
[0062] In some configurations, the sole portion 14 may include a
foam layer F (see, e.g., FIGS. 3A, 3B) that, for example, extends
between the upper portion 12 and one or both of the forefoot
portion 100 and the heel portion 200. Alternatively, a foam element
(not shown) may be located within indentations that may be formed
in the lower areas of one or both of the forefoot portion 100 and
the heel portion 200.
[0063] Referring to FIGS. 4-6, the exemplary forefoot portion 100
is shown isolated from the article of footwear 10. A
cross-sectional view of an exemplary forefoot portion (referenced
from the forefoot portion 100 of FIGS. 4-6) is shown generally at
100a in FIG. 7A. The exemplary forefoot portion 100a is also
represented as a portion of the article of footwear 10 in FIG. 3A,
and, furthermore, a method for manufacturing the exemplary forefoot
portion 100a is also described in the following disclosure and
shown in FIGS. 14A-14E. Although a structural configuration of the
forefoot portion 100 as represented by the cross-sectional views of
FIGS. 3A, 7A and 14A-14E is shown, the exemplary forefoot portion
100a should not be interpreted as a limiting structural
configuration of the forefoot portion 100, alone, or, an article of
footwear 10 incorporating the forefoot portion 100. Accordingly,
the forefoot portion 100, or, an article of footwear 10 including
the forefoot portion 100 may include alternative structural
configurations as seen and described in, but not limited to,
exemplary forefoot portions shown generally at 100b, 100c, 100d,
100e, 100f and 100g in FIGS. 7B, 7C, 7D, 7E, 7F and 7G,
respectively.
[0064] Referring to FIGS. 4-6, the forefoot portion 100 may define
an exemplary fluid-filled body 102 derived from three or more
layers of material. In an example, the three or more layers of
material may include two or more barrier layers and one or more
iridescent layers.
[0065] In one example as seen in FIGS. 7A and 14A, the exemplary
forefoot portion 100a is defined by a fluid-filled body 102 derived
from a first layer of material defining a first barrier layer 102a,
a second layer of material defining a second barrier layer 102b,
and a third layer of material defining an iridescent layer 102c.
With reference to FIG. 7A, the fluid-filled body 102 defining the
forefoot portion 100a is formed by arranging: (1) at least a
portion of an upper surface 102c.sub.U of the iridescent layer 102c
adjacent a lower surface 102b.sub.L of the second barrier layer
102b and (2) at least a portion of an upper surface 102b.sub.U of
the second barrier layer 102b adjacent a lower surface 102a.sub.L
of the first barrier layer 102a.
[0066] At least one of the first barrier layer 102a and the second
barrier layer 102b may be formed from a polymer material (e.g., a
thermoplastic polyurethane (TPU) material). The one or more
iridescent layers 102c may be formed from a polymer material (e.g.,
a polyurethane (PU) material) that provides at least a portion of
the fluid-filled body 102 defining the forefoot portion 100a with
an iridescent appearance caused by a diffraction of light waves
directed toward the fluid-filled body 102.
[0067] In some instances, the one or more iridescent layers 102c
includes mica. In some examples, the mica is deposited on one or
both of an upper surface 102c.sub.U and a lower surface 102c.sub.L
of the one or more iridescent layers 102c. In other examples, the
one or more iridescent layers 102c is impregnated with mica.
[0068] In some instances, the PU material defining the one or more
iridescent layers 102c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 102c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 102c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 102a and the second barrier layer 102b thereby
permitting the PU material defining the one or more iridescent
layers 102c to be laminated to the TPU material defining at least
one of the first barrier layer 102a and the second barrier layer
102b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 14A-14E).
[0069] As seen in FIGS. 14A-14E, a mold 150 may be utilized for
shaping the first barrier layer 102a, the second barrier layer
102b, and the iridescent layer 102c in the form the fluid-filled
body 102 defining the forefoot portion 100a during a molding or
thermoforming process. In some instances, adhesive bonding or
thermal bonding may be utilizing for forming the fluid-filled body
102 during the molding or thermoforming process.
[0070] In another example as seen in FIG. 7B, an exemplary forefoot
portion 100b is defined by a fluid-filled body 102 derived from a
first layer of material defining a first barrier layer 102a, a
second layer of material defining a second barrier layer 102b, and
a third layer of material defining an iridescent layer 102c. The
fluid-filled body 102 defining the forefoot portion 100b is formed
by arranging: (1) at least a portion of an upper surface 102b.sub.U
of the second barrier layer 102b adjacent a lower surface
102a.sub.L of the first barrier layer 102a and (2) at least a
portion of an upper surface 102a.sub.U of the first barrier layer
102a adjacent a lower surface 102c.sub.L of the iridescent layer
102c. At least one of the first barrier layer 102a and the second
barrier layer 102b may be formed from a polymer material (e.g., a
thermoplastic polyurethane (TPU) material). The one or more
iridescent layers 102c may be formed from a polymer material (e.g.,
a polyurethane (PU) material) that provides at least a portion of
the fluid-filled body 102 defining the forefoot portion 100b with
an iridescent appearance caused by a diffraction of light waves
directed toward the fluid-filled body 102.
[0071] In some instances, the one or more iridescent layers 102c
includes mica. In some examples, the mica is deposited on one or
both of an upper surface 102c.sub.U and a lower surface 102c.sub.L
of the one or more iridescent layers 102c. In other examples, the
one or more iridescent layers 102c is impregnated with mica.
[0072] In some instances, the PU material defining the one or more
iridescent layers 102c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 102c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 102c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 102a and the second barrier layer 102b thereby
permitting the PU material defining the one or more iridescent
layers 102c to be laminated to the TPU material defining at least
one of the first barrier layer 102a and the second barrier layer
102b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 14A-14E).
[0073] As seen in FIGS. 14A-14E, a mold 150 may be utilized for
shaping the first barrier layer 102a, the second barrier layer 102b
and the iridescent layer 102c in the form the fluid-filled body 102
defining the forefoot portion 100b during a molding or
thermoforming process. In some instances, adhesive bonding or
thermal bonding may be utilizing for forming the fluid-filled body
102 during the molding or thermoforming process.
[0074] In yet another example as seen in FIG. 7C, an exemplary
forefoot portion 100c is defined by a fluid-filled body 102 derived
from a first layer of material defining a first barrier layer 102a,
a second layer of material defining a second barrier layer 102b and
a third layer of material defining an iridescent layer 102c. The
fluid-filled body 102 defining the forefoot portion 100c is formed
by arranging: (1) at least a portion of an upper surface 102b.sub.U
of the second barrier layer 102b adjacent a lower surface
102c.sub.L of the iridescent layer 102c and (2) at least a portion
of an upper surface 102c.sub.U of the iridescent layer 102c
adjacent a lower surface 102a.sub.L of the first barrier layer
102c. At least one of the first barrier layer 102a and the second
barrier layer 102b may be formed from a polymer material (e.g., a
thermoplastic polyurethane (TPU) material). The one or more
iridescent layers 102c may be formed from a polymer material (e.g.,
a polyurethane (PU) material) that provides at least a portion of
the fluid-filled body 102 defining the forefoot portion 100c with
an iridescent appearance caused by a diffraction of light waves
directed toward the fluid-filled body 102.
[0075] In some instances, the one or more iridescent layers 102c
includes mica. In some examples, the mica is deposited on one or
both of an upper surface 102c.sub.U and a lower surface 102c.sub.L
of the one or more iridescent layers 102c. In other examples, the
one or more iridescent layers 102c is impregnated with mica.
[0076] In some instances, the PU material defining the one or more
iridescent layers 102c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 102c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 102c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 102a and the second barrier layer 102b thereby
permitting the PU material defining the one or more iridescent
layers 102c to be laminated to the TPU material defining at least
one of the first barrier layer 102a and the second barrier layer
102b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 14A-14E).
[0077] As seen in FIGS. 14A-14E, a mold 150 may be utilized for
shaping the first barrier layer 102a, the second barrier layer 102b
and the iridescent layer 102c in the form the fluid-filled body 102
defining the forefoot portion 100c during a molding or
thermoforming process. In some instances, adhesive bonding or
thermal bonding may be utilizing for forming the fluid-filled body
102 during the molding or thermoforming process.
[0078] In an example as seen in FIG. 7D, an exemplary forefoot
portion 100d is defined by a fluid-filled body 102 derived from a
first layer of material defining a first barrier layer 102a, a
second layer of material defining a second barrier layer 102b, a
third layer of material defining a first iridescent layer 102c and
a fourth layer of material defining a second iridescent layer 102d.
The fluid-filled body 102 defining the forefoot portion 100d is
formed by arranging: (1) at least a portion of an upper surface
102c.sub.U of the first iridescent layer 102c adjacent a lower
surface 102b.sub.L of the second barrier layer 102b, (2) at least a
portion of an upper surface 102b.sub.U of the second barrier layer
102b adjacent a lower surface 102a.sub.L of the first barrier layer
102c and (3) at least a portion of an upper surface 102a.sub.U of
the first barrier layer 102a adjacent a lower surface 102d.sub.L of
the second iridescent layer 102d. At least one of the first barrier
layer 102a and the second barrier layer 102b may be formed from a
polymer material (e.g., a thermoplastic polyurethane (TPU)
material). The one or more iridescent layers 102c, 102d may be
formed from a polymer material (e.g., a polyurethane (PU) material)
that provides at least a portion of the fluid-filled body 102
defining the forefoot portion 100d with an iridescent appearance
caused by a diffraction of light waves directed toward the
fluid-filled body 102.
[0079] In some instances, the one or more iridescent layers 102c,
102d includes mica. In some examples, the mica is deposited on one
or both of an upper surface 102c.sub.U, 102d.sub.U and a lower
surface 102c.sub.L, 102d.sub.L of the one or more iridescent layers
102c, 102d. In other examples, the one or more iridescent layers
102c, 102d is impregnated with mica.
[0080] In some instances, the PU material defining the one or more
iridescent layers 102c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 102c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 102c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 102a and the second barrier layer 102b thereby
permitting the PU material defining the one or more iridescent
layers 102c to be laminated to the TPU material defining at least
one of the first barrier layer 102a and the second barrier layer
102b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 14A-14E).
[0081] As seen in FIGS. 14A-14E, a mold 150 may be utilized for
shaping the first barrier layer 102a, the second barrier layer
102b, the first iridescent layer 102c and the second iridescent
layer 102d in the form the fluid-filled body 102 defining the
forefoot portion 100d during a molding or thermoforming process. In
some instances, adhesive bonding or thermal bonding may be
utilizing for forming the fluid-filled body 102 during the molding
or thermoforming process.
[0082] In an example as seen in FIG. 7E, an exemplary forefoot
portion 100e is defined by a fluid-filled body 102 derived from a
first layer of material defining a first barrier layer 102a, a
second layer of material defining a second barrier layer 102b, a
third layer of material defining a first iridescent layer 102c and
a fourth layer of material defining a second iridescent layer 102d.
The fluid-filled body 102 defining the forefoot portion 100e is
formed by arranging: (1) at least a portion of an upper surface
102c.sub.U of the first iridescent layer 102c adjacent a lower
surface 102b.sub.L of the second barrier layer 102b, (2) at least a
portion of an upper surface 102b.sub.U of the second barrier layer
102b adjacent a lower surface 102d.sub.L of the second iridescent
layer 102d and (3) at least a portion of an upper surface
102d.sub.U of the second iridescent layer 102d adjacent a lower
surface 102a.sub.L of the first barrier layer 102a. At least one of
the first barrier layer 102a and the second barrier layer 102b may
be formed from a polymer material (e.g., a thermoplastic
polyurethane (TPU) material). The one or more iridescent layers
102c, 102d may be formed from a polymer material (e.g., a
polyurethane (PU) material) that provides at least a portion of the
fluid-filled body 102 defining the forefoot portion 100e with an
iridescent appearance caused by a diffraction of light waves
directed toward the fluid-filled body 102.
[0083] In some instances, the one or more iridescent layers 102c,
102d includes mica. In some examples, the mica is deposited on one
or both of an upper surface 102c.sub.U, 102d.sub.U and a lower
surface 102c.sub.L, 102d.sub.L of the one or more iridescent layers
102c, 102d. In other examples, the one or more iridescent layers
102c, 102d is impregnated with mica.
[0084] In some instances, the PU material defining the one or more
iridescent layers 102c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 102c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 102c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 102a and the second barrier layer 102b thereby
permitting the PU material defining the one or more iridescent
layers 102c to be laminated to the TPU material defining at least
one of the first barrier layer 102a and the second barrier layer
102b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 14A-14E).
[0085] As seen in FIGS. 14A-14E, a mold 150 may be utilized for
shaping the first barrier layer 102a, the second barrier layer
102b, the first iridescent layer 102c and the second iridescent
layer 102d in the form the fluid-filled body 102 defining the
forefoot portion 100e during a molding or thermoforming process. In
some instances, adhesive bonding or thermal bonding may be
utilizing for forming the fluid-filled body 102 during the molding
or thermoforming process.
[0086] In another example as seen in FIG. 7F, an exemplary forefoot
portion 100f is defined by a fluid-filled body 102 derived from a
first layer of material defining a first barrier layer 102a, a
second layer of material defining a second barrier layer 102b, a
third layer of material defining a first iridescent layer 102c and
a fourth layer of material defining a second iridescent layer 102d.
The fluid-filled body 102 defining the forefoot portion 100f is
formed by arranging: (1) at least a portion of an upper surface
102b.sub.U of the second barrier layer 102b adjacent a lower
surface 102c.sub.L of the first iridescent layer 102c, (2) at least
a portion of an upper surface 102c.sub.U of the first iridescent
layer 102c adjacent a lower surface 102a.sub.L of the first barrier
layer 102a and (3) at least a portion of an upper surface
102a.sub.U of the first barrier layer 102a adjacent a lower surface
102d.sub.L of the second iridescent layer 102d. At least one of the
first barrier layer 102a and the second barrier layer 102b may be
formed from a polymer material (e.g., a thermoplastic polyurethane
(TPU) material). The one or more iridescent layers 102c, 102d may
be formed from a polymer material (e.g., a polyurethane (PU)
material) that provides at least a portion of the fluid-filled body
102 defining the forefoot portion 100f with an iridescent
appearance caused by a diffraction of light waves directed toward
the fluid-filled body 102.
[0087] In some instances, the one or more iridescent layers 102c,
102d includes mica. In some examples, the mica is deposited on one
or both of an upper surface 102c.sub.U, 102d.sub.U and a lower
surface 102c.sub.L, 102d.sub.L of the one or more iridescent layers
102c, 102d. In other examples, the one or more iridescent layers
102c, 102d is impregnated with mica.
[0088] In some instances, the PU material defining the one or more
iridescent layers 102c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 102c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 102c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 102a and the second barrier layer 102b thereby
permitting the PU material defining the one or more iridescent
layers 102c to be laminated to the TPU material defining at least
one of the first barrier layer 102a and the second barrier layer
102b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 14A-14E).
[0089] As seen in FIGS. 14A-14E, a mold 150 may be utilized for
shaping the first barrier layer 102a, the second barrier layer
102b, the first iridescent layer 102c and the second iridescent
layer 102d in the form the fluid-filled body 102 defining the
forefoot portion 100f during a molding or thermoforming process. In
some instances, adhesive bonding or thermal bonding may be
utilizing for forming the fluid-filled body 102 during the molding
or thermoforming process.
[0090] In yet another example as seen in FIG. 7G, an exemplary
forefoot portion 100g is defined by a fluid-filled body 102 derived
from a first layer of material defining a first barrier layer 102a,
a second layer of material defining a second barrier layer 102b, a
third layer of material defining a first iridescent layer 102c, a
fourth layer of material defining a second iridescent layer 102d,
and a fifth layer of material defining a third iridescent layer
102e. The fluid-filled body 102 defining the forefoot portion 100g
is formed by arranging: (1) at least a portion of an upper surface
102c.sub.U of the first iridescent layer 102c adjacent a lower
surface 102b.sub.L of the second barrier layer 102b, (2) at least a
portion of an upper surface 102b.sub.U of the second barrier layer
102b adjacent a lower surface 102d.sub.L of the second iridescent
layer 102d (3) at least a portion of an upper surface 102d.sub.U of
the second iridescent layer 102d adjacent a lower surface
102a.sub.L of the first barrier layer 102a and (4) at least a
portion of an upper surface 102a.sub.U of the first barrier layer
102a adjacent a lower surface 102e.sub.L of the third iridescent
layer 102e. At least one of the first barrier layer 102a and the
second barrier layer 102b may be formed from a polymer material
(e.g., a thermoplastic polyurethane (TPU) material). The one or
more iridescent layers 102c, 102d, 102e may be formed from a
polymer material (e.g., a polyurethane (PU) material) that provides
at least a portion of the fluid-filled body 102 defining the
forefoot portion 100g with an iridescent appearance caused by a
diffraction of light waves directed toward the fluid-filled body
102.
[0091] In some instances, the one or more iridescent layers 102c,
102d includes mica. In some examples, the mica is deposited on one
or both of an upper surface 102c.sub.U, 102d.sub.U and a lower
surface 102c.sub.L, 102d.sub.L of the one or more iridescent layers
102c, 102d. In other examples, the one or more iridescent layers
102c, 102d is impregnated with mica.
[0092] In some instances, the PU material defining the one or more
iridescent layers 102c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 102c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 102c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 102a and the second barrier layer 102b thereby
permitting the PU material defining the one or more iridescent
layers 102c to be laminated to the TPU material defining at least
one of the first barrier layer 102a and the second barrier layer
102b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 14A-14E).
[0093] As seen in FIGS. 14A-14E, a mold 150 may be utilized for
shaping the first barrier layer 102a, the second barrier layer
102b, the first iridescent layer 102c, the second iridescent layer
102d and the third iridescent layer 102e in the form the
fluid-filled body 102 defining the forefoot portion 100g during a
molding or thermoforming process. In some instances, adhesive
bonding or thermal bonding may be utilizing for forming the
fluid-filled body 102 during the molding or thermoforming
process.
[0094] As seen in FIGS. 3A, 4-5 and 7A, the first barrier layer
102a defines an upper surface 104 of the fluid-filled body 102.
Referring to FIGS. 3A, 6 and 7A, the iridescent layer 102c defines
a lower surface 106 of the fluid-filled body 102. Furthermore, as
seen in FIGS. 3A, 4 and 7A, the iridescent layer 102c defines a
side surface 108 of the fluid-filled body 102; the side surface 108
connects the upper surface 104 to the lower surface 106. As seen in
FIG. 3A, the upper surface 104 of the fluid-filled body 102 of the
forefoot portion 100 is connected to upper portion 12. Optionally,
if an outsole portion 36 is included in the design of the article
of footwear 10, the outsole portion may, as seen in FIG. 3A, be
disposed over some of the lower surface 106 of the fluid-filled
body 102 of the forefoot portion 100 such that some of the lower
surface 106 is exposed and not obscured by the outsole portion
36.
[0095] Referring to FIGS. 3A and 7A, one or more of the three or
more layers 102a, 102b, 102c that forms the fluid-filled body 102
contributes to the fluid-filled body 102 defining an outer
peripheral flange 110 and one or more internal ribs 112. The one or
more internal ribs 112 maintain the first barrier layer 102a and
the second barrier layer 102b in a spaced-apart relationship by a
distance D such that the fluid-filled body 102 defines a plurality
of fluid-filled chambers 114. The plurality of fluid-filled
chambers 114 enclose or contain a fluid within forefoot portion
100.
[0096] In some examples, as seen in FIGS. 4-6, the one or more
internal ribs 112 includes seven internal ribs 112a-112g including
a first internal rib 112a, a second internal rib 112b, a third
internal rib 112c, a fourth internal rib 112d, a fifth internal rib
112e, a sixth internal rib 112f and a seventh internal rib 112g. In
some instances, the one or more (e.g., seven) internal ribs 112
define eight fluid-filled chambers 114a-114h including a first
fluid-filled chamber 114a, a second fluid-filled chamber 114b, a
third fluid-filled chamber 114c, a fourth fluid-filled chamber
114d, a fifth fluid-filled chamber 114e, a sixth fluid-filled
chamber 114f, a seventh fluid-filled chamber 114g and an eighth
fluid-filled chamber 114h.
[0097] The one or more internal ribs 112 may also form at least one
fluid conduit 116 that permits each of the fluid-filled chambers
114a-114h of the plurality of fluid-filled chambers 114 to be in
fluid communication with one another. The fluid conduits 116 may be
formed along the length of each of the one or more internal ribs
112 and/or at opposite ends of the one or more internal ribs near
the outer peripheral flange 110. As such, the fluid conduits 116
may permit the fluid within forefoot portion 100 to be transferred
between fluid-filled chambers 114a-114h.
[0098] As will be described in the following disclosure at FIGS.
14A-14E, adjacent layers of the one or more of the three or more
layers 102a, 102b, 102c that forms the fluid-filled body 102 are
joined to each other to form a bond that seals the fluid within the
plurality of fluid-filled chambers 114 defined by the fluid-filled
body 102 forming the forefoot portion 100. Although the
fluid-filled chambers 114a-114h effectively contain the fluid
within forefoot portion 100, each of the fluid-filled chambers
114a-114h are placed in fluid communication by way of the fluid
conduits 116. In some configurations, one or more of the fluid
conduits 116 may not be formed by the one or more internal ribs 112
in order to segregate the fluid in one of fluid-filled chambers
114a-114h from the fluid in another fluid-filled chamber 114a-114h;
in such instances, the fluid provided in the segregated
fluid-filled chambers 114a-114h may be pressurized differently. In
other configurations, the forefoot portion 100 may be a part of a
fluid system that, for example, pumps fluid into the fluid-filled
chambers 114a-114h to tailor the pressure within the forefoot
portion 100 to the preferences or running style of the wearer.
[0099] Referring to FIGS. 3A and 7A, the upper surface 104 may have
a generally concave, rounded and relatively smooth profile that
supports the foot when the article of footwear 10 is worn. In an
example, the rounded configuration of upper surface 104 lays on a
curved plane that is cooperatively formed by: (1) the fluid-filled
chambers 114a-114h; (2) the outer peripheral flange 110; and (3)
the fluid conduits 116. In contrast, the lower surface 106 may be
more contoured, with the fluid-filled chambers 114a-114h extending
or protruding downward from the outer peripheral flange 110. As a
result, portions of the fluid-filled chambers 114a-114h may
protrude downwardly to form independent supports or cushioning
elements in the sole portion 14.
[0100] In some implementations, undulations or other
discontinuities formed by the upper surface 104, which supports the
foot, that are greater than, for example, one (1) millimeter may
decrease footwear comfort. The pressure of the fluid within the
fluid-filled chambers 114a-114h tend to press outward upon the
first barrier layer 102a that forms the upper surface 104 and the
iridescent layer 102c that forms the lower surface 106, which may
cause areas of forefoot portion 100 corresponding with fluid-filled
chambers 114a-114h to bulge or protrude outward. Although the upper
surface 104 may exhibit some undulations adjacent to the
fluid-filled chambers 114a-114h, the size of these undulations may
be generally limited to less than, for example, one (1) millimeter,
thereby enhancing the comfort of the article of footwear 10.
[0101] Various features of forefoot portion 100 may operate
cooperatively to limit the size of the undulations in the upper
surface 104. Exemplary features may include, for example: (1) a
thickness of any of the first barrier layer 102a; the second
barrier layer 102b and the iridescent layer 102c that contribute to
the formation of the fluid-filled chambers 114a-114h, (2) the
pressure of the fluid within the fluid-filled chambers 114a-114h;
and (3) the width of the fluid-filled chambers 114a-114h. In
general, as the thickness of any of the first barrier layer 102a,
the second barrier layer 102b and the iridescent layer 102c that
contribute to the formation of any of the fluid-filled chambers
114a-114h increases, or, as the pressure of the fluid within the
fluid-filled chambers 114a-114h decreases, the degree to which the
fluid-filled chambers 114a-114h bulge or protrude outward and form
undulations decreases. For footwear applications, in some
instances, any of the first barrier layer 102a, the second barrier
layer 102b and the iridescent layer 102c may be defined by a
thickness of three-quarters of a (0.75) millimeter (e.g., 0.03
inch) and a fluid pressure of 138 kilopascals (20 pounds per square
inch) within the fluid-filled chambers 114a-114h provides a
suitable degree of compliance, force attenuation, and other
properties. Given the above-described exemplary thickness and
pressure, having a maximum width of less than fourteen (14)
millimeters, and possibly less than twelve (12) millimeters, in the
fluid-filled chambers 114a-114h may limit the size of the
undulations formed by the upper surface 104 to less than, for
example, one (1) millimeter. While the iridescent layer 102c is
described as including a similar thickness as the first and second
barrier layers 102a, 102b, the iridescent layer 102c may include a
much smaller thickness in comparison to the thickness of the layers
102a, 102b. For example, the iridescent layer 102c may include a
thickness that is less than one millimeter (1 mm). In one example,
the iridescent layer 102c includes a thickness of 0.18 mm.
[0102] In the configuration shown in FIGS. 5 and 6, adjacent
internal ribs 112a-112g of the one or more internal ribs 112 may be
arranged in a substantially parallel relationship. Furthermore in
some examples, adjacent internal ribs 112a-112g of the one or more
internal ribs 112 may be spaced apart by a width W such that each
fluid-filled chamber 114a-114h of the plurality of fluid-filled
chambers 114 are arranged in a substantially parallel relationship.
In some instances, the width W may be defined by a maximum width of
less than fourteen (14) millimeters. In some examples, the width W
may be defined by a maximum width of less than twelve (12)
millimeters. In other examples, the width W may be defined by a
maximum width greater than fourteen (14) millimeters.
[0103] Although exemplary dimensions of the width W of the
fluid-filled chambers 114a-114h have been described above, the
exemplary dimensions of the width W may be limited to less than
fourteen (14) or twelve (12) millimeters, and, as such, a height
dimension H (see, e.g., FIG. 7A) and a length dimension L (see,
e.g., FIG. 7A) of the fluid-filled chambers 114a-114h may vary
considerably. In general, and, with all other factors being the
same, as the volume of each of the fluid-filled chambers 114a-114h
increases, the degree of cushioning or force attenuation provided
by forefoot portion 100 also increases. By maximizing the height H
and length L of portions or segments of the fluid-filled chambers
114a-114h, cushioning or force attenuation properties may also be
enhanced. As an example, in some configurations of forefoot portion
100, the height H of fluid-filled chambers 114a-114h may be more
than fourteen (14) millimeters, with the height H being measured in
a direction that is perpendicular to the width W.
[0104] The outer peripheral flange 110 forms a peripheral seam or
bonded area that joins the first barrier layer 102a, the second
barrier layer 102b, and the iridescent layer 102c and assists with
sealing the fluid within forefoot portion 100. In general, the
outer peripheral flange 110 may be defined by a height of at least
five (5) millimeters and extends in an outward direction from a
remainder of forefoot portion 100. Relative to the voids that
contain the fluid within the fluid-filled chambers 114a-114h, the
outer peripheral flange 110 extends outward from the voids. More
particularly, the outer peripheral flange 110 extends in an upward
direction from the peripheral area or an upper area of forefoot
portion 100 whereas the area of outer peripheral flange 110
extending from the upper surface 104 faces toward and is secured to
upper portion 12 while the area of outer peripheral flange 110
extending toward the lower surface 106 forms a portion of the side
surface 108 of the article of footwear 10. Given that outer
peripheral flange 110 is a relatively thick and stiff portion of
forefoot portion 100, the outer peripheral flange 110 may enhance
the stability of the article of footwear 10. The outer peripheral
flange 110 may also provide a defined lasting margin during steps
of the manufacturing process that involve bonding upper portion 12
to forefoot portion 100.
[0105] Referring to FIG. 7A, the outer peripheral flange 110 is
depicted as having a tapered configuration, with the portions of
the outer peripheral flange 110 located adjacent to the voids of
the fluid-filled chambers 114a-114h having greater thickness than
the portions of the outer peripheral flange 110 that are spaced
from the voids and form a distal end. In effect, therefore, the
outer peripheral flange 110 may have a tapered configuration with a
first thickness adjacent to the voids and a second thickness spaced
away from the voids whereby the first thickness is greater than the
second thickness. Moreover, thickness of the portions of the outer
peripheral flange 110 located adjacent to the voids (i.e., the
first thickness) may be greater than the sum of the thicknesses of
any of the first barrier layer 102a, the second barrier layer 102b
and the iridescent layer 102c forming the upper surface 104 and the
lower surface 106. As noted above, the outer peripheral flange 110
may be a relatively thick and stiff portion of forefoot portion
100; a portion of the stiffness may be due, therefore, to a greater
thickness of the outer peripheral flange 110 adjacent to the
fluid-filled chambers 114a-114h. A process for forming the outer
peripheral flange 110 to have this configuration is discussed in
the following disclosure at FIGS. 14A-14E.
[0106] Although the outer peripheral flange 110 is present in areas
adjacent to the fluid-filled chambers 114a-114h, the outer
peripheral flange 110 may be absent or have minimal height and
thickness in some areas between the fluid-filled chambers
114a-114h. This configuration may provide enhanced flexibility to
the forefoot portion 100. More particularly, given that the outer
peripheral flange 110 may be a relatively thick and stiff portion
of the forefoot portion 100, areas where the outer peripheral
flange 110 are absent or minimized may have greater
flexibility.
[0107] Various factors may be considered when selecting materials
for any of the first barrier layer 102a, the second barrier layer
102b and the iridescent layer 102c forming the forefoot portion
100. As an example, the engineering properties of the materials
(e.g., tensile strength, tear strength, flexural fatigue strength,
modulus of elasticity, and abrasion resistance) may be considered.
The ability of the materials to be shaped into the fluid-filled
chambers 114a-114h and bonded to form the outer peripheral flange
110 during the manufacture of forefoot portion 100 may also be
considered. Additionally, the ability of the materials to prevent
the transmission (e.g., diffusion, permeation) of the fluid
contained by forefoot portion 100 may be considered. Suitable
materials for forefoot portion 100 include a variety of thermoset
and thermoplastic polymer materials. An advantage of thermoplastic
polymer materials is that they may be molded (e.g., thermoformed)
to impart the shapes of the fluid-filled chambers 114a-114h and the
outer peripheral flange 110. Moreover, thermoplastic polymer
materials may be thermal bonded to each other to form the outer
peripheral flange 110. Given these considerations, examples of
polymer materials that may be utilized for the forefoot portion 100
include any of the following: polyurethane, urethane, thermoplastic
polyurethane, polyester, polyester polyurethane, polyether,
polyether polyurethane, latex, polycaprolactone, polyoxypropylene,
polycarbonate macroglycol, and mixtures thereof.
[0108] Although any of the materials noted above may be utilized
for the forefoot portion 100, various materials exhibit both
diffusion-prevention and thermoplastic properties. Although various
configurations may be utilized, this material generally includes
layers of a thermoplastic polymer material and a barrier material.
The thermoplastic polymer material provides the ability to form
contoured shapes and thermal bonds, as well as a suitable degree of
tensile strength, tear strength, flexural fatigue strength, modulus
of elasticity, and abrasion resistance. The barrier material is
effective in limiting the transmission of the fluid within the
forefoot portion 100 (e.g., air, nitrogen, or sulfur-hexafluoride).
As another example, the forefoot portion 100 may be formed from
other layered materials, including a flexible microlayer membrane
that has alternating layers of a gas barrier material and an
elastomeric material. Further suitable materials include
thermoplastic films containing a crystalline material. Another
suitable material may be a polyurethane material including a
polyester polyol.
[0109] Referring to FIGS. 8-10, the exemplary heel portion 200 is
shown separate from the article of footwear 10. A cross-sectional
view of an exemplary heel portion (referenced from the heel portion
200 of FIGS. 8-10) is shown generally at 200a in FIG. 11A. The
exemplary heel portion 200a is also represented as a portion of the
article of footwear 10 in FIG. 3B, and, furthermore, a method for
manufacturing the exemplary heel portion 200a is also described in
the following disclosure at FIGS. 17A-17D. Although a structural
configuration of the heel portion 200 as represented by the
cross-sectional views of FIGS. 3B, 11A and 17A-17D is shown, the
exemplary heel portion 200a should not be interpreted as a limiting
structural configuration of the heel portion 200, alone, or, an
article of footwear 10 incorporating the heel portion 200.
Accordingly, the heel portion 200, or, an article of footwear 10
including the heel portion 200 may include alternative structural
configurations as seen and described in, but not limited to,
exemplary heel portions seen generally at 200b, 200c, 200d, 200e,
200f and 200g in FIGS. 11B, 11C, 11D, 11E, 11F and 11G,
respectively.
[0110] Referring to FIGS. 8-10, the heel portion 200 may define an
exemplary fluid-filled body 202 derived from three or more layers
of material. In an example, the three or more layers of material
may include two or more barrier layers and one or more iridescent
layers.
[0111] In one example as seen in FIGS. 11A and 17A, the exemplary
heel portion 200a is defined by a fluid-filled body 202 derived
from a first layer of material defining a first barrier layer 202a,
a second layer of material defining a second barrier layer 202b and
a third layer of material defining an iridescent layer 202c. With
reference to FIG. 11A, the fluid-filled body 202 defining the heel
portion 200a is formed by arranging: (1) at least a portion of an
upper surface 202c.sub.U of the iridescent layer 202c adjacent a
lower surface 202b.sub.L of the second barrier layer 202b and (2)
at least a portion of an upper surface 202b.sub.U of the second
barrier layer 202b adjacent a lower surface 202a.sub.L of the first
barrier layer 202a. At least one of the first barrier layer 202a
and the second barrier layer 202b may be formed from a polymer
material (e.g., a thermoplastic polyurethane (TPU) material). The
one or more iridescent layers 202c may be formed from a polymer
material (e.g., a polyurethane (PU) material) that provides at
least a portion of the fluid-filled body 202 defining the heel
portion 200a with an iridescent appearance caused by a diffraction
of light waves directed toward the fluid-filled body 202.
[0112] In some instances, the one or more iridescent layers 202c
includes mica. In some examples, the mica is deposited on one or
both of an upper surface 202c.sub.U and a lower surface 202c.sub.L
of the one or more iridescent layers 202c. In other examples, the
one or more iridescent layers 202c is impregnated with mica.
[0113] In some instances, the PU material defining the one or more
iridescent layers 202c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 202c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 202c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 202a and the second barrier layer 202b thereby
permitting the PU material defining the one or more iridescent
layers 202c to be laminated to the TPU material defining at least
one of the first barrier layer 202a and the second barrier layer
202b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 17A-17D).
[0114] As seen in FIGS. 17A-17D, the first barrier layer 202a, the
second barrier layer 202b and the iridescent layer 202c are shaped
to form the fluid-filled body 202 during a molding or thermoforming
process. In some instances, adhesive bonding or thermal bonding may
be utilizing for forming the fluid-filled body 202 during the
molding or thermoforming process.
[0115] In another example as seen in FIG. 11B, an exemplary heel
portion 200b is defined by a fluid-filled body 202 derived from a
first layer of material defining a first barrier layer 202a, a
second layer of material defining a second barrier layer 202b and a
third layer of material defining an iridescent layer 202c. The
fluid-filled body 202 defining the heel portion 200b is formed by
arranging: (1) at least a portion of an upper surface 202b.sub.U of
the second barrier layer 202b adjacent a lower surface 202a.sub.L
of the first barrier layer 202a and (2) at least a portion of an
upper surface 202a.sub.U of the first barrier layer 202a adjacent a
lower surface 202c.sub.L of the iridescent layer 202c. At least one
of the first barrier layer 202a and the second barrier layer 202b
may be formed from a polymer material (e.g., a thermoplastic
polyurethane (TPU) material). The one or more iridescent layers
202c may be formed from a polymer material (e.g., a polyurethane
(PU) material) that provides at least a portion of the fluid-filled
body 202 defining the heel portion 200b with an iridescent
appearance caused by a diffraction of light waves directed toward
the fluid-filled body 202.
[0116] In some instances, the one or more iridescent layers 202c
includes mica. In some examples, the mica is deposited on one or
both of an upper surface 202c.sub.U and a lower surface 202c.sub.L
of the one or more iridescent layers 202c. In other examples, the
one or more iridescent layers 202c is impregnated with mica.
[0117] In some instances, the PU material defining the one or more
iridescent layers 202c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 202c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 202c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 202a and the second barrier layer 202b thereby
permitting the PU material defining the one or more iridescent
layers 202c to be laminated to the TPU material defining at least
one of the first barrier layer 202a and the second barrier layer
202b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 17A-17D).
[0118] As seen in FIGS. 17A-17E, a mold 250 may be utilized for
shaping the first barrier layer 202a, the second barrier layer 202b
and the iridescent layer 202c in the form the fluid-filled body 202
defining the forefoot portion 200b during a molding or
thermoforming process. In some instances, adhesive bonding or
thermal bonding may be utilizing for forming the fluid-filled body
202 during the molding or thermoforming process.
[0119] In yet another example as seen in FIG. 11C, an exemplary
heel portion 200c is defined by a fluid-filled body 202 derived
from a first layer of material defining a first barrier layer 202a,
a second layer of material defining a second barrier layer 202b and
a third layer of material defining an iridescent layer 202c. The
fluid-filled body 202 defining the heel portion 200c is formed by
arranging: (1) at least a portion of an upper surface 202b.sub.U of
the second barrier layer 202b adjacent a lower surface 202c.sub.L
of the iridescent layer 202c and (2) at least a portion of an upper
surface 202c.sub.U of the iridescent layer 202c adjacent a lower
surface 202a.sub.L of the first barrier layer 202c. At least one of
the first barrier layer 202a and the second barrier layer 202b may
be formed from a polymer material (e.g., a thermoplastic
polyurethane (TPU) material). The one or more iridescent layers
202c may be formed from a polymer material (e.g., a polyurethane
(PU) material) that provides at least a portion of the fluid-filled
body 202 defining the heel portion 200c with an iridescent
appearance caused by a diffraction of light waves directed toward
the fluid-filled body 202.
[0120] In some instances, the one or more iridescent layers 202c
includes mica. In some examples, the mica is deposited on one or
both of an upper surface 202c.sub.U and a lower surface 202c.sub.L
of the one or more iridescent layers 202c. In other examples, the
one or more iridescent layers 202c is impregnated with mica.
[0121] In some instances, the PU material defining the one or more
iridescent layers 202c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 202c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 202c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 202a and the second barrier layer 202b thereby
permitting the PU material defining the one or more iridescent
layers 202c to be laminated to the TPU material defining at least
one of the first barrier layer 202a and the second barrier layer
202b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 17A-17D).
[0122] As seen in FIGS. 17A-17E, a mold 250 may be utilized for
shaping the first barrier layer 202a, the second barrier layer 202b
and the iridescent layer 202c in the form the fluid-filled body 202
defining the forefoot portion 200c during a molding or
thermoforming process. In some instances, adhesive bonding or
thermal bonding may be utilizing for forming the fluid-filled body
202 during the molding or thermoforming process.
[0123] In an example as seen in FIG. 11D, an exemplary heel portion
200d is defined by a fluid-filled body 202 derived from a first
layer of material defining a first barrier layer 202a, a second
layer of material defining a second barrier layer 202b, a third
layer of material defining a first iridescent layer 202c and a
fourth layer of material defining a second iridescent layer 202d.
The fluid-filled body 202 defining the heel portion 200d is formed
by arranging: (1) at least a portion of an upper surface 202c.sub.U
of the first iridescent layer 202c adjacent a lower surface
202b.sub.L of the second barrier layer 202b, (2) at least a portion
of an upper surface 202b.sub.U of the second barrier layer 202b
adjacent a lower surface 202a.sub.L of the first barrier layer 202c
and (3) at least a portion of an upper surface 202a.sub.U of the
first barrier layer 202a adjacent a lower surface 202d.sub.L of the
second iridescent layer 202d. At least one of the first barrier
layer 202a and the second barrier layer 202b may be formed from a
polymer material (e.g., a thermoplastic polyurethane (TPU)
material). The one or more iridescent layers 202c, 202d may be
formed from a polymer material (e.g., a polyurethane (PU) material)
that provides at least a portion of the fluid-filled body 202
defining the heel portion 200d with an iridescent appearance caused
by a diffraction of light waves directed toward the fluid-filled
body 202.
[0124] In some instances, the one or more iridescent layers 202c,
202d includes mica. In some examples, the mica is deposited on one
or both of an upper surface 202c.sub.U, 202d.sub.U and a lower
surface 202c.sub.L, 202d.sub.L of the one or more iridescent layers
202c, 202d. In other examples, the one or more iridescent layers
202c, 202d is impregnated with mica.
[0125] In some instances, the PU material defining the one or more
iridescent layers 202c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 202c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 202c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 202a and the second barrier layer 202b thereby
permitting the PU material defining the one or more iridescent
layers 202c to be laminated to the TPU material defining at least
one of the first barrier layer 202a and the second barrier layer
202b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 17A-17D).
[0126] As seen in FIGS. 17A-17E, a mold 250 may be utilized for
shaping the first barrier layer 202a, the second barrier layer
202b, the first iridescent layer 202c and the second iridescent
layer 202d in the form the fluid-filled body 202 defining the
forefoot portion 200d during a molding or thermoforming process. In
some instances, adhesive bonding or thermal bonding may be
utilizing for forming the fluid-filled body 202 during the molding
or thermoforming process.
[0127] In an example as seen in FIG. 11E, an exemplary heel portion
200e is defined by a fluid-filled body 202 derived from a first
layer of material defining a first barrier layer 202a, a second
layer of material defining a second barrier layer 202b, a third
layer of material defining a first iridescent layer 202c and a
fourth layer of material defining a second iridescent layer 202d.
The fluid-filled body 202 defining the heel portion 200e is formed
by arranging: (1) at least a portion of an upper surface 202c.sub.U
of the first iridescent layer 202c adjacent a lower surface
202b.sub.L of the second barrier layer 202b, (2) at least a portion
of an upper surface 202b.sub.U of the second barrier layer 202b
adjacent a lower surface 202d.sub.L of the second iridescent layer
202d and (3) at least a portion of an upper surface 202d.sub.U of
the second iridescent layer 202d adjacent a lower surface
202a.sub.L of the first barrier layer 202a. At least one of the
first barrier layer 202a and the second barrier layer 202b may be
formed from a polymer material (e.g., a thermoplastic polyurethane
(TPU) material). The one or more iridescent layers 202c, 202d may
be formed from a polymer material (e.g., a polyurethane (PU)
material) that provides at least a portion of the fluid-filled body
202 defining the heel portion 200e with an iridescent appearance
caused by a diffraction of light waves directed toward the
fluid-filled body 202.
[0128] In some instances, the one or more iridescent layers 202c,
202d includes mica. In some examples, the mica is deposited on one
or both of an upper surface 202c.sub.U, 202d.sub.U and a lower
surface 202c.sub.L, 202d.sub.L of the one or more iridescent layers
202c, 202d. In other examples, the one or more iridescent layers
202c, 202d is impregnated with mica.
[0129] In some instances, the PU material defining the one or more
iridescent layers 202c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 202c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 202c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 202a and the second barrier layer 202b thereby
permitting the PU material defining the one or more iridescent
layers 202c to be laminated to the TPU material defining at least
one of the first barrier layer 202a and the second barrier layer
202b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 17A-17D).
[0130] As seen in FIGS. 17A-17E, a mold 250 may be utilized for
shaping the first barrier layer 202a, the second barrier layer
202b, the first iridescent layer 202c and the second iridescent
layer 202d in the form the fluid-filled body 202 defining the
forefoot portion 200e during a molding or thermoforming process. In
some instances, adhesive bonding or thermal bonding may be
utilizing for forming the fluid-filled body 202 during the molding
or thermoforming process.
[0131] In another example as seen in FIG. 11F, an exemplary heel
portion 200f is defined by a fluid-filled body 202 derived from a
first layer of material defining a first barrier layer 202a, a
second layer of material defining a second barrier layer 202b, a
third layer of material defining a first iridescent layer 202c and
a fourth layer of material defining a second iridescent layer 202d.
The fluid-filled body 202 defining the heel portion 200f is formed
by arranging: (1) at least a portion of an upper surface 202b.sub.U
of the second barrier layer 202b adjacent a lower surface
202c.sub.L of the first iridescent layer 202c, (2) at least a
portion of an upper surface 202c.sub.U of the first iridescent
layer 202c adjacent a lower surface 202a.sub.L of the first barrier
layer 202a and (3) at least a portion of an upper surface
202a.sub.U of the first barrier layer 202a adjacent a lower surface
202d.sub.L of the second iridescent layer 202d. At least one of the
first barrier layer 202a and the second barrier layer 202b may be
formed from a polymer material (e.g., a thermoplastic polyurethane
(TPU) material). The one or more iridescent layers 202c, 202d may
be formed from a polymer material (e.g., a polyurethane (PU)
material) that provides at least a portion of the fluid-filled body
202 defining the heel portion 200f with an iridescent appearance
caused by a diffraction of light waves directed toward the
fluid-filled body 202.
[0132] In some instances, the one or more iridescent layers 202c,
202d includes mica. In some examples, the mica is deposited on one
or both of an upper surface 202c.sub.U, 202d.sub.U and a lower
surface 202c.sub.L, 202d.sub.L of the one or more iridescent layers
202c, 202d. In other examples, the one or more iridescent layers
202c, 202d is impregnated with mica.
[0133] In some instances, the PU material defining the one or more
iridescent layers 202c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 202c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 202c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 202a and the second barrier layer 202b thereby
permitting the PU material defining the one or more iridescent
layers 202c to be laminated to the TPU material defining at least
one of the first barrier layer 202a and the second barrier layer
202b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 17A-17D).
[0134] As seen in FIGS. 17A-17E, a mold 250 may be utilized for
shaping the first barrier layer 202a, the second barrier layer
202b, the first iridescent layer 202c and the second iridescent
layer 202d in the form the fluid-filled body 202 defining the
forefoot portion 200f during a molding or thermoforming process. In
some instances, adhesive bonding or thermal bonding may be
utilizing for forming the fluid-filled body 202 during the molding
or thermoforming process.
[0135] In yet another example as seen in FIG. 11G, an exemplary
heel portion 200g is defined by a fluid-filled body 202 derived
from a first layer of material defining a first barrier layer 202a,
a second layer of material defining a second barrier layer 202b, a
third layer of material defining a first iridescent layer 202c, a
fourth layer of material defining a second iridescent layer 202d
and a fifth layer of material defining a third iridescent layer
202e. The fluid-filled body 202 defining the heel portion 200g is
formed by arranging: (1) at least a portion of an upper surface
202c.sub.U of the first iridescent layer 202c adjacent a lower
surface 202b.sub.L of the second barrier layer 202b, (2) at least a
portion of an upper surface 202b.sub.U of the second barrier layer
202b adjacent a lower surface 202d.sub.L of the second iridescent
layer 202d (3) at least a portion of an upper surface 202d.sub.U of
the second iridescent layer 202d adjacent a lower surface
202a.sub.L of the first barrier layer 202a and (4) at least a
portion of an upper surface 202a.sub.U of the first barrier layer
202a adjacent a lower surface 202e.sub.L of the third iridescent
layer 202e. At least one of the first barrier layer 202a and the
second barrier layer 202b may be formed from a polymer material
(e.g., a thermoplastic polyurethane (TPU) material). The one or
more iridescent layers 202c, 202d, 202e may be formed from a
polymer material (e.g., a polyurethane (PU) material) that provides
at least a portion of the fluid-filled body 202 defining the heel
portion 200g with an iridescent appearance caused by a diffraction
of light waves directed toward the fluid-filled body 202.
[0136] In some instances, the one or more iridescent layers 202c,
202d includes mica. In some examples, the mica is deposited on one
or both of an upper surface 202c.sub.U, 202d.sub.U and a lower
surface 202c.sub.L, 202d.sub.L of the one or more iridescent layers
202c, 202d. In other examples, the one or more iridescent layers
202c, 202d is impregnated with mica.
[0137] In some instances, the PU material defining the one or more
iridescent layers 202c may be commercially available from Korea
Fine Chemical Co., Ltd. and sold under the trade-name Excellon RL.
In some examples, the PU material defining the one or more
iridescent layers 202c may be defined by one or more of the
following characteristics: (1) a thickness approximately equal to
0.15 mm, (2) a shore A hardness of approximately 95, (3) a tensile
strength of approximately 275 kgf/cm.sup.2, (4) an elongation of
approximately 364%, (5) a 300% modulus of approximately 128
kgf/cm.sup.2 and (6) a tear strength of approximately 84 kgf/cm. In
some embodiments, the PU material defining the one or more
iridescent layers 202c may be defined to have about the same
stretchability as the TPU material defining at least one of the
first barrier layer 202a and the second barrier layer 202b thereby
permitting the PU material defining the one or more iridescent
layers 202c to be laminated to the TPU material defining at least
one of the first barrier layer 202a and the second barrier layer
202b during a manufacturing procedure (e.g., a molding procedure as
seen in, for example, FIGS. 17A-17D).
[0138] As seen in FIGS. 17A-17E, a mold 250 may be utilized for
shaping the first barrier layer 202a, the second barrier layer
202b, the first iridescent layer 202c, the second iridescent layer
202d and the third iridescent layer 202e in the form the
fluid-filled body 202 defining the forefoot portion 200g during a
molding or thermoforming process. In some instances, adhesive
bonding or thermal bonding may be utilizing for forming the
fluid-filled body 202 during the molding or thermoforming
process.
[0139] As seen in FIGS. 3B, 8-9 and 11A, the first barrier layer
202a defines an upper surface 204 of the fluid-filled body 202.
Referring to FIGS. 3B, 10 and 11A, the iridescent layer 202c
defines a lower surface 206 of the fluid-filled body 202.
Furthermore, as seen in FIGS. 3B, 8 and 11A, the iridescent layer
202c defines a side surface 208 of the fluid-filled body 202; the
side surface 208 connects the upper surface 204 to the lower
surface 206. As seen in FIG. 3B, the upper surface 204 of the
fluid-filled body 202 of the heel portion 200 is connected to upper
portion 12. Optionally, if an outsole portion 36 is included in the
design of the article of footwear 10, the outsole portion may, as
seen in FIG. 3B, be disposed over some of the lower surface 206 of
the fluid-filled body 202 of the heel portion 200 such that some of
the lower surface 206 is exposed and not obscured by the outsole
portion 36.
[0140] Referring to FIGS. 3B and 11A, one or more of the three or
more layers 202a, 202b, 202c that forms the fluid-filled body 202
contributes to the fluid-filled body 202 defining an outer
peripheral flange 210. Furthermore, as seen in FIGS. 8-10, one or
more of the three or more layers 202a, 202b, 202c that forms the
fluid-filled body 202 contributes to the fluid-filled body 202
defining a webbing 212 that generally defines the upper surface
204. As seen in FIGS. 3B and 11A, the first barrier layer 202a and
the second barrier layer 202b are arranged in a spaced-apart
relationship by a distance D such that the fluid-filled body 202
defines a fluid-filled chamber 214. The fluid-filled chamber 214
encloses or contains a fluid within heel portion 200.
[0141] The fluid-filled chamber 214 and the outer peripheral flange
210 each define a generally U-shaped configuration that, when
incorporated into the article of footwear 10, extends: (1) along
the lateral side 22, (2) around a rear portion of the heel region
20 and (3) along the medial side 24, thereby extending around a
peripheral area of heel portion 200. As similarly described above
with respect to the plurality of fluid-filled chambers 114, the
fluid-filled chamber 214 encloses or contains a fluid within heel
portion 200 and is formed by the first barrier layer 202a and the
second barrier layer 202b. One or more of the three or more layers
202a, 202b, 202c that forms the fluid-filled body 202 contributes
to the fluid-filled body 202 defining the outer peripheral flange
210; as seen in FIG. 11A, one or more of the three or more layers
202a, 202b, 202c are molded and joined together, protruding
outwardly from fluid-filled chamber 214. The webbing 212 extends
through a central area of heel portion 200 and between lateral and
medial portions of the fluid-filled chamber 214. Like the outer
peripheral flange 210, the webbing 212 is formed from portions of
one or more of the three or more layers 202a, 202b, 202c that are
joined together. Although adhesive bonding may be utilized in
joining two or more of the three or more layers 202a, 202b, 202c in
one or more areas defining, for example, the outer peripheral
flange 210 and the webbing 212, thermal bonding may also join two
or more of the three or more layers 202a, 202b, 202c during the
molding or thermoforming process.
[0142] The fluid-filled chamber 214 is the primary component of
heel portion 200 that encloses the fluid. In areas immediately
adjacent to the fluid-filled chamber 214, the three or more layers
202a, 202b, 202c are joined to each other to form a bond that seals
the fluid within heel portion 200. More particularly, the outer
peripheral flange 210 and the webbing 212 cooperatively bound or
otherwise extend around the fluid-filled chamber 214 and are formed
from areas of the three or more layers 202a, 202b, 202c that are
bonded to each other, thereby sealing the fluid within the
fluid-filled chamber 214. In further configurations of the article
of footwear 10, the fluid-filled chamber 214 may be subdivided into
two or more sub-chambers that may be pressurized differently. In
other configurations, the heel portion 200 may be a part of a fluid
system that pumps fluid into the fluid-filled chamber 214. In still
further configurations, the medial and lateral portions may be
connected through a central portion of the webbing 212.
[0143] The upper surface 204 has a generally concave configuration,
as depicted in, for example, FIG. 11A, that supports the foot when
the article of footwear 10 is worn. As such, the foot effectively
rests within the U-shaped configurations of the fluid-filled
chamber 214 and the outer peripheral flange 210. This configuration
may provide stability to the article of footwear 10 and ensures
that the foot remains properly positioned relative to heel portion
200 and other portions of sole portion 14.
[0144] The outer peripheral flange 210 may also form a peripheral
seam or bonded area that joins the three or more layers 202a, 202b,
202c and assists with sealing the fluid within heel portion 200. In
general, the outer peripheral flange 210 has a height of at least
five (5) millimeters and extends in an outward direction from a
remainder of heel portion 200. In some instances, the outer
peripheral flange 210 extends in an upward direction from the
peripheral area or an upper area of heel portion 200. In some
embodiments, the area of the outer peripheral flange 210
corresponding with the upper surface 204 faces toward and is
secured to upper portion 12 whereas the area of the outer
peripheral flange 210 corresponding with lower surface 206 faces
away from and forms a portion of an exterior surface of the article
of footwear 10 (e.g., one surface of the outer peripheral flange
210 is secured to the upper portion 12 and the opposite surface of
the outer peripheral flange 210 faces away from the upper portion
12). In some examples, the outer peripheral flange 210 is a
relatively thick and stiff portion of heel portion 200, enhancing
the stability of the article of footwear 10. As with the outer
peripheral flange 110 of the forefoot portion 100, the outer
peripheral flange 210 may provide a defined lasting margin during
steps of the manufacturing process that involve bonding upper
portion 12 to heel portion 200.
[0145] Referring to the cross-sectional view of FIG. 11A, in an
example, the outer peripheral flange 210 is depicted as having a
tapered configuration, with the portions of the outer peripheral
flange 210 located adjacent to the fluid-filled chamber 214 having
greater thickness than the portions of the outer peripheral flange
210 that are spaced from the fluid-filled chamber 214. In some
instances, the outer peripheral flange 210 has a tapered
configuration with a first thickness adjacent to the void in the
fluid-filled chamber 214 and a second thickness spaced away from
the void, the first thickness being greater than the second
thickness. Moreover, in other examples, the thickness of the
portions of the outer peripheral flange 210 located adjacent to the
void (i.e., the first thickness) is greater than either of: (1) the
thickness of the webbing 212 in the central area of heel portion
200 and (2) the sum of the thicknesses of the three or more layers
202a, 202b, 202c. Although the outer peripheral flange 210 is
formed from the three or more layers 202a, 202b, 202c, the outer
peripheral flange 210 has a greater thickness than both of the
three or more layers 202a, 202b, 202c combined.
[0146] Although the configuration of the heel portion 200 discussed
above provides an exemplary configuration for use in the article of
footwear 10, a variety of other configurations may also be
utilized. In an example, the outer peripheral flange 210 may angle
outwardly rather than having a vertical orientation; in such a
configuration, the outer peripheral flange 210 may support edges of
the foot, rather than extending along sides of the foot. In other
examples, the fluid-filled chamber 214 may bulge outwardly to a
lesser degree, which locates the outer peripheral flange 210 at the
immediate periphery of heel portion 200 and forms vertical sides
for the heel portion 200. In yet another example, the width of the
fluid-filled chamber 214 may increase, which may modify the
cushioning or force attenuation properties of the heel portion 200.
In other configurations, the outer peripheral flange 210 may have a
squared aspect.
[0147] Although the area between opposite sides of the fluid-filled
chamber 214 and under the webbing 212 may be open, other components
such as, for example, foam elements may be located in this area. In
one example, a foam element may be located under and in contact
with the webbing 212. Among other aspects, the foam element may
affect the flexibility or force attenuation properties of heel
portion 200. Moreover, the shape and location of the foam element
may also affect properties of heel portion 200. In an example, the
foam element has a tapered configuration, which may alter
properties between forward and rearward areas of the heel portion
200. Similarly, the foam element is tapered and spaced from the
webbing 212. Accordingly, the heel portion 200 may vary in many
aspects.
[0148] Referring to FIGS. 12-14E, a methodology for manufacturing a
forefoot portion 100 is described. With reference to FIGS. 12-13,
an exemplary mold 150 for forming the forefoot portion 100 is shown
including a first mold portion 152a and a second mold portion 152b.
As seen in FIGS. 14A-14E, the mold 150 forms the forefoot portion
100 defining the fluid-filled body 102 of FIG. 7A from the first
barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c. More particularly, the mold 150 facilitates
the manufacturing process by: (1) shaping the first barrier layer
102a, the second barrier layer 102b and the iridescent layer 102c
in areas corresponding with the plurality of fluid-filled chambers
114, the outer peripheral flange 110, and the fluid conduits 116
and (2) joining the first barrier layer 102a, the second barrier
layer 102b and the iridescent layer 102c in areas corresponding
with the outer peripheral flange 110.
[0149] Referring to FIGS. 12 and 14A, the first mold portion 152a
includes a mold surface defined by an outer peripheral pinch
surface 154 that is joined to an inner peripheral first
seam-forming surface 156 that is joined to a central compression
surface 158. The outer peripheral pinch surface 154 and the inner
peripheral first seam-forming surface 156 are angled relative to
each other, with the outer peripheral pinch surface 154 being more
vertical than the inner peripheral first seam-forming surface
156.
[0150] Referring to FIGS. 13 and 14A, the second mold portion 152b
includes an outer peripheral pinch edge surface 160 that is joined
to an inner peripheral second seam-forming surface 162 that is
joined to a central compression surface 164. In some instances, the
outer peripheral pinch edge surface 160 may define a relatively
sharp corner or angled area of the second mold portion 152b, the
inner peripheral second seam-forming surface 162 extends downward
and may be generally parallel to the outer peripheral pinch surface
154 of the first mold portion 152a.
[0151] Referring to FIG. 14D, the first mold portion 152a
cooperates with the second mold portion 152b to define a void 166
within the mold 150. As will be described in the following
disclosure at FIGS. 14A-14E, when the first barrier layer 102a, the
second barrier layer 102b and the iridescent layer 102c are
arranged between the first mold portion 152a and the second mold
portion 152b and disposed within the void 166, the surfaces 154-158
of the first mold portion 152a and the surfaces 160-164 of the
second mold portion 152b define a shape corresponding to the
forefoot portion 100, such that upon pressurization of the void
166, the surfaces 154-158 of the first mold portion 152a and the
surfaces 160-164 of the second mold portion 152b forms the first
barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c to define features of forefoot portion 100
described above at FIGS. 4-7A.
[0152] Referring to FIG. 14A, each of the first barrier layer 102a,
the second barrier layer 102b and the iridescent layer 102c are
initially located between each of the first mold portion 152a and
the second mold portion 152b, which are arranged in a spaced-apart
or open configuration. In this configuration, the first barrier
layer 102a is positioned adjacent to or opposite the first mold
portion 152a and the iridescent layer 102c is positioned adjacent
to or opposite the second mold portion 152b. In addition to the
arrangement of the first barrier layer 102a and the iridescent
layer 102c as described above, the second barrier layer 102b is
disposed between the first barrier layer 102a and the iridescent
layer 102c. In some examples, prior to positioning the iridescent
layer 102c adjacent or opposite the second mold portion 152b, the
iridescent layer 102c may be attached to one of the first barrier
layer 102a or the second barrier layer 102b; in the illustrated
example as seen in FIG. 14B, an upper surface 102c.sub.U of the
iridescent layer 102c is attached to a lower surface 102b.sub.L of
the second barrier layer 102b.
[0153] A shuttle frame or other device (not shown) may be utilized
to assist in positioning any of the first barrier layer 102a, the
second barrier layer 102b and the iridescent layer 102c. As part of
the manufacturing process, one or all of the first barrier layer
102a, the second barrier layer 102b and the iridescent layer 102c
are heated to a temperature that facilitates shaping and bonding of
the first barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c. As an example, various radiant heaters or
other devices (not shown) may be utilized to heat the first barrier
layer 102a, the second barrier layer 102b and the iridescent layer
102c; the act of heating the first barrier layer 102a, the second
barrier layer 102b and the iridescent layer 102c may occur prior to
locating the first barrier layer 102a, the second barrier layer
102b and the iridescent layer 102c between the first mold portion
152a and the second mold portion 152b. As another example, one or
both of the first mold portion 152a and the second mold portion
152b may be heated such that contact of the first barrier layer
102a with the surfaces 154-158 of the first mold portion 152a
and/or the iridescent layer 102c with the surfaces 160-164 of the
second mold portion 152b at a later portion of the manufacturing
process raises the temperature to a level that facilitates shaping
and bonding of the first barrier layer 102a, the second barrier
layer 102b and the iridescent layer 102c.
[0154] Referring to FIG. 14B, once the first barrier layer 102a,
the second barrier layer 102b and the iridescent layer 102c are
positioned as described above, the first mold portion 152a and the
second mold portion 152b translate or otherwise move toward each
other and begin to close upon and capture the first barrier layer
102a, the second barrier layer 102b and the iridescent layer 102c
therebetween within the void 166 formed by the first mold portion
152a and the second mold portion 152b. As the first mold portion
152a and the second mold portion 152b move toward each other,
various techniques may be utilized to draw the first barrier layer
102a, the second barrier layer 102b and the iridescent layer 102c
against the surfaces 154-158 of the first mold portion 152a and/or
the iridescent layer 102c with the surfaces 160-164 of the second
mold portion 152b, thereby beginning the process of shaping the
first barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c.
[0155] In an example, air may be partially evacuated (by, e.g.,
vacuum ports formed by the first mold portion 152a and/or the
second mold portion 152b) from void 166 between: (1) one or more of
the surfaces 154-158 of the first mold portion 152a and the first
barrier layer 102a and (2) one or more of the surfaces 160-164 of
the second mold portion 152b and the iridescent layer 102c. By
removing air from the void 166, the first barrier layer 102a and
the iridescent layer 102c are drawn into contact with one or more
of the surfaces 154-158 of the first mold portion 152a and one or
more of the surfaces 160-164 of the second mold portion 152b. In
another example, air may be injected into the void 166 between, for
example: (1) the first barrier layer 102a and the second barrier
layer 102b and/or (2) the second barrier layer 102b and the
iridescent layer 102c, thereby elevating the pressure between the
first barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c. During a preparatory stage of this process,
an injection needle may be located between the first barrier layer
102a, the second barrier layer 102b and the iridescent layer 102c
and a gas may then be ejected from the injection needle such that
the first barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c engage one or more of the surfaces 154-158 of
the first mold portion 152a and one or more of the surfaces 160-164
of the second mold portion 152b. Each of these techniques may be
used together or independently.
[0156] Referring to FIG. 14C, as mold the first mold portion 152a
and the second mold portion 152b continue to move toward each
other, the first barrier layer 102a, the second barrier layer 102b
and the iridescent layer 102c are pinched between the first mold
portion 152a and the second mold portion 152b. More particularly,
the first barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c are compressed between the outer peripheral
pinch surface 154 of the first mold portion 152a and the outer
peripheral pinch edge surface 160 of the second mold portion 152b.
In addition to beginning the process of separating excess portions
of the first barrier layer 102a, the second barrier layer 102b and
the iridescent layer 102c from portions that form forefoot portion
100, the pinching of the first barrier layer 102a, the second
barrier layer 102b and the iridescent layer 102c begins the process
of bonding or joining the first barrier layer 102a, the second
barrier layer 102b and the iridescent layer 102c in the area
defined by the outer peripheral flange 110.
[0157] Referring to FIG. 14D, the first mold portion 152a and the
second mold portion 152b are further advanced toward each other
such that the mold 150 is arranged in a closed configuration. As
the arrangement of the first mold portion 152a and the second mold
portion 152b changes from what is shown in FIG. 14C to that of FIG.
14D, the outer peripheral pinch surface 154 of the first mold
portion 152a contacts and slides against a portion of the inner
peripheral second seam-forming surface 162 of the second mold
portion 152b. The contact between the outer peripheral pinch
surface 154 of the first mold portion 152a and the inner peripheral
second seam-forming surface 162 of the second mold portion 152b
effectively severs excess portions of the first barrier layer 102a,
the second barrier layer 102b and the iridescent layer 102c from
portions that form forefoot portion 100. In addition, the sliding
movement pushes portions of the material forming the first barrier
layer 102a, the second barrier layer 102b and the iridescent layer
102c downward and further into the void 166. Moreover, the material
forming the first barrier layer 102a, the second barrier layer 102b
and the iridescent layer 102c compacts or otherwise collects in the
area between the inner peripheral first seam-forming surface 156 of
the first mold portion 152a and the inner peripheral second
seam-forming surface 162 of the second mold portion 152b. Given
that the inner peripheral first seam-forming surface 156 of the
first mold portion 152a and the inner peripheral second
seam-forming surface 162 of the second mold portion 152b are angled
relative to each other, the compacted material defined by the first
barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c forms a generally triangular or tapered
structure, which results in the formation of the outer peripheral
flange 110. In addition to forming the outer peripheral flange 110,
the first barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c are shaped to form the plurality of
fluid-filled chambers 114.
[0158] Referring to FIG. 14E, a peripheral portion of the void 166
proximate the inner peripheral first seam-forming surface 156 of
the first mold portion 152a and the inner peripheral second
seam-forming surface 162 of the second mold portion 152b defines an
area that forms the outer peripheral flange 110. The non-parallel
configuration between the inner peripheral first seam-forming
surface 156 of the first mold portion 152a and the inner peripheral
second seam-forming surface 162 of the second mold portion 152b
results in a tapered space where the first barrier layer 102a, the
second barrier layer 102b and the iridescent layer 102c collects to
form the outer peripheral flange 110. A distance across the space
between the inner peripheral first seam-forming surface 156 of the
first mold portion 152a and the inner peripheral second
seam-forming surface 162 of the second mold portion 152b is greater
adjacent to a portion of the void 166 that forms the plurality of
fluid-filled chambers 114 than in the area where the inner
peripheral first seam-forming surface 156 of the first mold portion
152a and the inner peripheral second seam-forming surface 162 of
the second mold portion 152b meet, which is spaced from the portion
of the void 166 that forms the plurality of fluid-filled chambers
114. Although the configuration of the tapered space between the
inner peripheral first seam-forming surface 156 of the first mold
portion 152a and the inner peripheral second seam-forming surface
162 of the second mold portion 152b may vary, an angle formed
between the inner peripheral first seam-forming surface 156 of the
first mold portion 152a and the inner peripheral second
seam-forming surface 162 of the second mold portion 152b may be in
a range of twenty degrees and forty-five degrees.
[0159] As discussed above, the material forming the first barrier
layer 102a, the second barrier layer 102b and the iridescent layer
102c compacts or otherwise collects in the area between the inner
peripheral first seam-forming surface 156 of the first mold portion
152a and the inner peripheral second seam-forming surface 162 of
the second mold portion 152b. This compaction effectively thickens
one or both of the first barrier layer 102a, the second barrier
layer 102b and the iridescent layer 102c (i.e., whereas the first
barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c have a first thickness in FIG. 14A and a
second, greater thickness at the stage depicted in FIG. 14D when
the outer peripheral flange 110 is formed). The compaction of the
first barrier layer 102a, the second barrier layer 102b and the
iridescent layer 102c occurs as the outer peripheral pinch surface
154 of the first mold portion 152a contacts and slides against a
portion of the inner peripheral second seam-forming surface 162 of
the second mold portion 152b.
[0160] Referring to FIG. 14E, when formation of the forefoot
portion 100 is complete, the mold 150 is opened and the forefoot
portion 100 is removed from the mold 150 in order to permit the
forefoot portion 100 to cool. A fluid may then be injected into
forefoot portion 100 to pressurize the plurality of fluid-filled
chambers 114, thereby completing the manufacture of forefoot
portion 100. As a final step in the process, the forefoot portion
100 may be incorporated into sole portion 14 of the article of
footwear 10.
[0161] Although a variety of manufacturing processes may be
utilized for forming the heel portion 200, the heel portion 200 may
be formed through a process that is substantially similar to the
process discussed above for forming the forefoot portion 100. With
reference to FIGS. 15-16, a mold 250 is shown including a first
mold portion 252a and a second mold portion 252b. As seen in FIGS.
17A-17D, the first mold portion 252a includes a mold surface
defined by an outer peripheral pinch surface 254 that is joined to
an inner peripheral first seam forming surface 256 that is joined
to a central compression surface 258. The second mold portion 252b
includes an outer peripheral pinch edge surface 260 that is joined
to an inner peripheral second seam-forming surface 262 that is
joined to a central compression surface 264.
[0162] The mold 250 forms the heel portion 200 defining the
fluid-filled body 202 of FIG. 11A from the first barrier layer
202a, the second barrier layer 202b and the iridescent layer 202c.
More particularly, the mold 250 facilitates the manufacturing
process by: (1) shaping the first barrier layer 202a, the second
barrier layer 202b and the iridescent layer 202c in areas
corresponding with the fluid-filled chamber 214 and the outer
peripheral flange 210 and (2) joining the first barrier layer 202a,
the second barrier layer 202b and the iridescent layer 202c in
areas corresponding with the outer peripheral flange 210. In
addition, the mold 250 may facilitate the bonding of the outsole
portion 36 to the heel portion 200.
[0163] Referring to FIG. 17A, each of the first barrier layer 202a,
the second barrier layer 202b and the iridescent layer 202c are
arranged between each of the first mold portion 252a and the second
mold portion 252b. Referring to FIG. 17A, each of the first barrier
layer 202a, the second barrier layer 202b and the iridescent layer
202c are initially located between each of the first mold portion
252a and the second mold portion 252b, which are arranged in a
spaced-apart or open configuration. In this configuration, the
first barrier layer 202a is positioned adjacent to or opposite the
first mold portion 252a and the iridescent layer 202c is positioned
adjacent to or opposite the second mold portion 252b. In addition
to the arrangement of the first barrier layer 202a and the
iridescent layer 202c as described above, the second barrier layer
202b is disposed between the first barrier layer 202a and the
iridescent layer 202c. In some examples, prior to positioning the
iridescent layer 202c adjacent or opposite the second mold portion
252b, the iridescent layer 202c may be attached to one of the first
barrier layer 202a or the second barrier layer 202b; in the
illustrated example as seen in FIG. 17B, an upper surface
202c.sub.U of the iridescent layer 202c is attached to a lower
surface 202b.sub.L of the second barrier layer 202b. In addition,
one or more elements that form the outsole portion 36 may also be
located relative to the mold 250.
[0164] Referring to FIG. 17B, once the first barrier layer 202a,
the second barrier layer 202b and the iridescent layer 202c are
positioned as described above, and, if optionally included, the
elements of the outsole portion 36 are located within depressions
268 formed by the second mold portion 252b, the first mold portion
252a and the second mold portion 252b translate or otherwise move
toward each other and begin to close upon and capture the first
barrier layer 202a, the second barrier layer 202b and the
iridescent layer 202c there-between within a void 266 (see, e.g.,
FIG. 17C) formed by the first mold portion 252a and the second mold
portion 252b. As discussed above in FIGS. 14A-14E, in a
substantially similar fashion, air may be partially evacuated from
the areas between: (1) surface portions of the first mold portion
252a and the first barrier layer 202a and (2) surface portions of
the second mold portion 252b and the iridescent layer 202c.
Additionally, air may be injected into the void 266 between, for
example: (1) the first barrier layer 202a and the second barrier
layer 202b and/or (2) the second barrier layer 202b and the
iridescent layer 202c, thereby elevating the pressure between the
first barrier layer 202a, the second barrier layer 202b and the
iridescent layer 202c. Using one or both of these techniques, the
first barrier layer 202a, the second barrier layer 202b and the
iridescent layer 202c are induced to engage the surfaces of the
first mold portion 252a and the second mold portion 252b.
[0165] Referring to FIG. 17C, as the first mold portion 252a and
the second mold portion 252b continue to move toward each other,
the first barrier layer 202a, the second barrier layer 202b and the
iridescent layer 202c are compressed between the first mold portion
252a and the second mold portion 252b. In an example, the first
barrier layer 202a, the second barrier layer 202b and the
iridescent layer 202c are compressed to form outer peripheral
flange 210 and the webbing 212.
[0166] In some instances, the iridescent layer 202c may bond with
the outsole portion 36. In some configurations, the outsole portion
36 may be thermal bonded to the heel portion 200 during the
manufacturing process. In an example, when each of the iridescent
layer 202c and the outsole portion 36 are formed from similar or
compatible materials, or, when the outsole portion 36 is at least
partially formed from a material defining the fluid-filled chamber
214, heating of the components may induce thermal bonding between
the components.
[0167] Referring to FIG. 17D, when formation of the heel portion
200 is complete, the mold 250 is opened and the heel portion 200 is
removed and permitted to cool. A fluid may then be injected into
heel portion 200 to pressurize the fluid-filled chamber 214,
thereby completing the manufacturing process of the heel portion
200. As a final step in the process, the heel portion 200 may be
incorporated into sole portion 14 of the article of footwear
10.
[0168] The following Clauses provide an exemplary configuration for
an article of footwear described above.
[0169] Clause 1: A fluid-filled chamber comprising a first barrier
layer, a second barrier layer attached to the first barrier layer
and cooperating with the first barrier layer to define an interior
void and a third layer attached to one of the first barrier layer
and the second barrier layer and including mineral mica operable to
provide the one of the first barrier layer and the second barrier
layer with an iridescent appearance caused by differential
refraction of light waves.
[0170] Clause 2: The fluid-filled chamber of Clause 1, wherein the
third layer is formed from a polymer material.
[0171] Clause 3: The fluid-filled chamber of Clause 1, wherein the
third layer is formed from a polyurethane material.
[0172] Clause 4: The fluid-filled chamber of Clause 1, wherein the
mica is at least one of ground mica, built-up mica, and sheet
mica.
[0173] Clause 5: The fluid-filled chamber of Clause 1, wherein the
mica is deposited on an outer surface of the third layer.
[0174] Clause 6: The fluid-filled chamber of Clause 1, wherein the
third layer is impregnated with mica.
[0175] Clause 7: The fluid-filled chamber of any of the preceding
Clauses, wherein the third layer is disposed within the interior
void.
[0176] Clause 8: The fluid-filled chamber of any of the preceding
Clauses, wherein the third layer is attached to an exterior surface
of at least one of the first barrier layer and the second barrier
layer.
[0177] Clause 9: The fluid-filled chamber of any of the preceding
Clauses, wherein the third layer is attached to an interior surface
of at least one of the first barrier layer and the second barrier
layer within the interior void.
[0178] Clause 10: An article of footwear incorporating the
fluid-filled chamber of any of the preceding Clauses.
[0179] Clause 11: A method comprising attaching a first iridescent
material to a first barrier sheet, inserting the first barrier
sheet into a mold, inserting a second barrier sheet into the mold,
applying at least one of heat and pressure to at least one of the
first barrier sheet, the second barrier sheet, and the iridescent
material via the mold, joining the first barrier sheet and the
second barrier sheet together to define a chamber and inflating the
chamber.
[0180] Clause 12: The method of Clause 11, wherein inserting the
first barrier sheet into the mold includes positioning the first
iridescent material between the first barrier sheet and the second
barrier sheet.
[0181] Clause 13: The method of Clause 11, wherein inserting the
first barrier sheet into the mold includes positioning the first
barrier sheet between the first iridescent material and the second
barrier sheet.
[0182] Clause 14: The method of any of the preceding Clauses,
further comprising attaching a second iridescent material to the
second barrier sheet.
[0183] Clause 15: The method of Clause 14, wherein inserting the
second barrier sheet into the mold includes positioning the second
iridescent material between the second barrier sheet and the first
barrier sheet.
[0184] Clause 16: The method of Clause 14, wherein inserting the
second barrier sheet into the mold includes positioning the second
barrier sheet between the second iridescent material and the first
barrier sheet.
[0185] Clause 17: The method of any of the preceding Clauses,
wherein providing the first iridescent material includes providing
a polymer material having an iridescent appearance caused by
differential refraction of light waves.
[0186] Clause 18: The method of any of the preceding Clauses,
wherein providing the first iridescent material includes providing
a material including mica.
[0187] Clause 19: The method of Clause 18, wherein providing a
material including mica includes providing a material impregnated
with mica.
[0188] Clause 20: The method of any of the preceding Clauses,
further comprising incorporating the chamber into an article of
footwear.
[0189] Clause 21: A method comprising inserting a first barrier
sheet into a mold, inserting a second barrier sheet into a mold,
inserting a first iridescent sheet into the mold, applying at least
one of heat and pressure to the first barrier sheet, the second
barrier sheet, and the iridescent sheet via the mold joining the
first barrier sheet and the second barrier sheet together to define
a chamber, joining the iridescent sheet to at least one of the
first barrier sheet and the second barrier sheet and inflating the
chamber.
[0190] Clause 22: The method of Clause 21, wherein inserting the
first barrier sheet into the mold includes positioning the first
iridescent material between the first barrier sheet and the second
barrier sheet.
[0191] Clause 23: The method of Clause 21, wherein inserting the
first barrier sheet into the mold includes positioning the first
barrier sheet between the first iridescent material and the second
barrier sheet.
[0192] Clause 24: The method of any of the preceding Clauses,
further comprising inserting a second iridescent material into the
mold.
[0193] Clause 25: The method of Clause 24, wherein inserting the
second iridescent material into the mold includes positioning the
second iridescent material between the second barrier sheet and the
first barrier sheet.
[0194] Clause 26: The method of Clause 24, wherein inserting the
second iridescent material into the mold includes positioning the
second barrier sheet between the second iridescent material and the
first barrier sheet.
[0195] Clause 27: The method of any of the preceding Clauses,
wherein providing the first iridescent material includes providing
a polymer material having an iridescent appearance caused by
differential refraction of light waves.
[0196] Clause 28: The method of any of the preceding Clauses,
wherein providing the first iridescent material includes providing
a material including mica.
[0197] Clause 29: The method of Clause 28, wherein providing a
material including mica includes providing a material impregnated
with mica.
[0198] Clause 30: The method of any of the preceding Clauses,
further comprising incorporating the chamber into an article of
footwear.
[0199] The foregoing description has been provided for purposes of
illustration and description. It is not intended to be exhaustive
or to limit the disclosure. Individual elements or features of a
particular configuration are generally not limited to that
particular configuration, but, where applicable, are
interchangeable and can be used in a selected configuration, even
if not specifically shown or described. The same may also be varied
in many ways. Such variations are not to be regarded as a departure
from the disclosure, and all such modifications are intended to be
included within the scope of the disclosure.
* * * * *