CN101257814A - 充气鞋或用于充气用品的气囊的制造方法 - Google Patents

充气鞋或用于充气用品的气囊的制造方法 Download PDF

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Publication number
CN101257814A
CN101257814A CNA2006800275794A CN200680027579A CN101257814A CN 101257814 A CN101257814 A CN 101257814A CN A2006800275794 A CNA2006800275794 A CN A2006800275794A CN 200680027579 A CN200680027579 A CN 200680027579A CN 101257814 A CN101257814 A CN 101257814A
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film
air bag
impervious material
plenum chamber
footwear
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CN101257814B (zh
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弗兰克·米利特
布赖恩·克里斯坦森
保罗·M·戴维斯
保罗·E·利奇菲尔德
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Reebok International Ltd
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Reebok International Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
    • B29C66/4326—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making hollow articles or hollow-preforms, e.g. half-shells
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    • A43—FOOTWEAR
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    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/18—Resilient soles
    • A43B13/189—Resilient soles filled with a non-compressible fluid, e.g. gel, water
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B13/00—Soles; Sole-and-heel integral units
    • A43B13/14—Soles; Sole-and-heel integral units characterised by the constructive form
    • A43B13/18—Resilient soles
    • A43B13/20—Pneumatic soles filled with a compressible fluid, e.g. air, gas
    • A43B13/203—Pneumatic soles filled with a compressible fluid, e.g. air, gas provided with a pump or valve
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
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    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/02—Uppers; Boot legs
    • A43B23/0245—Uppers; Boot legs characterised by the constructive form
    • A43B23/028—Resilient uppers, e.g. shock absorbing
    • A43B23/0285—Resilient uppers, e.g. shock absorbing filled with a non-compressible fluid, e.g. gel or water
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
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    • A43B23/00—Uppers; Boot legs; Stiffeners; Other single parts of footwear
    • A43B23/02—Uppers; Boot legs
    • A43B23/0245—Uppers; Boot legs characterised by the constructive form
    • A43B23/028—Resilient uppers, e.g. shock absorbing
    • A43B23/029—Pneumatic upper, e.g. gas filled
    • A—HUMAN NECESSITIES
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    • A—HUMAN NECESSITIES
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    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
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    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00—Clothing
    • B32B2437/02—Gloves, shoes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/06—Embossing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing
    • Y10T156/108—Flash, trim or excess removal

Abstract

本发明涉及一种用于制造充气用品或用于充气用品的气囊的方法，该方法时间效率高、简单、成本低，并且因无需昂贵的特定构造的金属加工而不会中断多个甚至定制用品或气囊构造和尺寸的制造。该方法包括施加布置在第一和第二薄膜之间的防渗材料，将第一薄膜粘附在第二薄膜上，使得两个薄膜在已经施加防渗材料之外的区域密封在一起，从而形成至少一个充气室和密封外周边缘，以及沿密封外周边缘切割以形成充气用品或气囊。防渗材料可以是涂料、油墨或有效防止第一薄膜粘附在第二薄膜上的表面处理。本发明的充气用品或气囊可以被用作例如包括鞋类的运动装备或用在其中。

Description

充气鞋或用于充气用品的气囊的制造方法
技术领域
本发明涉及充气用品或用于充气用品例如鞋类或者服装的防流体渗透气囊的制造方法。
背景技术
充气制造用品或用于充气制造用品的气囊多年来一直公知。这种制造用品包括充气床垫和枕头、充气救生衣和救生艇以及运动装备。在运动装备领域，充气气囊一直被包裹在球的内部(例如篮球、足球、英式足球等)，以及在防护服装用品例如棒球和拳击手套、头盔、护胸和鞋类的内部。当用于鞋类时，充气气囊可以为穿用者的脚提供定制的缓冲并提高适配性。在一些情况下，充气气囊可以束紧系统将鞋固定在穿用者的脚上。充气气囊还被用在鞋的鞋底上以向穿用者的脚底提供缓冲并减缓来自走、跑和跳的冲击力。
2004年7月12日提交的美国申请No.10/887,927(并且在2005年2月10日作为美国公开专利申请No.20050028404-A1被公开)公开了一种具有充气气囊的鞋。申请人在此将该申请的全部内容引入作为参考。
授予Cohen等人的美国专利No.5,113,599(’599专利)公开了一种具有充气气囊的运动鞋。该专利公开了用于鞋舌、鞋侧面和鞋中部、环绕脚踝、脚底或整个鞋上的多种充气气囊构造。该专利的气囊由第一热塑性氨基甲酸酯(TPU)薄膜和共同延伸的第二TPU薄膜制成。第一和第二薄膜沿预定的焊接或样式线相互连接。气囊的外周焊接线形成密封的气囊室或腔并防止空气从中逸出。第一和第二薄膜还在多个圆点或内部焊接线处相互连接以控制气囊的厚度，防止不符合要求的“凸出”，这种凸出会给穿用者带来不适或阻碍适配。
’599专利的气囊的第一和第二薄膜利用射频(RF)或电介质焊接技术焊接在一起。RF或电介质焊接采用高频无线电能量激励热塑性材料分子到达它们熔化并焊接在一起以形成坚固结合的点。为了焊接’599专利的气囊，共同延伸的薄膜被放置在RF机的铜模具(具有代表所需外周、圆形和内部焊接线的突起区域)与床面之间。在使铜模具与RF床面相互接触之后，RF机通电并且第一和第二薄膜仅在铜模具的突起区域上相互结合以形成外周、圆形和内部焊接线。在完成焊接步骤之后，充气气囊被从剩余的共同延伸的第一和第二薄膜上冲切下并通过粘合剂、常规缝合或其它紧固装置适当地组装成鞋。’599专利的第一和第二薄膜还可以通过常规加热并适当图案的铜模具或者通过施加适用于热塑性薄膜的化学粘合剂或粘结剂相互粘附。
该专利还公开了通过永久固定在气囊上的泵对采用上述RF焊接技术或适用于气囊薄膜的任意其它密封方法的气囊进行充气。备选地，可以通过与同样在易于由穿用者接触到的位置固定在气囊上的充气/放气阀相连的外置泵对气囊充气。在美国专利No.5.074.765和No.5,144,708中公开了适用于鞋类充气气囊的其它泵和阀。
尽管采用RF焊接技术制造充气气囊不需要任何粘合剂或其它材料，并且具有精确制作图案、降低薄膜靠近焊接线的区域上的热降解以及提高密封强度的优点，但为了充气气囊图案而利用机器或化学蚀刻铜模具成本高且耗时，尤其是在生产大尺寸范围和多重构造的制造用品的情况下。常规加热的铜模具的制成也是昂贵的，同时化学粘合剂很脏并且需要在控制环境下进行固化。另外，RF焊接技术相当灵敏，要求薄膜足够厚以防止薄膜过度熔化，由此导致气囊漏气。
因此，需要提供一种用于制造充气用品或用于充气用品的气囊的方法，该方法成本相对较低、具有较高的时间效率并且可以利用对制造过程产生很小到没有任何中断或延迟的过程和材料制造多种气囊构造和尺寸。
发明内容
本发明的制造方法与现有技术中公知的方法相比有利之处在于其更简单、实质上基本连续、易于变形从而可以制造多种充气用品或气囊构造、并且因不需要昂贵的构造特殊的铜的机械加工而具有更高的经济性。
本发明的一种实施方式是一种用于制造充气鞋类用品的方法，包括以下步骤：提供第一薄膜；向第一薄膜的第一侧施加具有气囊构造的防渗材料；提供第二薄膜，使得防渗材料布置在第一薄膜与第二薄膜之间；使第一薄膜粘附在第二薄膜上以在防渗材料施加到第一薄膜的区域之外形成密封外周区域，从而形成至少一个充气室；沿密封外周区域切割以形成具有至少一个充气室和密封外周边缘的气囊；以及将气囊结合在鞋内以形成充气鞋类用品。防渗材料可以是涂料、油墨、纸、织物、感光剂、颗粒或酸。防渗材料还可以是第一薄膜的压印或织构表面。
所述方法还包括以下步骤，形成气囊构造负像的筛网、模板或型板，并采用所述筛网、模板或型板向第一薄膜施加具有气囊构造的防渗材料。
在另一实施方式中，本发明涉及一种用于制造充气气囊的方法，包括以下步骤：提供具有第一侧和第二侧的第一薄膜；向第一薄膜的第一侧施加防渗材料；向第一薄膜的第一侧提供第二薄膜，使得防渗材料布置在第一薄膜与第二薄膜之间；将第一薄膜粘附在第二薄膜上以在防渗材料施加到第一薄膜第一侧的区域之外形成密封外周区域，从而形成至少一个总体形状与气囊构造相一致的充气室；以及沿密封外周区域切割以形成具有至少一个充气室和密封外周边缘的气囊。
通过激光、喷水或金属模具完成切割步骤。防渗材料可以是涂料、油墨、纸、织物、感光剂、颗粒或酸。防渗材料可以印刷在第一薄膜的第一侧。
第一或第二薄膜可以是粘附在基底上的热塑性薄膜的叠层。气囊可以包括用于容纳充气或放气阀配件的细长区域。
在另一实施方式中，本发明涉及一种用于制造定制的充气制造用品的方法，包括以下步骤：提供数据库，其中所述数据库包括用于至少一个定制气囊设计的至少一个信息记录；提供第一薄膜；根据至少一个信息记录向第一薄膜的第一侧施加防渗材料以在第一薄膜上形成至少一个定制气囊设计；在第一薄膜上提供第二薄膜，使得防渗材料布置在第一薄膜与第二薄膜之间；将第一薄膜粘附在第二薄膜上以在已经向第一薄膜施加防渗材料的区域之外形成密封外周区域，从而形成至少一个总体形状与所述定制气囊设计相一致的充气室；以及沿密封外周区域切割以形成具有至少一个充气室和密封外周边缘的气囊。
防渗材料可以通过与数据库相连的智能打印机(采用数字打印机或其它已知的打印技术)被印刷在第一薄膜上。通过同样与数据库相连的激光打印机完成切割步骤。信息记录可以包含有关用户颜色喜好和脚的组织构造的信息。
附图说明
结合在此并构成说明书一部分的附图示出了本发明，并与描述部分一起进一步用于解释本发明的原理以及使相关领域的技术人员能够实践本发明。
图1是本发明用于制造充气用品或用于充气物品的气囊的方法中各个步骤的示意图；
图2是在筛网印花上形成的充气气囊设计或构造的负像；
图3是采用图2所示的印花筛框向第一薄膜施加防渗材料的方法中的各个步骤的示意图；
图4是在第一和第二薄膜之间布置转印的防渗材料的方法的示意图；
图5是第一和第二薄膜密封在一起的方法的示意图；
图6是根据本发明方法制成的充气用品或气囊的示意图；
图7是用于向第一薄膜施加防渗材料的步骤的备选实施方式的示意图；以及
图8是如何提供配件的示意图。
具体实施方式
要求充气制造用品或气囊耐用、以及制造快速、简单和低成本。本发明目的是通过简化制造过程并避免进行昂贵和耗时的铜的机械加工来减少通常与充气产品或用于充气制造用品的气囊的制造相关成本和时间，以及改变、允许制造具有多个尺寸和构造的充气用品或气囊。
尽管常规气囊制造方法依赖于对气囊构造的特殊加工，将两个或多个薄膜焊接或密封在一起以形成充气区域或室，但本发明根据预定或定制图案采用向薄膜中的一个(或在镜像中的两个薄膜)施加的防渗材料以防止薄膜在热和/或压力施加在其上时粘附在一起，从而形成充气区域或室。防渗材料很容易以多种构造施加在任一薄膜上，从而可以低成本、快速、基本上连续地并且以高度制造灵活性制造充气用品或气囊。
如图1所示，本发明方法大体上包括以下步骤，(1)提供在大多场合下防流体渗透并被用于对气囊或充气制造用品充气的第一薄膜，(2)向第一薄膜的第一侧施加防渗材料，(3)在第一薄膜上提供第二薄膜，使得防渗材料布置在第一薄膜与第二薄膜之间，(4)将第一薄膜粘附在第二薄膜上以形成密封的外周区域(除了施加防渗材料的区域)，从而形成至少一个充气室，以及(5)沿密封的外周区域切割以形成具有密封外周边缘用于制造用品的充气用品或充气气囊。还可以想到防渗材料可以施加在第二薄膜上或以镜像施加在两个薄膜相面对的两侧。备选地，防渗材料可以表现为简单位于第一和第二薄膜之间的单独材料(或第三薄膜)的形式。
现在回到所述方法的各个步骤，第一和第二薄膜可以是相同或不同的材料，假定它们各自由可以粘附在一起以形成防流体渗透的密封的热塑性材料制成。薄膜可以由多种热塑性树脂或其它弹性材料制成，这些材料包括但不局限于热聚氨酯(TPU)、乙烯醋酸乙烯酯/聚乙烯共聚物、聚酯弹性体(例如可以从DuPont购买的
Figure A20068002757900101
材料)、聚乙烯、聚丙烯、氯丁橡胶、天然橡胶、涤纶/聚酯、聚氯乙烯、热塑性橡胶、丁腈橡胶、丁基橡胶、硫化橡胶、甲基橡胶、硅酮橡胶、聚乙烯乙酸酯、丁橡胶N.、丁橡胶S.、聚苯乙烯、乙烯丙烯、聚丁二烯、氯磺酸化聚乙烯、尼龙或其它物质。用于本发明方法的适当TPU薄膜等级的一个特殊实例是在产品ST1880下可以从JP Stevens购买的聚酯型聚氨酯。该薄膜等级具有88-92的肖氏A硬度以及包括
Figure A20068002757900102
(可以从DowChemical购买)、
Figure A20068002757900103
(可以从Noveon购买)或(可以从BASF购买)的基础树脂的配方。本领域技术人员可以认识到任何数量的热塑性或弹性材料都适用于本发明，假定该材料是柔性的并能够与具有相同性能的另一材料形成防流体渗透的密封。还可以想到在食品包装领域中采用的薄片薄膜以及其它材料例如聚酯薄膜都可以应用于本发明的制造方法。
而且，尽管图1所示的方法已经被描述为提供第一和第二“薄膜”，但这种薄膜无需是单层材料。实际上，第一和第二薄膜中的任意一个或二者可以是热塑性层和仅施加在热塑性层一侧(使热塑性层的相对一侧密封在第二薄膜(或叠层)上)的基底的叠层。基底可以是多种织物例如任意的人造或天然纤维或织物中任意一种。被用作鞋类充气气囊叠层的织物的一个非限制性实例是可以从Dae Woo International Corporation(釜山，韩国)购买的无纺高密度混合物(70％尼龙和30％聚酯)。已经研制了几种方法在热塑性层与基底之间形成叠层。一种方法包括将热塑性树脂直接在基底上浇注挤压成形以在其上形成薄层。假定基底至少局部是多孔的，热塑性树脂将穿过基底的孔并粘结在其上。其它本领域技术人员已知的叠层形成方法也适于形成作为本发明薄膜的叠层。例如，可以通过施加热和压力、粘合剂或粘结剂或者通过超声波粘结将热塑性层粘附在基底上而由热塑性层和基底形成叠层。此外，叠层可以包括多个热塑性层以及多个基底层，假定至少一个热塑性层能够被密封在另一热塑性层上以形成至少一个充气气囊室。
现在参照图1中提出的方法的步骤2，向第一薄膜的第一侧施加防渗材料。防渗材料可以是防止在施加热和/或压力时第一薄膜粘附在本发明的第二薄膜上的任意材料或处理。更具体地，防渗材料可以是涂料、油墨、
Figure A20068002757900111
涂层、硅酮涂层，保持第一和第二薄膜的热塑性层完整但在已经施加防渗材料或处理的地方防止薄膜相互粘附的特定或表面处理。
在防渗材料是例如涂料的情况下，根据所述方法的步骤2以与丝网印制类似的方式向第一薄膜施加涂料。丝网印制(或丝网印刷)是长期采用的用于经济地大批量生产标志、印刷和织物设计的过程。丝网印制的基本思路是形成主丝网，涂料(或其它适当的介质)穿过主丝网在大量复制品上转印设计或印痕。通常，通过光学处理将设计的图画或描图转印到在框架上得到紧密拉伸的薄的、微粒光感应的、涂有凝胶的衣服(或“丝网”)上。当凝胶曝光时，凝胶得到曝光的部分变硬或固化，同时未曝光的部分保持柔软。固化后，软凝胶被洗掉，在丝网上留下设计的“负”像。丝网是开放的网格(就像筛子)，使得涂料或其它介质可以从中通过。
加框的丝网被放置靠在被赋予设计图案的物体上。涂料随后被施加在其上并利用刮板或类似装置绕丝网被拉动以通过丝网将设计转印到下方的物体上。在需要具有多种颜色的设计时，必须为每种颜色准备单独的丝网(类似于常规油墨印刷方法种的颜色分离过程)。利用丝网印制方法，可以由单个丝网形成成千上万的“印刷品”。近来，由单丝材料例如聚酯代替丝网形成印刷筛网。
通过将上述丝网印制技术应用于本发明方法，可以在步骤1的第一薄膜上“印刷”或转印多种气囊构造和尺寸以作为本发明的方式材料。例如，图2表示形成在印刷丝网或筛框24上的充气气囊设计或构造20的负像。在筛网或丝网在区域22中可见时，涂料、油墨或其它介质通过丝网被转印到步骤1的第一薄膜上。气囊设计或构造20包括防止涂料、油墨或其它介质转印到第一薄膜上的圆形构件26和线性构件28。当第一和第二薄膜粘附在一起(在下文所述的方法的步骤3中)时，第一和第二薄膜将在圆形构件26和线性构件28处相互粘附以形成上述现有技术中的圆形焊接和焊接线的等效物，从而控制气囊的厚度和充气并且对于服装或鞋类来说适应人体组织构造。充气气囊设计或构造的负像20还包括筛网30的可见区域，其从筛网边缘颜色到区域22。区域30形状为导管形并且要形成用于容纳入口或出口阀或其它配件的通道以使流体可以导入和/或从本发明的充气用品或气囊中释放。尽管区域30被示出为图2所示的导管形，但本领域技术人员应该认识到区域30可以呈现对充气制造用品或气囊充气或放气所需的配件进行适配的任意必要形状。
相关领域的技术人员还应该认识到尽管在图2中已经示出了特定的负片气囊设计或构造，但气囊(以及由本发明方法最终形成的气囊)的负设计可以具有为了实现充气用品或气囊的作用或功能所需的任意形状。例如，当用于鞋类时，气囊可以被构造成装配在鞋舌内，沿着中部和侧面，绕脚踝并在脚弓、脚后跟或趾骨头部之下。同样，气囊可以被设计成装配在救生衣、护胸、头盔、手套或任何其它充气制造用品的外壳内。
同样，所述的线性和圆形构件可以被放置在任意位置以适应气囊的功能并安装要求控制气囊的充气和/或凸出。另外，线性和/或圆形构件无需是线性或圆形的，而是在由人穿用的制造用品上带有气囊的位置可以为细长、弯曲或满足气囊功能目的或使用者组织构造的任意几何形状。
继续描述本发明方法中的各个步骤，在利用所需充气气囊设计或构造20的负像形成筛网24之后，筛网24被放置在第一薄膜42的第一侧40的顶部，如图3所示。涂料、油墨或其它介质P随后被施加并绕筛网24被拉动以将充气气囊的构造或设计转印到第一薄膜42作为可见区域22的第一侧40上。因而，通过利用涂料、油墨或其它介质将充气气囊构造的图像转印在第一薄膜的第一侧上，可以按照本发明方法的步骤2将防渗材料施加到第一薄膜的第一侧。
图4表示所述方法的步骤3。在该步骤中，第二薄膜46的第一侧44位于第一薄膜42的第一侧40上，使得充气气囊构造20的防渗材料图像48和导管30的防渗材料图像50位于第一薄膜42与第二薄膜46之间。在图4中，透过第二薄膜46可以看到防渗材料。
在本发明方法的步骤4中，第一薄膜42粘附在第二薄膜46上，使得两个薄膜被密封在一起以在向第一薄膜施加防渗材料的位置之外的位置形成密封外周区域，从而形成至少一个充气室。在已经向第一薄膜施加防渗材料的位置，不发生任何粘附以形成最终充气产品或气囊的充气室。在图4中，密封区域以阴影区域49示出，同时至少一个充气室以52示出。在密封时，圆形构件26和线性构件28构成圆形和线性密封或焊接54，56。
第一和第二薄膜通过与薄膜形成接触的加热图案粘附在一起，或者共同延伸薄膜可以通过例如层叠领域众所周知的加热辊被进给到一起。还可以采用其它已知的用于密封或层叠热塑性薄膜的装置(例如超声波焊接)实现本发明的目的。薄膜还可以被制成感光的，使得它们可以在光的作用下相互粘附。
在方法的步骤5中，如图5所示，在充气室附近沿密封外周区域的边缘以切割线58进行切割以形成具有至少一个充气室52、圆形焊接54、线性焊接56、充气/放气导管50和外周边缘62的充气用品或气囊60(参见图6)。可以通过缝合、粘合剂或其它适当的紧固装置沿外周边缘62将气囊固定在鞋部件上的方式将图6所示的充气气囊60固定在制造用品例如鞋类用品上或内。
因而，如上所述，本发明的方法能够使充气用品或用于充气用品的气囊快速、容易地得到制造并且不采用昂贵的对充气用品或气囊的特定构造的金属加工。实际上，可以利用已知的丝网印制或印刷以及层叠技术实施本发明的方法，从而可以以相对较低的成本连续制造多个形状的充气用品或气囊。而且，最有利的是，当需要改变气囊构造时，不需要在制造过程中定购、机械加工和更换昂贵的金属加工件。而是形成新需要的气囊构造的新的筛网/负像并替换在前的筛网/负像-简单、快速和低成本的过程，还与制造过程的下游步骤(也就是粘附和切割)相适合。备选地，新的筛网/负像可以通过数字方式送入制造过程。
回到对本发明方法的步骤2的论述，上述丝网印制尤其有利于用于消费品的充气产品或气囊的制造，因为丝网印制可以采用多种颜色形成具有视觉吸引力、彩色设计或外观形式的气囊。还可以想到多种颜色用于适当设计的筛网以将产品商标、牌名或标志转印到薄膜上并由此转印到充气用品或气囊上。
尽管以上已经针对用于丝网印制或印刷技术的涂料或油墨描述了本发明的防渗材料和应用步骤，但可以想到防渗材料可以具有其它形式。例如，防渗材料可以是施加在第一薄膜第一侧的涂满粘合剂的纸、织物或塑性材料(例如聚乙烯)以防止第一和第二薄膜粘附在一起，从而形成至少一个充气腔。
还可行的是防渗材料是“自由浮动”的并不连接在第一或第二薄膜任何一个上。实际上，防渗材料可以是位于第一和第二薄膜之间的特殊类型的薄膜(或多个薄膜)，其不会与第一和第二薄膜粘结(例如，薄膜在它们于加热之后冷却时与第一和第二薄膜脱离)。备选地，防渗材料可以暂时施加在第一或第二薄膜中的一个上。
在另一实施方式中，防渗材料可以是喷射在适当形状的模板上的颗粒、肥皂、表面活性剂、释放涂层或喷雾、或者
Figure A20068002757900151
或硅酮涂层，以将防渗材料按所需用品或气囊构造转印在第一薄膜的第一侧上，从而防止第一和第二薄膜在本发明的密封步骤过程中相互粘附。
在本发明的另一实施方式中，应用上述丝网印制或印刷技术，防渗材料还可以是酸或其它液态化学品，其被转印到第一薄膜的第一侧以化学蚀刻、腐蚀或磨损第一薄膜，阻碍第一薄膜与第二薄膜连接。还可以想到感光材料可以被转印在第一薄膜上并随后曝光以实现本发明防渗材料的目的。
在另一实施方式中，第一薄膜可以被压延进入热辊与另一热或冷辊之间以在第一薄膜的一个施加或压印织构(具有整体所需的气囊构造)，从而防止第一薄膜与第二薄膜粘附，形成充气室。
还可以想到本发明的方法能够施加由报纸或印刷行业采用的印刷技术(也就是印刷薄膜和辊)以将多种充气用品或气囊的形状转印在与第二薄膜粘附形成充气室的第一薄膜上。
在本发明的另一方面，参照图7，本发明的上述实施方式可以与“按需”印刷技术结合以形成定制的充气产品。具体地说，通过利用“智能”数字打印机70在薄膜上印刷防渗材料来完成向第一薄膜施加防渗材料的步骤，所述数字打印机70具有与定制信息数据库72的接口，从而形成具有定制气囊构造、定制圆形和线性构件布置以及定制颜色的独特设计。
实施中，例如鞋的用户可以进入计算机74，其中包括用户想要在鞋上展示的特定颜色或设计。设计可以是标记例如名字、字或符号或者可以是人或地的照片。还可以想到输入用户脚的组织构造扫描(例如在购买地点显示)，从而能够定制制造充气用品或气囊，适应用户脚的组织构造以提高适配性、缓冲和支撑。输入的信息随后被传输到与打印机70有接口的数据库72。打印机之后将访问数据库并在第一薄膜76上打印出独特的设计。第一薄膜76可以被构造成得到辊压的薄片材料，其随后与类似得到辊压的第二薄膜78接合。第一薄膜76和第二薄膜78随后通过加热辊80，82压延以将这两个薄膜粘附在一起并形成气囊的充气室。随后采用上述方法将气囊从薄膜上切下。在采用激光将气囊从薄膜上切下时，还可以通过使激光与数据库相连而使激光变得“智能”，以根据薄膜上印刷的定制气囊设计对从薄膜上切割气囊进行控制。本发明还设想可以通过提供具有腐蚀、溶解或“吞食”穿透薄膜的化学品的切割模具从薄膜上“切下”气囊。
本发明的方法不仅可以定制，而且实质上是连续的，因为为了变换不同构造、颜色或标记的气囊设计根本不需要中断所述方法中的步骤。当气囊嵌入鞋内时，气囊可以如美国专利No.5,343,638所述构成鞋的外壳。由于气囊具有印在薄膜内侧的设计，因此该设计在鞋的外侧可以看到，从而形成独特的定制鞋。
同样，防渗材料可以具有热反射材料的形式以使气囊具有绝缘特性。气囊随后被构造成例如服装，从而形成绝缘衬衫、夹克、背心、罩或其它服装用品。
进一步可以设想防渗材料可以是背景得到印刷的设计(例如水下布景)，并且气囊可以存储流体和装饰性元素(例如塑料鱼和气泡)，用于面向特定类型用户群的孩子的穿着或其它制造用品。
还可以想到气囊由多于两个的薄膜构成，以形成具有多层充气室的气囊。在该实施方式中，可以选定特殊的防渗材料和薄膜，使得气囊的每一层充气室具有不同的充气质量或特性以实现充气制造用品的目的。
如上所述，由本发明方法制成的充气气囊还包括用于与充气或放气阀相连的导管50。尽管该导管本身作为一种用于连接充气和放气配件与充气用品或气囊的装置或结构，但还设想可以在流体传送和控制领域中已知的配件通过在本发明方法的步骤3之前预先形成于第二薄膜上的开口与用品相连。还设想可以在第一与第二薄膜之间插入在用于构造充气技术领域中采用的单向阀和其它结构的领域已知的材料，从而可以控制流体进出充气室。
图8表示在本发明的制造过程中常规配件如何被构造成气囊60。图8A表示在完成步骤3之后但在步骤4之前本发明的制造过程。如图8A所示，防渗材料80位于第一薄膜82与第二薄膜84之间。第一薄膜82和第二薄膜84都具有适当定位以布置泵、进气阀或用于充气气囊的其它已知配件的开口86，88。由具有与第二薄膜84类似或相同属性的薄膜材料构成的垫圈90位于开口88上。配件例如由具有与第一薄膜82类似或相同属性的材料构成的数字操作泵92位于开口86上。随后完成本发明的步骤4以在向第二薄膜84施加防渗材料80之外的所有区域上使第一薄膜82与第二薄膜84粘附，并且将垫圈90与第二薄膜84粘附，使泵92与第一薄膜82粘附。构件82和84、90和84、以及92和82在虚线指示的区域上(没有防渗材料80)相互粘附。在完成步骤4之后，如图8B所示，在已经形成充气室或流体导管的气囊区域上泵粘附在第一薄膜上并且垫圈粘附在第二薄膜上。因而，流体(由箭头F表示)通过泵到达气囊内以对由施加防渗材料的区域限定的充气腔进行充气。
尽管用于使流体进入气囊的泵已经在图8中示出，但应该注意到其它配件(例如流体释放阀、流体入口、流体调节器和止回阀)可以采用同一技术连接在薄膜上。此外，本领域技术人员应该认识到本发明的方法可以采用用于将配件固定在充气气囊上的其它已知技术。
以上描述的具体实施方式充分地揭示了本发明总的性质，以至于其他人通过应用相关领域技术内的知识(包括在此引用的参考内容)在不脱离本发明总体思想和精神的前提下无需实验可以很容易地为多种应用修改和/或改变这些具体实施方式。因此，这种改变和修改基于在此提出的教导和指导被认为是处于公开实施方式的等效方式的意图和范围内。例如，已经通过防流体渗透薄膜的内容描述了本发明。自然，薄膜的特性可以被变为在气囊中采用的流体的功能。例如，如果气囊要被用于包含液体或大分子量的气体，则在不背离本发明精神的前提下气囊可以允许扩散或反向扩散进入和离开袋囊。同样，气囊可以有意被制成多孔的以在达到预定内部压力时允许流体扩散或从气囊中逸出。这一点可以通过增加薄膜穿孔或通过采用具有已知扩散率的薄膜来实现。
将会认识到在此采用的措辞或术语是为了描述而不是限制，本说明书的术语或措辞将通过技术人员依据在此提出的教导和指导并结合本领域普通技术人员的知识进行解释。

Claims (24)

1.一种制造充气鞋类用品的方法，包括步骤：
(a)提供第一薄膜；
(b)向所述第一薄膜的第一侧施加具有气囊构造的防渗材料；
(c)在所述第一薄膜上提供第二薄膜，使得所述防渗材料布置在所述第一薄膜与所述第二薄膜之间；
(d)将所述第一薄膜粘附在所述第二薄膜上以在防渗材料已经施加到所述第一薄膜的区域之外形成密封外周区域，从而形成至少一个整体形状与所述气囊构造相一致的充气室；
(e)沿所述密封外周区域切割以形成具有所述至少一个充气室和密封外周边缘的气囊；以及
(f)将所述气囊结合在鞋内以形成充气鞋类用品。
2.如权利要求1所述的方法，其特征在于，所述防渗材料是涂料、油墨、纸、织物、感光剂、颗粒或酸。
3.如权利要求1所述的方法，其特征在于，所述防渗材料是所述第一薄膜的压印或织构表面。
4.如权利要求1所述的方法，其特征在于，所述第一和第二薄膜是热塑性层。
5.如权利要求4所述的方法，其特征在于，所述第一或第二薄膜中的任一个是由热塑性层和基底组成的叠层。
6.如权利要求1所述的方法，其特征在于，还包括步骤：形成所述气囊构造负像的筛网、模板或型板，并采用所述筛网、模板或型板向所述第一薄膜施加具有所述气囊构造的防渗材料。
7.如权利要求1所述的方法，其特征在于，通过使所述气囊的所述密封外周边缘与鞋结合而将所述气囊结合在鞋内。
8.如权利要求1所述的方法，其特征在于，通过激光、喷水、金属模具或具有腐蚀或溶解材料的切割模具完成所述切割步骤。
9.如权利要求3所述的方法，其特征在于，通过将所述第一薄膜压延在两个辊之间而向所述第一薄膜施加所述压印或织构表面，所述辊中的一个具有凸出的织构或压花。
10.如权利要求1所述的方法，其特征在于，通过将所述第一和第二薄膜压延穿过第一和第二辊来完成将所述第一薄膜粘附在所述第二薄膜上的步骤。
11.如权利要求1所述的方法，其特征在于，通过向所述第一薄膜或所述第二薄膜任意一个的一侧施加加热图案来完成将所述第一薄膜粘附在所述第二薄膜上的所述步骤。
12.一种制造充气气囊的方法，包括步骤：
(a)提供具有第一侧和第二侧的第一薄膜；
(b)向所述第一薄膜的所述第一侧施加防渗材料；
(c)在所述第一薄膜的所述第一侧提供第二薄膜，使得所述防渗材料布置在所述第一薄膜与所述第二薄膜之间；
(d)将所述第一薄膜粘附在所述第二薄膜上以在防渗材料已经施加到所述第一薄膜第一侧的区域之外形成密封外周区域，从而形成至少一个整体形状与所述气囊构造相一致的充气室；以及
(e)沿所述密封外周区域切割以形成具有所述至少一个充气室和密封外周边缘的气囊。
13.如权利要求12所述的方法，其特征在于，所述防渗材料是涂料、油墨、纸、织物、感光剂、颗粒或酸。
14.如权利要求12所述的方法，其特征在于，所述防渗材料是所述第一薄膜的所述第一侧的压印或织构表面。
15.如权利要求12所述的方法，其特征在于，所述第一和第二防流体渗透的薄膜是热塑性层。
16.如权利要求15所述的方法，其特征在于，所述第一或第二薄膜中的任一个是由热塑性层和基底组成的叠层。
17.如权利要求12所述的方法，其特征在于，还包括将所述充气气囊组装在制造用品内的步骤。
18.如权利要求12所述的方法，其特征在于，还包括步骤，形成所述气囊构造负像的筛网、模板或型板，并采用所述筛网、模板或型板向所述第一薄膜的所述第一侧施加具有所述气囊构造的所述防渗材料。
19.如权利要求12所述的方法，其特征在于，通过激光、喷水或金属模具完成所述切割步骤。
20.如权利要求14所述的方法，其特征在于，通过将所述第一薄膜压延在两个辊之间而向所述第一薄膜施加所述压印或织构表面，所述辊中的一个具有凸出的织构或压花。
21.如权利要求12的方法，其特征在于，通过施加加热图案而将所述第一薄膜密封在所述第二薄膜上。
22.如权利要求12的方法，其特征在于，所述气囊构造包括用于容纳充气或放气阀配件的细长区域。
23.一种制造定制的充气制造用品的方法，包括以下步骤：
(a)提供数据库，其中所述数据库包括用于至少一个定制气囊设计的至少一个信息记录；
(b)提供第一薄膜；
(c)根据所述至少一个信息记录向所述第一薄膜的第一侧施加防渗材料以形成至少一个定制气囊设计；
(d)在所述第一薄膜上提供第二薄膜，使得所述防渗材料布置在所述第一薄膜与所述第二薄膜之间；
(e)将所述第一薄膜粘附在所述第二薄膜上以在防渗材料已经施加到所述第一薄膜的区域之外形成密封外周区域，从而形成至少一个总体形状与所述定制气囊设计相一致的充气室；以及
(f)沿所述密封外周区域切割以形成具有所述至少一个充气室和密封外周边缘的气囊。
24.一种制造充气气囊的方法，包括步骤：
(a)提供第一薄膜；
(b)提供第二薄膜；
(c)将防渗材料定位在所述第一薄膜与所述第二薄膜之间的区域；
(d)将所述第一薄膜粘附在所述第二薄膜上以在防渗材料已经施加在所述第一薄膜与第二薄膜之间的区域之外形成密封外周区域，从而形成至少一个整体形状与所述气囊构造相一致的充气室；以及
(e)沿所述密封外周区域切割以形成具有所述至少一个充气室和密封外周边缘的气囊。
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US11/171,475 US7622014B2 (en) 2005-07-01 2005-07-01 Method for manufacturing inflatable footwear or bladders for use in inflatable articles
US11/171,475 2005-07-01
PCT/US2006/025566 WO2007005600A2 (en) 2005-07-01 2006-06-30 Method for manufacturing inflatable footwear or bladders for use in inflatable articles

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CN105109078A (zh) * 2010-10-12 2015-12-02 锐步国际有限公司 用在鞋类和其它制造物品中的可膨胀的囊的制造方法
CN102529287A (zh) * 2010-10-12 2012-07-04 锐步国际有限公司 用在鞋类和其它制造物品中的可膨胀的囊的制造方法
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CN107404976A (zh) * 2015-04-08 2017-11-28 耐克创新有限合伙公司 包括具有图像的囊状元件的物品以及制造该物品的方法
CN113693330B (zh) * 2015-04-08 2023-10-10 耐克创新有限合伙公司 带有蚀刻特征的囊状元件的制法和具有该囊状元件的物品
CN110215012A (zh) * 2019-06-11 2019-09-10 福建省万物智联科技有限公司 一种自动穿戴充气鞋的制作方法
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CN111660569A (zh) * 2020-04-24 2020-09-15 信泰(福建)科技有限公司 一种鞋服用气囊及其加工工艺
CN111660569B (zh) * 2020-04-24 2022-04-08 信泰(福建)科技有限公司 一种鞋服用气囊及其加工工艺

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US20070000605A1 (en) 2007-01-04
WO2007005600A2 (en) 2007-01-11
CN101257814B (zh) 2011-10-26
EP1909606A2 (en) 2008-04-16
EP1909606B1 (en) 2017-09-27
US20170087764A1 (en) 2017-03-30
US8540838B2 (en) 2013-09-24
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US9516921B2 (en) 2016-12-13

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