CN102529287A - 用在鞋类和其它制造物品中的可膨胀的囊的制造方法 - Google Patents

用在鞋类和其它制造物品中的可膨胀的囊的制造方法 Download PDF

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Publication number
CN102529287A
CN102529287A CN2011103046681A CN201110304668A CN102529287A CN 102529287 A CN102529287 A CN 102529287A CN 2011103046681 A CN2011103046681 A CN 2011103046681A CN 201110304668 A CN201110304668 A CN 201110304668A CN 102529287 A CN102529287 A CN 102529287A
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China
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film
expandable
capsule
article
footwear
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CN2011103046681A
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CN102529287B (zh
Inventor
保罗·M·戴维斯
保罗·E·利奇菲尔德
弗兰克·米莱特
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Reebok International Ltd Great Britain
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Reebok International Ltd Great Britain
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    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B7/00—Footwear with health or hygienic arrangements
    • A43B7/14—Footwear with health or hygienic arrangements with foot-supporting parts
    • 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
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
    • A43B17/02—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined wedge-like or resilient
    • A43B17/03—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined wedge-like or resilient filled with a gas, e.g. air
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • 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
    • A43—FOOTWEAR
    • A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
    • A43B7/00—Footwear with health or hygienic arrangements
    • A43B7/32—Footwear with health or hygienic arrangements with shock-absorbing means
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D111/00—Shoe machines with conveyors for jacked shoes or for shoes or shoe parts
    • A—HUMAN NECESSITIES
    • A43—FOOTWEAR
    • A43D—MACHINES, TOOLS, EQUIPMENT OR METHODS FOR MANUFACTURING OR REPAIRING FOOTWEAR
    • A43D27/00—Machines for trimming as an intermediate operation
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    • B29C65/087—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations using a rotary sonotrode or a rotary anvil using both a rotary sonotrode and a rotary anvil
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/004—Preventing sticking together, e.g. of some areas of the parts to be joined
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    • B29C65/14—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation
    • B29C65/1403—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using wave energy, i.e. electromagnetic radiation, or particle radiation characterised by the type of electromagnetic or particle radiation
    • B29C65/1425—Microwave radiation
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    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/004—Preventing sticking together, e.g. of some areas of the parts to be joined
    • B29C66/0042—Preventing sticking together, e.g. of some areas of the parts to be joined of the joining tool and the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/532—Joining single elements to the wall of tubular articles, hollow articles or bars
    • B29C66/5326—Joining single elements to the wall of tubular articles, hollow articles or bars said single elements being substantially flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5346—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/61—Joining from or joining on the inside
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及用在鞋类和其它制造物品中的可膨胀的囊的制造方法。具体的，本发明是制造用在制造物品中的可膨胀的囊的方法。该方法包括以下步骤：提供第一聚合物膜；以与可膨胀的囊的构造对应的图案将可固化的释放涂层施加到聚合物膜；将释放涂层固化到第一聚合物膜；为第一聚合物膜提供第二聚合物膜以形成成层元件使得释放涂层被布置在聚合物膜之间；将成层元件定位在两个材料层之间；施加热和压力以除在释放涂层被施加的区域之外将聚合物膜附着到一起，从而形成由密封周边包围的可膨胀的隔室；以及从附着的第一聚合物膜和第二聚合物膜移除材料层。

Description

用在鞋类和其它制造物品中的可膨胀的囊的制造方法
技术领域
本发明涉及制造可膨胀的囊的方法，并且还涉及可膨胀的囊以及包括这种可膨胀的囊的鞋类和其它制造物品。
背景技术
可膨胀的制造物品或用于可膨胀的制造物品的囊已知数十年了。这种制造物品包括可膨胀的空气垫和枕头、可膨胀的救生船和救生圈以及运动装备。在运动装备的领域中，可膨胀的囊已经被结合到球(比如篮球、橄榄球、足球等)的内部，以及结合到服装和防护性装备比如棒球和拳击手套、头盔、护胸和鞋类中。当用于鞋类中时，可膨胀的囊可用于为穿着者的足部提供定制的缓冲并提高合身性。在某些情形中，可膨胀的囊可代替鞋带系统来将鞋固定到穿着者的足部。可膨胀的囊也可用在鞋的鞋底中以为穿着者的足部的底部提供缓冲并吸收来自步行、跑步和跳跃中的冲击力。
美国专利No.7,278,445公开了具有可膨胀的囊的鞋，其公开内容在此通过引用整体并入。
Cohen等人的美国专利No.5,113,599(`599专利)公开了具有可膨胀的囊的运动鞋。该专利公开了用于在鞋舌中、在外侧面和内侧面上、围绕脚踝、在足部下方或在整个鞋中使用的各种可膨胀的囊构造。该专利的囊由第一热塑性聚氨酯(TPU)膜和同延的第二TPU膜形成。第一膜和第二膜沿预限定的焊接部或图案线附接到彼此。囊的外周焊接线产生密封的囊隔室或室并防止空气逃离囊。第一膜和第二膜还在多个圆形部位或内部焊接线处附接到彼此以控制囊的厚度从而防止不期望的“鼓胀”，该不期望的“鼓胀”能引起穿着者不舒适或抑制合适的配合。
`599专利的囊的第一膜和第二膜利用射频(RF)或电介质焊接而被焊接在一起。RF或电介质焊接利用高频射电能将热塑性材料的分子搅动到其熔化并焊接在一起而形成强结合的部位。为了焊接`599专利的囊，将同延的膜置于黄铜模具(具有代表期望的外周、圆形和内部焊接线的升高区域)和RF机器上的压板之间。在使黄铜模具和RF压板彼此接触之后，激活RF机器且仅在黄铜模具上的升高区域处使第一膜和第二膜结合到彼此以形成外周、圆形和内部焊接线。在完成焊接步骤时，从同延的第一膜和第二膜的其余部分模切可膨胀的囊，且适当地，通过粘合剂、常规缝合或其它紧固方式将可膨胀的囊组装到鞋内。`599专利的第一膜和第二膜还可通过常规地加热的且适当地图案化的黄铜模具或者通过施加适合用于热塑性膜的化学粘合剂或结合剂而彼此附着。
该专利还公开了通过利用上述的RF焊接技术或任何其它适合用于其膜的密封方法永久地固定到囊的泵来对囊充注。可替代地，可通过可连接到充注/抽放阀的非车载泵来充注囊，该非车载泵还在穿着者容易接近的位置中固定到囊。在美国专利5,074,765和5,144,708中公开了适合用于鞋类的可膨胀的囊的其它泵和阀。
尽管利用RF焊接制造可膨胀的囊不需要粘合剂或额外的材料且具有精密图案化、在膜的靠近焊接线的区域中降低的热退化、以及密封的强度的优点，但是加工或化学蚀刻用于可膨胀的囊图案的黄铜模具的成本高且是耗时的，特别是在制造物品以大范围的尺寸和多种构造进行生产时。常规地加热的黄铜模具的加工也是昂贵的，同时化学附着是麻烦的且需要在受控环境中的固化时间。而且，RF焊接技术是极端敏感的，需要膜足够厚以防止膜的过度熔化(这将引起囊的破口)，且常常导致沿其边缘“卷曲”的加工的囊(这能使其组装到比如鞋类的制造物品中变得复杂)。
因而，希望提供一种利用在制造过程中几乎不中断或延迟的工艺和材料来制造用于鞋类和其它物品的可膨胀的囊的方法，该方法相对低价、时间有效并允许制造各种囊构造和尺寸。
发明内容
本发明的制造方法优于本领域已知的那些方法，因为本发明的方法较简单，本质上是半连续或半自动的，容易修改以允许制造各种囊构造，并且通过避免对于昂贵构造特有的黄铜加工刀具的需要而是更经济的。在本发明的一个方面中，一种制造可膨胀的物品的方法包括以下步骤：提供具有内侧和外侧的第一聚合物膜；以与可膨胀的囊的可膨胀的隔室的构造对应的图案将可固化的释放涂层施加到第一聚合物膜的内侧；通过施加紫外光将释放涂层固化到第一聚合物膜的内侧；为第一聚合物膜提供具有内侧和外侧的第二聚合物膜以形成成层元件，使得释放涂层被布置在第一聚合物膜的内侧和第二聚合物膜的内侧之间；将成层元件定位在第一材料层和第二材料层之间；对围绕成层元件定位的第一材料层和第二材料层施加热和压力，以除了释放涂层被施加于第一聚合物膜的内侧的区域之外将第一聚合物膜附着到第二聚合物膜，从而形成由密封周边包围的可膨胀的隔室；以及从附着的第一聚合物膜和第二聚合物膜移除第一材料层和第二材料层。可固化的释放涂层可以是硅强化的。可固化的释放涂层可以通过丝网印刷而被施加到第一聚合物膜的内侧。第一材料层和第二材料层可以是聚四氟乙烯涂覆的玻璃纤维增强布。第一材料层和第二材料层中的至少一个可被纹理化。施加热和压力步骤可通过旋转层压来实现。该方法还可包括沿密封周边切割以形成具有密封的附接边沿的可膨胀的囊以及通过在附接边沿将可膨胀的囊附接到鞋类物品来将可膨胀的囊结合到鞋类物品的步骤。该方法还可包括将充注设备和抽放设备联接到可膨胀的囊的步骤。第一聚合物膜或第二聚合物膜中的一个可以是包括聚合物层和衬底的层压物。
在本发明的另一方面中，一种用于制造可膨胀的囊的方法包括以下步骤：以与可膨胀的囊的可膨胀的隔室的形状对应的构造将隔离材料定位在第一膜和第二膜之间；将其间定位有隔离材料的第一膜和第二膜定位在第一材料层和第二材料层之间；除了隔离材料的附近之外将第一膜附着到第二膜，从而形成具有由密封的连续地基本平的周边包围的可膨胀的隔室的可膨胀的囊；以及从可膨胀的囊移除第一材料层和第二材料层。该方法还可包括通过在可膨胀的囊的周边处将可膨胀的囊固定到鞋类物品来将可膨胀的囊结合到鞋类物品的步骤。隔离材料可为涂料、墨、纸、织品、光敏剂、金属丝、箔或颗粒物。隔离材料可以是可固化的释放涂层，且将隔离材料定位在第一膜和第二膜之间的步骤可包括将释放涂层施加到第一膜、将释放涂层固化到第一膜以及将固化的释放涂层夹在第一膜和第二膜之间的子步骤。释放涂层可利用网屏、模板或型板而被施加到第一膜。释放涂层可通过施加紫外光而被固化。第一材料层和第二材料层可以是聚四氟乙烯涂覆的玻璃纤维增强布。第一层和第二层中的至少一个可被纹理化。可通过旋转层压、通过在压板之间热压或通过施加真空和热来实现附着步骤。该方法还可包括将充注设备和抽放设备联接到可膨胀的囊的步骤。第一膜或第二膜中的至少一个可以是包括聚合物层和衬底的层压物。隔离材料可包括至少两个释放涂层。在提供了两个释放涂层的情况下，将隔离材料定位在第一膜和第二膜之间的步骤可包括将第一释放涂层施加到第一膜、将第二释放涂层施加到第二膜、固化释放涂层中的至少一个以及将固化的释放涂层夹在第一膜和第二膜之间的子步骤。施加于第二膜的释放涂层可以是不连续的涂层。
在本发明的又一方面中，一种可膨胀的鞋类物品包括鞋底以及附接到鞋底的鞋帮，该鞋帮具有可膨胀的囊。可膨胀的囊包括：第一膜；释放剂，该释放剂以与可膨胀的囊的可膨胀的隔室的形状对应的图案被施加并固化到第一膜；以及第二膜，该第二膜附着到第一膜使得释放剂被布置在第一膜和第二膜之间，且第一膜和第二膜在释放剂附近彼此不附着，从而形成具有外周边缘的可膨胀的隔室，其中可膨胀的囊没有升高的焊接线或升高的附着接缝，且其中可膨胀的囊的外表面的至少一部分被纹理化。可膨胀的囊的外表面基本上全部可被纹理化。可膨胀的囊的纹理化的外表面可对应于当第一膜和第二膜被附着到彼此时与第一膜或第二膜中的至少一个的外表面邻近地定位的纹理化材料层的纹理。材料层可以是聚四氟乙烯涂覆的玻璃纤维增强布。可膨胀的囊可包括从可膨胀的隔室的外周边缘延伸到可膨胀的囊的边缘的基本平的附着的附接边沿，以便于可膨胀的囊至鞋类物品的鞋帮的附接。固化的释放剂可通过施加紫外光而被硅强化和固化。膜中的至少一个可以是结合到衬底的聚合物层。鞋类物品可包括充注设备和抽放设备。
在又一实施方式中，一种可膨胀的鞋类物品包括：鞋帮；鞋底，该鞋底附接到鞋帮；以及可膨胀的囊，该可膨胀的囊附接到鞋类物品。可膨胀的囊包括：第一单层膜，该第一单层膜具有内表面和纹理化的外表面；释放剂，该释放剂以与可膨胀的囊的可膨胀的隔室的形状对应的图案施加并固化到第一单层膜的内表面；第二单层膜，该第二单层膜具有内表面和纹理化的外表面，第二单层膜以与第一单层膜面对的关系布置并附着到第一单层膜，使得释放剂被布置在第一单层膜的内表面和第二单层膜的内表面之间，释放剂防止第一单层膜在释放剂被施加的区域中附着到第二单层膜，从而形成可膨胀的囊的可膨胀的隔室。第一单层膜和第二单层膜的纹理化的外表面的纹理可通过在将第一单层膜附着到第二单层膜期间与第一单层膜和第二单层膜的外表面邻近地布置的纺织材料而被赋予第一单层膜和第二单层膜。
附图说明
结合到本文中且形成说明书一部分的附图示出了本发明且连同说明书一起进一步用于解释本发明的原理且使相关领域技术人员能实施本发明。
图1是本发明的制造可膨胀的物品或用在可膨胀的物品中的囊的方法的步骤的描绘；
图2是形成于印刷网屏上的可膨胀的囊设计或构造的负像；
图3是利用图2的印刷网屏将隔离材料施加到本方法的第一膜的步骤的描绘；
图4是定位在本方法的第一膜和第二膜之间的转印的隔离材料的描绘；
图5是本方法的密封在一起的第一膜和第二膜的描绘；
图6是根据本发明的方法制造的可膨胀的物品或囊的描绘；
图7是将隔离材料施加到第一膜的步骤的可选实施方式的描绘；
图8是如何提供附件的描绘；
图9示出了根据本发明的实施方式的制造用于鞋类和其它制造物品的可膨胀的囊的方法的步骤；
图10是图9的方法的第一膜的顶部平面图，其中释放涂层被施加于第一膜；
图11是基本的丝网印刷过程的平面图；
图12是图9的方法的成层元件的顶部平面图，该成层元件包括第一膜(具有固化到其的释放涂层)和第二膜；
图13是图9的方法的成层元件的顶部平面图，该成层元件定位在第一层和第二层之间；
图14是根据本发明的实施方式的旋转层压机器的侧向示意图；
图15是附着的第一膜和第二膜的顶部平面图，其中释放涂层被固化在其间，显示了根据本发明的实施方式的通过第一材料层和第二材料层赋予膜的织品；
图16是根据本发明的实施方式的阀体的顶部平面图；
图17是根据本发明的实施方式的可膨胀的囊的局部顶部平面图，其中囊的一部分被切掉以提供充注设备和抽放设备的附接；
图18是根据本发明的实施方式的阀体和插入的布股的透视图；
图19是根据图9的方法制造的根据本发明的实施方式的完成的可膨胀的囊的顶部平面图，其具有附接的充注设备和抽放设备；并且
图20示出了根据本发明的另一实施方式的制造可膨胀的囊的方法的步骤。
具体实施方式
期望的是可膨胀的制造物品或囊耐用以及制造快速、容易且低价。本发明通过简化制造工艺并避免对于黄铜刀具(其能是加工或形成以及更换昂贵且耗时的)的需要来努力减小通常与用于可膨胀的制造物品的可膨胀的物品或囊的制造相关的时间和成本，以允许制造具有各种尺寸和构造的可膨胀的物品或囊。
尽管常规的囊制造方法依赖于构造囊所特有的加工工具将两个或更多个膜焊接或密封在一起以形成可膨胀区域或隔室，但是本发明的方法采用根据预限定或定制的图案施加于膜之一(或两个膜)的隔离材料(此处也称为释放涂层或释放剂)来防止当对膜施加热和/或压力时膜附着在一起，从而产生可膨胀的区域或隔室。隔离材料可容易地以各种配置施加于膜中的任一个，以允许低价地、快速地、基本连续地且以高程度的制造灵活性来制造可膨胀的物品或囊。
如图1所示，本发明的方法通常包括以下步骤：1(a)提供第一膜，对于大部分应用来说，该第一膜对充注囊或可膨胀的制造物品所使用的流体不能渗透，1(b)对第一膜的第一侧施加隔离材料，1(c)为第一膜提供第二膜使得隔离材料被布置在第一膜和第二膜之间，1(d)除了在已经施加了隔离材料的区域之外，将第一膜附着到第二膜以形成密封的外周区域，以形成至少一个可膨胀的隔室，以及可选地，1(e)沿密封的外周区域切割以形成用于制造物品的具有密封的外周边缘的可膨胀的物品或可膨胀的囊。还考虑了能对第二膜或对两个膜的面对的侧施加隔离材料。可替代地，隔离材料可采取简单地定位在第一膜和第二膜之间的分隔材料(或第三膜)的形式。
现转向图1的方法的步骤，第一膜和第二膜可为相同或不同的材料，只要它们每个由可附着到一起以形成不透流体的密封的材料制成。膜可由各种聚合物形成，比如热塑性树脂、其它弹性体材料、热固性材料及其复合材料，包括但不限于，热塑性聚氨酯(TPU)、乙烯醋酸乙烯共聚物/聚乙烯共聚物、聚酯弹性体(比如可从DuPont得到的
Figure BDA0000097440110000081
材料)、聚乙烯、聚丙烯、氯丁橡胶、天然橡胶、达可纶/聚酯、聚氯乙烯、热塑性橡胶、腈橡胶、丁基橡胶、硫化橡胶、甲基橡胶、硅酮橡胶、聚醋酸乙烯酯、丁腈橡胶、丁苯橡胶、聚苯乙烯、乙烯丙烯、聚丁二烯、氯磺化聚乙烯(chlorfulfonated polythylene)、尼龙、局部凝固的热固性材料、乙烯醋酸乙烯共聚物(EVA)泡沫、热固性橡胶、预浸料和其它材料。用于本发明方法的合适类型的TPU膜的一个具体示例是能以产品号ST1880从JP Stevens得到的聚酯型氨基甲酸酯膜。该膜种类具有88-92的Shore A硬度和具有
Figure BDA0000097440110000082
(可从Dow Chemical得到)、
Figure BDA0000097440110000083
(可从Noveon得到)或(可从BASF得到)的基树脂的配制。本领域技术人员能理解，任何数量的热塑性材料、弹性体和热固性材料可适用于本发明，只要这样的材料是柔性的且能够与具有相同特性的另一材料形成不透流体的密封。还考虑到，在食品包装技术中采用的片膜以及比如聚酯或双轴定向的聚对苯二甲酸乙二醇酯(比如膜)的其它材料能用于本发明的制造方法。
此外，尽管图1的方法被描述为提供第一和第二“膜”，但是该膜不必为单一的材料层。实际上，第一膜和第二膜中任一或两者可为热塑性层和仅施加于聚合物层一侧的衬底的层压物(允许聚合物层的相对侧被密封到第二膜(或层压物))。衬底可为任何各种类型的织品，比如任何合成或天然纤维或织物。用作鞋类的可膨胀的囊的层压物的织物的一个非限制性示例是非纺的高密度70％尼龙和30％聚酯混合物，可从Dae Woo International Corporation(Pusan，Korea)得到。已经开发了很多方法来在聚合物层和衬底之间形成层压物。一种这样的方法包括将热塑性树脂直接铸造挤压到衬底上以在其上形成薄层。只要衬底是至少部分多孔的，聚合物树脂将穿透衬底的孔并结合至衬底。本领域技术人员已知的其它层压物形成方法也将适合于形成用作本发明的膜的层压物。例如，层压物可由聚合物层和衬底通过施加热和压力、粘合剂或结合剂将聚合物层附着到衬底或通过超声结合来形成。另外，层压物可包括不止一层聚合物层，以及不止一层衬底，只要至少一层聚合物层能够密封到另一聚合物层以形成可膨胀的囊的至少一个隔室。
现转向图1阐述的方法的步骤1(b)，将隔离材料施加于第一膜的第一侧。隔离材料可为在施加热和/或压力时防止第一膜附着到本发明的第二膜的任何材料或处理。更具体地，隔离材料可为涂料、墨、聚四氟乙烯(PTFE)(比如，
Figure BDA0000097440110000091
)涂层、硅涂层、纸、织品、光敏剂、箔、金属丝、颗粒物或表面处理，其维持第一膜和第二膜的完整性，但仍防止膜在隔离材料或处理被施加的地方附着到彼此。
在隔离材料为涂料时，比如，能根据本方法的步骤1(b)以与丝网印制法相似的方式将涂料施加到第一膜。丝网印制法(或丝网印刷)是经济地大量生产的标识、印刷品和织物设计等的常用工艺。丝网印制法的基本构思(如通常在图11中已知的)是产生主网屏，涂料(或其它合适的介质)穿过该主网屏以赋予大量复制品设计或印记。通常，设计的图样或迹线借助光学过程转印到薄的细晶光敏凝胶涂覆的布(或“丝织物”)上，其被紧紧地伸展在框架上。当凝胶暴露时，凝胶的暴露于光的部分硬化或固化，而未露出的部分保持柔软。在固化之后，柔软的凝胶被洗掉，在丝织物上留下“负”的设计图像。丝织物是开孔的(类似网屏)，使得涂料或其它介质能穿过其中。
将带框架的丝织物放置成抵靠将要对其赋予该设计的物体。随后将涂料施加至该带框架的丝织物并利用刮板或类似的装置使涂料拉过丝织物以使所述设计通过丝织物转印到下面的物体。在希望具有多种颜色的设计的情况下，必须为每种颜色准备分离的网屏(类似于常规墨印刷方法中的颜色分离过程)。利用该丝网印制方法，能由单一的丝织物制成成千上万的“印刷品”。最近，印刷网屏由诸如聚酯的单丝材料而不是丝织物形成。
通过将上述丝网印制技术应用于本发明的方法，各种囊构造和尺寸能被“印刷”到或赋予步骤1(a)的第一膜以起到本发明的隔离材料的作用。例如，图2示出了形成在印刷丝织物或网屏24上的可膨胀的囊设计或构造20的负像。在网屏或丝织物在区域22处可见的地方，涂料、墨或其它介质将通过网屏并转印到步骤1(a)的第一膜。囊设计或构造20包括圆形元件26和直线元件28，圆形元件26和直线元件28防止涂料、墨或其它介质转印到第一膜上。当第一膜和第二膜附着到一起时(在下述方法的步骤1(d)中)，第一膜和第二膜将在圆形元件26和直线元件28处附着到彼此以形成上述现有技术的圆形焊接部和焊接线的等同物，从而控制囊的厚度和膨胀，并且相对于衣服或鞋类，适应人体的解剖学。可膨胀的囊设计或构造的负像20还包括网屏的可见区域30，该网屏的可见区域30从网屏的边缘延伸到区域22内。区域30是导管状的形状并且预期形成用于接纳入口或出口阀或其它配件以允许流体被引入本发明的可膨胀的物品或囊和/或从本发明的可膨胀的物品或囊释放的通道。尽管在图2中区域30被显示为导管形状，但是本领域技术人员应理解，区域30可采取适应充注或抽放可膨胀的制造物品或囊所需要的配件所必要的任何形状。
本领域技术人员还应认识到，尽管图2示出了特定的负囊设计或构造，但是囊(且因而，由本发明的方法最终形成的囊)的负设计可采取可膨胀的物品或囊的预期目的或功能所需的任何形状。例如，当用在鞋类中时，囊可被构造成装在鞋的鞋舌内，沿内侧面和外侧，围绕脚踝并在足弓、足跟或跖骨头下方。类似地，囊可被设计成装在救生船的船体、护胸、头盔、手套、空气垫、包装或任何其它可膨胀的制造物品内。
同样，所描述的直线元件和圆形元件可被置于任何位置以适应囊的功能并根据需要控制囊的膨胀和/或鼓胀。此外，直线元件和/或圆形元件不必为直线的或圆形的，而是可以为细长的、弯曲的或任何几何形状以满足囊的功能性目的或使用者的解剖学，其中囊将被结合到由人类穿戴的制造物品内。
继续图1的方法的步骤，在使网屏24形成有期望的可膨胀的囊设计或构造20的负像之后，将网屏24置于第一膜42的第一侧40之上，如图3所示。然后将涂料、墨或其它介质P施加到并拉过网屏24以将可膨胀的囊的构造或设计转印到第一膜42的第一侧40上，作为可见区域22。因而，通过利用涂料、墨或其它介质将可膨胀的囊构造的图像转印到第一膜的第一侧上，根据需要，通过本发明的方法的步骤1(b)将隔离材料施加到第一膜的第一侧。
图4示出了图1的方法的步骤1(c)。在该步骤中，将第二膜46的第一侧44定位在第一膜42的第一侧40上，使得可膨胀的囊构造20的隔离材料图像48和导管30的隔离材料图像50被定位在第一膜42和第二膜46之间。在图4中，隔离材料通过第二膜46是可见的。
在图1的方法的步骤1(d)中，将第一膜42附着到第二膜46使得膜被密封在一起以在除隔离材料被施加至第一膜的地方之外形成密封的外周区域，从而形成至少一个可膨胀的隔室。在隔离材料已经被施加至第一膜的地方，将不发生附着，从而产生所得到的可膨胀的物品或囊的可膨胀的隔室。在图4中，密封区域在阴影线区域49中示出，而至少一个可膨胀的隔室在52处示出。在密封时，圆形元件26和直线元件28形成圆形和直线密封或焊接部54、56。
第一膜和第二膜可通过使加热压板与膜接触而被附着，或者可使同延的膜一起输送通过例如在层压技术中通常已知的加热辊。其它用于密封或层压热塑性膜的已知方式(比如，超声焊接)也能用于实现本发明的目的。膜还能被制成是光敏的使得它们将在施加光时附着到彼此。
在图1的方法的步骤1(e)中，且如图5所示，在可膨胀的隔室附近沿密封的外周区域的边缘在切割线58处进行切割以形成具有至少一个可膨胀的隔室52、圆形焊接部54、直线焊接部56、抽放/充注导管50和外周边缘62的可膨胀的物品或囊60(参见图6)。能通过根据预限定或定制的囊构造(但稍微大点)构造的冲裁模或者通过其它合适的切割方式比如激光切割或水射流切割来进行该切割。
通过利用缝合、粘合剂或其它合适的紧固方式沿外周边缘62将囊固定到鞋部件，图6的可膨胀的囊60可被固定到或固定在制造物品内，例如，鞋类物品。
因而，如上所述，本发明的方法的该实施方式使得能够快速、容易且在不使用昂贵的物品或囊构造所特有的金属刀具加工的情况下来制造可膨胀的物品或用于可膨胀的物品的囊。实际上，该方法能用于已知的丝网印制或印刷和层压技术以允许以较低的成本连续制造多形状的可膨胀的物品或囊。此外，且最有利地，当需要囊构造改变时，不需要在制造过程中定制、加工和更换昂贵的金属刀具加工部件。相反，最新希望的囊构造的新的网屏/负像被制造且互换现有的网屏/负像——简单的、快速的且低价的过程，这也是与制造过程的下游步骤(即，附着和切割)相符的。可替代地，新的网屏/负像能被以数字方式供入制造过程。
返回到图1的方法的步骤1(b)，上述丝网印制技术对于制造用于消费者产品的可膨胀的物品或囊是特别有优势的，因为丝网印制允许使用多种颜色来形成具有视觉上引入注意的、带颜色的设计或装饰的囊。还考虑多种颜色能用于合适设计的网屏以将产品商标、类型或标记的图像转印到膜上，且因此转印到可膨胀的物品或囊。
尽管本发明的隔离材料和施加步骤已经参考丝网印制或印刷技术使用的涂料或墨进行描述，但是考虑隔离材料可采取任何形式。例如，隔离材料可为施加于第一膜的第一侧以防止第一膜和第二膜附着到一起的纸(例如，粘合剂背衬纸)、织物、箔、金属丝、颗粒物或塑料材料(比如聚乙烯)，从而形成至少一个可膨胀的室。
还可能的是，隔离材料可为“自由浮动的”且不附接到第一膜或第二膜。实际上，隔离材料可为定位在第一膜和第二膜之间的将不结合到第一膜和第二膜的特定类型的膜(或多个膜)(比如，在施加热之后，该膜将在其冷却时从第一膜和第二膜释放)。其它“自由浮动的”隔离材料能包括，比如定位在第一膜和第二膜之间的纸、织物、箔、金属丝、颗粒物或塑料材料。可替代地，隔离材料可暂时地施加于第一膜或第二膜之一。
在另一实施方式中，隔离材料可为颗粒物、肥皂、表面活性剂、释放涂层或释放剂、或者聚四氟乙烯或硅涂层，其被喷涂在合适地形成的型板上以按期望的物品或囊构造将隔离材料转印到第一膜的第一侧上，从而防止第一膜和第二膜在本发明的密封步骤期间附着到彼此。
在本发明的又一实施方式中，且利用上述的丝网印制或印刷技术，隔离材料也能为酸性或其它液体化学物质，其被转印到第一膜的第一侧以化学地蚀刻、腐蚀或磨蚀第一膜，从而抑制第一膜附接到第二膜。还考虑了将光敏材料转印到第一膜且随后暴露于光以满足本发明的隔离材料的目的。
在另一实施方式中，第一膜能在热辊和另一热或冷辊之间被压延以在第一膜的一侧上施加或压印纹理(具有总体期望的囊构造)，从而防止其附着到第二膜以形成可膨胀的隔室。
还能想到，本发明的方法能够应用报纸或印刷工业所用的印刷技术(即，印刷膜和辊)来将各种可膨胀的物品或囊形状转印到第一膜，用于附着到第二膜以形成可膨胀的隔室。
在本发明的另一方面中，且参考图7，上述本发明的实施方式能结合“立即响应式”印刷技术来使用以产生定制的可膨胀的产品。具体地，能通过利用“灵活的”数字印刷机70将隔离材料印刷到膜上(可能地利用上述的技术)来实现将隔离材料施加到第一膜的步骤1(b)，数字印刷机70可以获得定制信息的数据库72以产生具有定制的囊构造、定制的圆形和直线元件的放置以及定制的颜色的独特设计。
实践中，鞋的消费者比如可将消费者想要显现在鞋上的具体的颜色或设计输入计算机74。设计能为比如名字、单词或符号的标记，或者可为人或地方的照片。还考虑消费者的足部的解剖学扫描能被输入(比如，在购买点的售货亭或显示器处)以便实现可膨胀的物品或囊的定制制造，其适应消费者的足部的解剖学以提高合适性、缓冲和支撑。输入的信息随后将被传送到印刷机70可以访问的数据库70。之后，印刷机访问数据库并将独特的设计印刷到第一膜76上。第一膜76能被构造为滚压的片材，其然后与相似地滚压的第二膜78接合在一起。第一膜76和第二膜78随后通过加热的辊77、79被压延以将膜附着到一起并产生囊的可膨胀的隔室。然后，利用上述方法将囊从膜切割下来。在利用激光从膜切割囊的情况下，也能通过将激光器连接到数据库以根据印刷到膜上的定制的囊设计来控制从膜切割囊而使激光器是“灵活的”。本发明还考虑了能通过为冲裁模提供腐蚀、溶解或“吃掉”膜的化学物质来从膜“切割”囊。
本发明的该方法不仅是可定制的，而且本质上是连续的，因为不必为了改变成不同的构造、颜色或标记的囊设计而中断方法步骤。当囊被建立在鞋中时，囊可形成如美国专利No.5,343,638中描述的鞋的外骨架。因为囊具有印刷到膜的内侧上的设计，所以该设计可制成在鞋的外侧上是可见的以形成独特定制的鞋。
类似地，隔离材料能采取热反射材料的形式以为囊提供隔热性质。随后，囊能被构造成服装，比如，以形成隔热的衬衫、夹克、背心、裤子或其它服装物品。
还能想到，隔离材料能为印刷的背景设计(比如，水下景象)，且囊能填充有流体和装饰元素(比如，塑料鱼和闪光)，用于儿童的穿戴或涉及特定类型消费者的其它制造物品。
还能想到，囊能由多于两个的膜形成以产生具有多个成层的可膨胀的隔室的囊。在该实施方式中，具体的隔离材料和膜可被选择成使得囊的每个成层的可膨胀的隔室具有不同的充注质量或特性以应对可膨胀的制造物品的目的。
如上所述，通过本发明方法形成的可膨胀的囊还包括用于与充注阀或抽放阀联接的导管50。尽管该导管用作将充注和抽放附件接合到可膨胀的物品或囊本身的一种装置和结构，但是还能想到能在图1的方法步骤1(c)之前经预形成在第二膜中的开口将流体输送和控制技术中已知的附件附接到物品。还能想到，能将本领域已知的构造可膨胀技术领域中有用的单向阀和其它结构的材料插入第一膜和第二膜之间以允许并控制流体向可膨胀的隔室的进入和从可膨胀的隔室的放出。
图8示出如何在本发明的制造过程中将常规的附件构造成囊60。图8A显示了在完成步骤1(c)之后但在步骤1(d)之前图1的方法的制造过程。如图8A所示，将隔离材料80定位在第一膜82和第二膜84之间。第一膜82和第二膜84都设置有适当定位成用于放置泵、入口阀、释放阀或其它已知的可膨胀的囊的附件的开口86、88。将由具有与第二膜84类似或相等的性质的膜材料构造的衬垫90定位在开口88上。将附件，比如，由具有与第一膜82相似或相等的性质的材料构造的数字操作的泵92定位在开口86上。随后执行本发明的步骤4以在除了隔离材料80已经被施加到第二膜84的地方之外的所有区域将第一膜82附着到第二膜84。之后将衬垫90附着到第二膜84且将泵92附着到第一膜82。在由虚线表示的区域(不存在隔离材料80的地方)将元件82和84、90和84以及92和82附着到彼此。在这些步骤之后，且如图8B所示，在囊的形成了可膨胀的隔室或流体导管的区域将泵附着到第一膜以及将衬垫附着到第二膜。因而，流体(由箭头F表示)经泵被引入囊，以充注由隔离材料的应用区域限定的可膨胀的室。
尽管图8示出了将流体引入囊的泵，但是应注意，可利用相同的技术将其它附件(比如，流体释放阀、流体入口、流体调节器和检验阀)附接到膜。而且，本领域技术人员应理解，其它将附件固定到可膨胀的囊的已知技术可用于本发明的方法。
图9示出了用于制造可膨胀的制造物品比如可膨胀的鞋类物品的另一方法。在一个实施方式中，该方法通常包括以下步骤：9(a)提供第一膜，9(b)以与囊的可膨胀的隔室的构造对应的图案将释放涂层施加到第一膜的第一表面，9(c)将释放涂层固化到第一膜的第一表面，9(d)为第一膜提供第二膜以形成成层元件使得固化的释放涂层被布置在第一膜和第二膜之间，9(e)将成层元件定位在第一材料层和第二材料层之间，9(f)对第一材料层和第二材料层施加热和压力以除在释放涂层被施加到第一膜的区域之外将第一膜附着到第二膜，从而形成有被密封周边所包围的可膨胀的隔室，9(g)从附着的第一膜和第二膜移除第一材料层和第二材料层，9(h)沿密封周边切割以形成具有可膨胀的隔室和密封附接边沿的可膨胀的囊，以及9(i)通过在附接边沿将可膨胀的囊附接到制造物品来将可膨胀的囊结合到制造物品中。
现转向根据如图9所示的一个实施方式的方法的更具体的论述，在方法的第一步骤9(a)中提供第一膜。该第一膜可被定尺寸以适应由其制造的囊且可被设置成独立的片或卷的形式。第一膜可为低密度聚乙烯膜。在一个具体实施方式中，第一膜为约0.085英寸厚的低密度聚乙烯膜且由Bloomer Plastics，Inc.(Bloomer，WI)以产品号MC 100V销售。除了该膜之外，在本公开的第[0037]段中给出的膜和材料适合于图9的方法的第一膜。而且，本领域技术人员将理解，任何数量的聚合物材料都适合用于图9的方法，只要该材料是柔性的且能够与具有相同物理性质的另一材料形成不透流体的密封。自然地，膜的特性也可根据囊中所用的流体而改变。比如，如果囊预期用于容纳液体或大分子量气体，则在不偏离本发明的精神的情况下，囊可允许扩散到袋或逆行扩散出袋。类似地，可有意图地将囊制成多孔的，以便当达到预定的内部压力时允许流体从囊扩散或逃离。这可通过对膜添加穿孔或通过使用具有已知扩散速率的膜来完成。
如图10所示，第一膜1000具有长度、宽度和厚度，其限定第一或内表面1010和第二或外表面1020。根据图9的方法的步骤9(b)，以与囊的可膨胀的隔室的构造对应的图案将释放涂层1030施加到第一膜1000的第一表面1010。类似于图1的方法的隔离材料(对此，“释放涂层”和“释放剂”是可互换的术语)，释放涂层1030防止第一膜1000附着到该方法的第二膜，从而形成可膨胀的隔室(在下面更详细地描述)。图9的方法的释放涂层优选地为通过紫外光可固化以将释放涂层固定到第一膜1000的第一表面1010的硅强化涂层。一种这样的硅强化释放涂层是可从Craig Adhesives&Coatings(Newark，NJ)得到的08D003DUV。明显地，其它材料适合用作图9的方法的释放涂层(包括上述段落[0039]、[0055]和本文其它段落中论述的那些)，只要这样的材料能适当地被施加并固定到第一膜以防止在施加热和压力时(或下面更详细论述的其它结合技术)第一膜附着到第二膜。
可利用任何合适的技术(包括上面关于图1的方法所描述的技术)将释放涂层1030施加到第一膜1000。在优选的实施方式中，通过丝网印刷将释放涂层1030施加到第一膜1000的第一表面1010。与本文关于图1的方法描述的丝网印刷技术类似，在网屏上形成可膨胀的囊图案的负像。参考图11，将网屏1110定位在通常表示为1120的丝网印刷单元上第一膜1000的第一表面1010上方。通过转印臂或刮板1125使释放涂层1030拉过网屏1110以将与可膨胀的囊的可膨胀的隔室对应的图案转印到第一表面1010。本领域技术人员应注意，可使用任何丝网印刷工艺或机器实现本方法的施加步骤9(b)。
图10所示的可膨胀的囊图案(其被转印到图11中的第一膜1000的第一表面1010)对应于鞋类物品的鞋帮中使用的囊，且包括可膨胀的鞋背或鞋舌隔室1040和两个可膨胀的侧部隔室1050。可膨胀的隔室1040、1050形成于释放涂层1030穿过网屏1110到达第一膜1000的第一表面1010的区域。图10的图案还包括圆形区域1060和大体的直线区域1070。这些区域形成于释放涂层不穿过网屏到达第一膜的区域且因此是不能膨胀的。圆形和直线区域1060、1070设置成控制囊的厚度和膨胀，且特别是关于鞋类，适应足部的解剖学和骨结构以避免不舒适的压力点。
周边1080围绕囊图案的外周延伸。周边1080也没有释放涂层1030，使得第一膜和第二膜能够在图9的方法的附着步骤中附着到彼此。该附着的周边最终形成附接边沿，其有利于将可膨胀的囊结合到将在下面详细论述的鞋类物品或其它制造物品。
本领域技术人员应认识到，尽管图10显示了可膨胀的鞋舌囊，但是该方法的可膨胀的囊可采取符合其预期目的或功能的任何构造。例如，对于鞋类，可膨胀的囊可被构造成装在鞋舌内，沿内侧面和/或外侧面，围绕脚踝或在足弓下方。类似地，可膨胀的囊可被设计成装在救生船的船体、护胸或头盔或手套内或者任何其它可膨胀的制造物品内。而且，所描述的直线区域和圆形区域(其当然可以采取任何形状或几何结构)可被置于任何位置以满足囊的功能性目的并根据需要控制囊的膨胀。
继续图9的方法的步骤，在将释放涂层施加到第一膜的第一表面之后，通过将第一膜与所施加的释放涂层暴露于紫外(UV)光源而将释放涂层固化到第一膜(参见步骤9(c))。例如，通过施加UV光直到固化将硅强化释放涂层08D003D UV固化到第一膜。明显地，固化释放涂层的需要依赖于待照明区域的尺寸和释放涂层的类型。在固化之后，将释放涂层固定到第一膜的第一表面并且在施加热、压力、超声能或应用其它力、能量或层压/结合技术时释放涂层基本上不熔化、剥落或以其它方式退化。
本领域技术人员将认识到，能根据已知的固化技术(例如，利用手持UV灯或UV光道)固化释放涂层，只要固化技术适合于所施加的释放涂层的配制和性质以及方法的其余步骤。
现转向图12，且根据图9的方法的步骤9(d)，为第一膜1000提供具有第一或内表面1210和第二或外表面1220的第二膜1200以形成成层元件1230。更具体地，通过以与固化的释放涂层1030面对的关系放置第二膜1200的第一表面1210来形成成层元件1230，使得释放涂层夹在或布置在第一膜1000的第一表面1010和第二膜1200的第一表面1210之间。第二膜1200由与第一膜1000相同的低密度聚乙烯膜形成，使得第一膜和第二膜能够在图9的方法的稍后步骤中结合到彼此。如上面关于第一膜1000提到的，第二膜1200可由任何类型的热塑性或弹性体膜形成。然而，第一膜和第二膜应由相同的材料、相似的材料或相容的材料形成以允许两个膜之间所需要的结合或密封。
根据图9的方法的步骤9(e)且参考图13，将成层元件1230(即第二膜1200和具有固化的释放涂层1030的第一膜1000)定位或夹在第一材料层1300和第二材料层1310之间。第一层1300和第二层1310通常不固定到成层元件1230，而是相反通常将成层元件1230松弛地定位在第一层1300和第二层1310之间。第一层1300和第二层1310能包括至少一个纹理化表面。例如，层能包括纺织表面、凹槽表面、结块表面、成波浪的表面或其组合。在优选实施方式中，至少一个层被充分地纹理化以防止或减少在将第一膜1000附着到第二膜1200的步骤期间成层元件1230的外表面附近的空气夹杂。在其它实施方式中，至少一个层被充分纹理化以防止或减少在将第一膜1000附着到第二膜1200的步骤期间成层元件1230的移动。在某些实施方式中，层可包括玻璃纤维或碳纤维、织物、硅、纸、聚对苯二甲酸乙二醇酯(比如双轴定向的聚对苯二甲酸乙二醇酯)或尼龙。例如，层可包括涂硅的纸、纹理化的硅片、聚四氟乙烯片、纹理化的双轴定向的聚对苯二甲酸乙二醇酯或聚四氟乙烯处理的玻璃纤维布。层优选地耐将第一膜1000附着到第二膜1200所用的温度。在某些实施方式中，层阻止在将第一膜和第二膜附着到一起的步骤期间粘到第一膜1000或第二膜1200。在某些实施方式中，层由防粘材料(比如聚四氟乙烯)制成。在其它实施方式中，层利用防粘材料(比如聚四氟乙烯)进行处理。
层可执行多个功能：(1)通过层压过程，层能携带包括第一膜和第二膜以及释放涂层的成层元件，以防止成层元件附着或熔融到层压设备的加热元件；(2)布的纺织织物能防止空气捕获在第一膜和/或第二膜上(比如，捕获在膜的一个和/或多个表面上)或者能减少空气捕获在第一和/或第二膜上的量，这能引起膜之间的鼓泡、翘曲、不一致的层压或者囊中薄弱或薄的区域；(3)层能防止或减少当与层压过程的加热元件靠近时(例如，当成层元件靠近但还没有被插入旋转层压机器的夹压辊时)成层元件的任何不想要的预加热和/或(4)层能防止或减少成层元件的部件相对于彼此的偏移或移动。
能制成第一层1300和第二层1310的聚四氟乙烯/玻璃纤维增强材料的示例能从Precision Coating Co.，Inc.(Dedham，MA)以产品号PC-10、PC-14、PC-10 TR、PC-10 Porous、PC-14 Porous、100-8SW2和100-10sw得到。能制成第一层1300和第二层1310的硅/玻璃纤维增强材料的一个示例能从Precision Coating Co.，Inc.以产品号PC S/W 10得到。在某些实施方式中，制成第一层1300和第二层1310的材料具有约5至20密尔(约0.127mm至约0.508mm)的厚度，比如约10至约15密尔(约0.254mm至约0.381mm)。层1300、1310能被切割或定尺寸成适应夹在其间的成层元件的尺寸。尽管描述了各种类型的适当的层，但是本领域技术人员将认识到，能够执行上述主要功能的任何材料将适合于层1300、1310。
继续到图9的方法的步骤9(f)，将热和压力施加到第一层1300和第二层1310(其中成层元件1230定位在其间)以将第一膜1000附着到第二膜1200，除了在释放涂层1030已经被施加到第一膜1000的区域或附近之外，以形成由密封周边包围的可膨胀的隔室。例如，在一个实施方式中，第一膜可在除释放涂层存在的地方和在紧邻释放涂层存在的区域之外的地方附着到第二膜。在本发明的优选实施方式中，利用加热的鼓旋转层压机器实现该方法的热和压力施加步骤。利用加热的鼓旋转层压机器，来自辅助源的加热的流体(比如，油)能循环通过机器的旋转鼓，该旋转鼓进而辐射热并将热施加至被带到旋转鼓附近的膜。加热的鼓旋转层压机器是理想的，因为循环通过鼓的加热的流体提供鼓的表面上的均匀的温度，以提供一致的熔化，因而提供膜的高度完整性的结合或层压。
图14显示了旋转层压机器1400。其中，旋转层压机器1400包括有支座的进给托盘1410、加热的旋转鼓1420、夹压辊1430、输送带1440和弹簧加载的出口托盘1450。为了利用旋转层压机器1400执行图9的方法的附着步骤(步骤9(f))，带有定位在其间的成层元件1230的第一层1300和第二层1310被带到机器并放置在有支座的进给托盘1410上以减小组合的层和成层元件的预加热。随后通过沿图14所示的箭头1的方向将层夹在或挤在夹压辊1430和加热的旋转鼓1420之间以将层进给到机器。之后，层抵靠着输送带1440被承载并经由输送带1440围绕加热的旋转鼓(箭头2)。类似于层1300、1310，输送带1440可由与上述用于层1300、1310的材料相似的材料形成，以便于层围绕加热的旋转鼓的运动以及防止第一膜和第二膜在层压过程期间粘着或附着到带。在一个实施方式中，输送带1440能由这样的材料形成且成层元件1230被直接放置在输送带1440上而不使用层1300、1310之一或两者。例如，输送带能由聚四氟乙烯/玻璃纤维材料制成，以便于成层元件1230围绕加热的旋转鼓的运动以及防止第一膜和第二膜在层压过程期间粘着或附着到带。
为了结合或附着第一膜1000和第二膜1200，机器1400的旋转鼓1420被加热以在一温度下操作并设定成在依赖于膜1000、1200、隔离材料80(比如，释放涂层1030)和层1300、1310的选择的速度下运行，但是该温度和速度被选择成足以至少部分地熔化至少一个膜且在某些实施方式中，完全地熔化膜中的至少一个或两者，且确保膜1000、1200的适当熔化和结合。随着层1300、1310围绕加热的旋转鼓被承载(且压力通过鼓和输送带被施加到层和成层元件)，第一膜1000和第二膜1200在除释放涂层1030被施加到第一膜1000的区域之外熔化并结合或附着到彼此。输送带1440将其间带有成层元件的层1300、1310携带至加热的旋转鼓的最下部的切向点(箭头3和4)，在此处其随后将层离开鼓并朝弹簧加载托盘1450地输送(箭头5)，该弹簧加载托盘1450允许层和其间布置的此刻附着的第一膜和第二膜从旋转层压机器的移除(箭头6)。
尽管关于加热的旋转层压机器描述了附着步骤，但是本领域技术人员应理解能利用其它层压技术来实现本文描述的方法的目标，包括但不限于使用压力源和热源。适当的压力源的示例包括压力机(比如，液压压力机)和真空的施加(比如，经真空袋或真空桌)。其中，适当的热源的示例包括：加热板；热灯(比如，红外线灯)；常规的对流或微波炉；以及电阻加热器。
在一个实施方式中，使用超声结合角状物来执行附着步骤。超声结合角状物的使用可包括超声旋转/连续结合角状物技术比如包括通过将两层或多层材料穿过振动角状物和旋转鼓之间来组装两层或多层材料的那些技术，其中振动角状物的高频机械运动以及在角状物与旋转鼓之间的压缩力在角状物接触材料的部位处产生摩擦热。
在另一实施方式中，附着步骤可包括真空的施加。真空的施加能防止空气被捕获在第一膜和/或第二膜(比如，捕获在膜的一个或多个表面上)或者能减小在附着步骤期间空气被捕获在第一膜和/或第二膜上的量且能防止或减小在附着步骤期间成层元件的部件相对于彼此的偏移或运动。
例如，可以将膜1000、1200置于层1300、1310之间且所得到的成层元件1230能经受真空和热和/或额外的压力。在一个实施方式中，成层元件1230置于真空袋内且对袋抽真空。随后能将热和/或额外的压力(比如，经由压力机)施加到真空袋和成层元件1230，导致第一膜1000和第二膜1200在释放涂层1030已经被施加于第一膜1000的区域之外熔化并结合或附着到彼此。在另一实施方式中，能将成层元件1230置于真空桌上，用片或膜覆盖，对成层元件1230抽真空且随后对成层元件施加热和/或额外的压力(比如，经由压力机)。
明显地，本领域已知的结合或层压热塑性或弹性体膜和材料的其它层压技术和设备将适合用于实现本发明的目的。
在从旋转层压机器移除层和当前附着的第一和第二膜之后，使层和膜冷却。在冷却之后，通过从第二膜1200剥离层1300以及从第一膜1000剥离层1310(方法的步骤9(g))来从成层元件移除层1300、1310。层1300、1310能方便地且有效地重新用于额外的膜的层压。如前面提到的，层1300、1310，特别是纹理化的层，有利地可防止或减少(a)空气被捕获在第一和/或第二膜上，以及(b)成层元件的部件相对于彼此的偏移或移动，两者都将导致不一致的结合或损害完整性的结合。利用该层压技术，所得到的附着膜基本上在其整个表面上是平的(即，没有升高的焊接线、接缝、脊或鼓起)。这有利于操纵膜来将可膨胀的囊组装到鞋类物品或其它制造物品。
还应注意，在膜1000、1200的熔化和层压之后，层1300、1310的任何纹理化的表面(或翘曲和编织)能被赋予到第一膜1000的第二或外表面1020和第二膜1200的第二或外表面1220。膜1000、1200的该纹理化(在图15中作为纹理T局部地表示)能改进将可膨胀的囊操纵和附接到鞋类物品内(或者至其结构)，特别是，如果这样的附接借助于液体粘合剂的话，因为粘合剂能够流到带纹理的表面的凹部，从而改善结合。
如上所述，在除隔离材料已经被施加的区域之外将第一膜1000附着到第二膜1200以形成由完全密封的周边包围的可膨胀的隔室。图15是除在隔离材料比如释放涂层1030已经被施加的区域之外被附着到一起以形成由密封周边1520和密封附接边沿1550包围的可膨胀的隔室1510的附着的第一和第二膜1500的顶部平面图。与仅在对膜施加了RF能的地方附近形成焊接线或接缝的常规射频(RF)焊接不同，周边1520(由附着膜1000、1200形成)从可膨胀的隔室的边缘(即，隔离材料的边缘)跨过其整个表面到附着膜的边缘被附着，如图15中的箭头S所示。
现转向图9的方法的步骤9(h)且继续参考图15，能通过沿切割线C切割膜的密封周边来从当前附着的膜切割可膨胀的囊以形成具有密封的附接边沿1550的可膨胀的囊1540。能利用任何合适的方式(包括在本公开中前面论述的任何切割方式)从附着膜切割可膨胀的囊1540。
以图9所示的方法的步骤9(i)完成，通过将可膨胀的囊1540在附接边沿1550处附接到鞋类物品来将可膨胀的囊结合到鞋类物品或其它制造物品。图9的方法的可膨胀的囊(具有完全密封的附接边沿1550)特别适合于结合到制造物品中(包括但不限于鞋类)，因为其能被纹理化(以用于改善操作)，沿其表面基本上是平的，且具有由用于改进制造物品的附接的密封膜构成的附接边沿。更具体地，RF焊接的囊可能难以组装到鞋类，例如，因为焊接线能导致囊的膜沿焊接线卷曲或挠曲。该卷曲能干扰囊至鞋类物品的放置和附接。此外，利用RF焊接，膜仅在焊接线处附接，这使膜沿可膨胀的囊的外边缘(即在附接边沿处)彼此分离。由于可膨胀的囊不被附着，所以必须特别小心以确保(1)缝合线穿过附接边沿的两个膜(如果通过缝合附着到鞋类物品的话)，(2)对两个膜施加粘合剂(如果通过粘合剂附着到鞋类物品的话)以确保可膨胀的囊充分地附接到鞋类物品并且能够承受在边沿施加到可膨胀的囊的力和增加的压力，或者(3)膜的未附着的部分的至少一部分被切掉。由图9的方法形成的附接边沿1550的基本上平的且附着的膜提供可膨胀的囊至鞋类物品(或其它制造物品)的容易且有效的附接。
已经描述了本发明的图9的方法的基本步骤，现将着重于其它或任选步骤。能使本发明的可膨胀的囊永久地膨胀(即，空气永久地密封在囊的可膨胀的隔室内)或者可膨胀的囊的充注能通过使用者将充注设备和抽放设备附接到囊的可膨胀的隔室而被定制。现将参考图9的方法形成的可膨胀的囊描述附接一种类型的充注设备和抽放设备的步骤。图16显示了具有端部敞开的柱塞壳体1610、端部敞开的泵连接器1620和端部敞开的密封套环1630的阀体1600。柱塞壳体1610、连接器1620和密封套环1630通过延伸通过并在泵连接器1620、柱塞壳体1610和密封套环1630之间延伸的导管1640流体地连接。具有中心布置的凹槽或沟道1660的舌状物1650被布置在密封套环1630内并从密封套环1630延伸。舌状物1650在端部敞开的柱塞壳体1610和密封套环1630的接合点处与阀体1600模制在一起。尽管舌状物1650居中地布置在密封套环1630内，但是其不阻挡或阻碍导管1640。
阀体1600由与形成第一膜1000和第二膜1200所用的材料(比如低密度聚乙烯)相容的材料形成，以使阀体能密封到第一膜和第二膜。阀体1600可由使阀体能以不透流体的方式密封或结合到可膨胀的囊的膜的任何材料形成。
现参考图17，显示了可膨胀的囊1540的局部平面图。为了将阀体1600附接到可膨胀的囊1540，切掉密封周边1520和邻近的可膨胀的隔室1510的一部分，如1710所示的。理想地，可膨胀的隔室被切掉在宽度上对应于阀体的密封套环和舌状物的区域。如图17所示，跨过其宽度切割可膨胀的囊1510以在可膨胀的隔室中形成流体入口1720。为了将阀体1600附接到可膨胀的囊，且如图18所示，将可移除的聚四氟乙烯/玻璃纤维布股1810插入阀体1600以在将阀体密封到可膨胀的囊的过程中产生正空气通道(如下面更详细论述的)。具有布股1810的阀体1600被插入柱塞壳体1610的敞开端且穿过导管1640至密封套环1630。从密封套环1630，布股1810沿舌状物1650的长度且在居中布置的沟道1660上进给。之后，将舌状物1650(具有在居中布置的沟道1660上的布股1810)供给到当前切开的流体入口1720，使得舌状物和布股位于一段可膨胀的隔室1510内，密封套环1630的上部1820与第二膜1200接触，且密封套环1630的下部1830与第一膜1000接触。具有阀体1600和插入其中的布股1810的可膨胀的囊1540随后被放入顶部和底部加热的密封模具内，该顶部和底部加热的密封模具被压闭合以仅对密封套环1630的上部和下部的边缘施加热和压力，从而将密封套环(且因此阀体)结合或密封到可膨胀的囊的第一膜和第二膜。应注意，可利用夹紧装置和聚四氟乙烯/玻璃纤维布来保护阀体免于与加热的密封模具接触，否则能导致阀体的熔化或退化。尽管密封套环当前被密封或结合到可膨胀的囊的第一膜和第二膜，但是布股1810防止可膨胀的囊的第二或上膜结合到在布股1810附近的舌状物1650或居中地布置的沟道1660。
在将热和压力施加于密封套环之后，将可膨胀的囊和夹紧装置移动到冷却模具站。冷却模具可具有将柔顺性的压力施加到阀体的密封部的硅海绵插入物，以维持阀体密封形状。当阀体密封部已经冷却时，从阀体1600的导管1640移除布股1810，以在阀体的结构和可膨胀的囊隔室的内部之间提供敞开的流体导管，从而允许空气(流体)进入可膨胀的囊和从可膨胀的囊流出。在移除布股1810之后，将常规的阀柱塞1910和弹簧(通过手动操作的手扳压机)压配合到阀体1600的柱塞壳体1610中(图19)。为了完整地形成充注设备和抽放设备，将具有敞开端的杆1940的数字球泵1920固定到阀体1600。
明显地，能将本领域已知的其它充注和抽放设备流体地连接到通过图9的方法制造的可膨胀的囊，包括但不限于本文的段落[0065]等中描述的那些。
还能想到，图9的方法的膜1000和1200不必为单一的材料层。实际上，膜之一或两者可为聚合物材料和仅被施加于聚合物层的一侧的衬底(一层或多层中的)的层压物(允许聚合物层的相对侧被结合到第二膜(或层压物))。能被层压到图9的方法的膜的织物或其它衬底的示例包括非纺材料、聚酯针织物、尼龙膜、聚酯膜比如双轴定向的聚对苯二甲酸乙二醇酯膜、以及本文段落[0038]中描述的那些材料。在某些实施方式中，任一或两个膜1000和1200可包括聚合物材料的高熔点层和聚合物材料的低熔点层。例如，两个层1000和1200都可以包括高熔点层和低熔点层，且图9的方法能通过将隔离材料布置在膜1000和1200的低熔点层之间并施加热和压力以在除隔离材料附近之外将膜1000的低熔点层附着到膜1200的高熔点层来执行。
还能想到，图9的方法能为连续的或半连续的，类似于图1的方法。例如，且类似于本文描述的图7的过程，图9的方法的释放涂层能被连续地“印刷”在聚合物材料和衬底的第一膜层压物的幅或卷上以允许将释放涂层连续且有效地施加到膜层压物的聚合物材料。类似地，方法的第一膜层压物(具有施加的释放涂层)可被定位成邻近聚合物材料的第二膜层压物且热和压力被施加以在除释放涂层附近之外附着层压物的聚合物材料。在某些情形中，衬底为熔点大体上比聚合物材料高的材料，使得衬底在施加热和压力过程中不软化。在某些实施方式中，层压物的衬底之一或两者被纹理化且不光滑。在示例性实施方式中，衬底为光滑的或纹理化的聚酯膜比如双轴向定向的聚对苯二甲酸乙二醇酯膜(比如，
Figure BDA0000097440110000271
膜)等。随后可从附着层移除衬底之一、两者或都不移除。在可替代的示例中，且类似于本文描述的图7，图9的方法的释放涂层可被连续地“印刷”在聚合物材料的第一膜层压物的幅或卷上。第一膜层压物(具有施加的释放涂层)能定位成邻近聚合物材料的第二膜，膜被给入两个材料层之间(比如，布的连续卷或其它纹理化表面)，且热和压力被施加至层以在除释放涂层附近之外附着层压物的聚合物材料。
应理解，尽管图9的方法已经关于用于鞋类的可膨胀的囊进行了描述，但是其步骤同等地适用于形成用于任何制造物品的可膨胀的囊。实际上，图1和图9的方法提供高质量的、可定制的或构造容易改变的、制造低价且简单的以及容易组装到可膨胀的囊指定的制造物品的可膨胀的囊的形成。
图20显示了制造可膨胀的囊的方法的另一实施方式。参考图20，方法包括以下步骤：20(a)以对应于可膨胀的囊的可膨胀的隔室的形状的构造将隔离材料定位在第一膜和第二膜之间，20(b)将其间定位有隔离材料的第一膜和第二膜定位在第一材料层和第二材料层之间，20(c)除在隔离材料附近之外将第一膜附着到第二膜，以形成具有由密封的连续地基本平的周边包围的可膨胀的隔室的可膨胀的囊，以及20(d)从可膨胀的囊移除第一材料层和第二材料层。本文关于图1和图9的制造方法描述的材料和/或技术中的一种或多种可单独或组合地在图20的方法步骤中采用。例如，步骤20(a)的隔离材料可为前面描述的可固化的释放涂层。在该实施方式中，步骤20(a)的定位步骤可进一步包括将释放涂层施加到第一膜、将释放涂层固化到第一膜以及将固化的释放涂层夹在第一膜和第二膜之间的子步骤。能利用网屏、模板、型板或本文论述的其它技术将释放涂层施加到第一膜。能通过施加紫外光或通过其它本文描述的固化方式来固化释放涂层。第一材料层和第二材料层可被纹理化且能由聚四氟乙烯涂覆的玻璃纤维增强布或本文描述的其它任何合适的材料形成。方法的附着步骤20(c)可通过旋转层压、通过在压板之间的热压制、通过施加真空和热或者通过本文描述的任何其它附着技术来实现。适当的充注设备和抽放设备也可联接到可膨胀的囊以分别允许将流体(比如空气)引入可膨胀的囊以及从可膨胀的囊释放流体(比如空气)。由图20的方法形成的可膨胀的囊可适合于结合到任何制造物品(包括但不限于鞋类或其它运动装备)，且可被切割尺寸以便于根据本文公开的技术。
而且，在某些可膨胀的制造物品(比如鞋类或防护性背心)中，可膨胀的囊需要弯曲以适应穿戴者的运动或其它功能性，且利用某些可膨胀的囊构造，这能引起囊内的流体(比如，空气)通道的挤压或阻挡，从而禁止其完全充注或抽放。该问题的新的解决方案是将囊的内表面纹理化。在本发明的一个实施方式中，这可利用由纹理化囊的膜之一或两者的内表面所包括的各种技术来实现。在另一技术中，以与可膨胀的囊的构造对应的图案将释放涂层施加到膜之一的内表面，而将不连续的涂层施加到另一膜的内表面。不连续地施加的释放涂层能为点、线的图案或将纹理提供到膜的内表面以辅助保持囊的流体通道打开的其它形状的图案。不连续地施加的层的没有释放涂层的区域能定向在流体流的预期的主方向上。可替代地，囊膜的内表面中的两个都能具有不连续地施加的释放涂层，使得施加于一个膜的释放涂层与施加于另一膜的释放涂层重叠，以允许释放涂层一起工作来防止膜的附着，从而产生期望的可膨胀的隔室。在又一实施方式中，诸如箔、纸或织物的隔离材料能用在可膨胀的囊中的预期弯曲部的附近以帮助在该区域中保持流体通道打开。本领域技术人员应认识到，前述纹理化技术可用于图1、图9或图20中描述的任何方法，或者可用于本文公开的和/或本发明的构思和精神所考虑的任何其它方法。
具体实施方式的前述说明将如此完全揭露本发明的基本本质以致在不偏离本发明的总体构思和精神的情况下，其他人能通过应用相关领域的技术内的知识(包括本文引用的参考文献的内容)而容易修改和/或改变该具体实施方式的各种应用而不用过度的实验。因此，基于本文给出的教导和指导，这样的改变和修改预期在所公开的实施方式的等同物的意义和范围内。将理解，本文使用的措辞或术语用于说明的目的且不用于限制，使得本说明书的术语或措辞由技术人员根据本文给出的教导和指导、结合本领域技术人员的知识来解释。

Claims (34)

1.一种用于制造可膨胀的物品的方法，包括以下步骤：
(a)提供具有内侧和外侧的第一聚合物膜；
(b)以与可膨胀的囊的可膨胀的隔室的构造对应的图案将可固化的释放涂层施加到所述第一聚合物膜的所述内侧；
(c)通过施加紫外光将所述释放涂层固化到所述第一聚合物膜的所述内侧；
(d)为所述第一聚合物膜提供具有内侧和外侧的第二聚合物膜，以形成成层元件，使得所述释放涂层被布置在所述第一聚合物膜的所述内侧和所述第二聚合物膜的所述内侧之间；
(e)将所述成层元件定位在第一材料层和第二材料层之间；
(f)对围绕所述成层元件定位的所述第一材料层和第二材料层施加热和压力，以除了在所述释放涂层已经被施加于所述第一聚合物膜的所述内侧的区域之外将所述第一聚合物膜附着到所述第二聚合物膜，从而形成由密封周边包围的可膨胀的隔室；以及
(g)从所述附着的第一聚合物膜和第二聚合物膜移除所述第一材料层和第二材料层。
2.如权利要求1所述的方法，其中所述可固化的释放涂层是硅强化的。
3.如权利要求2所述的方法，其中所述可固化的释放涂层通过丝网印刷而被施加到所述第一聚合物膜的所述内侧。
4.如权利要求1所述的方法，其中所述第一材料层和第二材料层是聚四氟乙烯涂覆的玻璃纤维增强布。
5.如权利要求1所述的方法，其中所述第一材料层和第二材料层中的至少一个材料层被纹理化。
6.如权利要求1所述的方法，其中所述施加热和压力的步骤通过旋转层压来实现。
7.如权利要求1所述的方法，还包括以下步骤：将充注设备和抽放设备联接到所述可膨胀的囊。
8.如权利要求1所述的方法，其中所述第一聚合物膜或第二聚合物膜中的一个聚合物膜是由聚合物层和衬底组成的层压物。
9.如权利要求1所述的方法，还包括以下步骤：
(h)沿所述密封周边切割，以形成具有密封的附接边沿的可膨胀的囊；以及
(i)通过在所述附接边沿处将所述可膨胀的囊附接到鞋类物品，来将所述可膨胀的囊结合到所述鞋类物品中。
10.一种用于制造可膨胀的囊的方法，包括以下步骤：
(a)以与所述可膨胀的囊的可膨胀的隔室的形状对应的构造将隔离材料定位在第一膜和第二膜之间；
(b)将其间定位有所述隔离材料的所述第一膜和第二膜定位在第一材料层和第二材料层之间；
(c)除了在所述隔离材料附近之外将所述第一膜附着到所述第二膜，从而形成所述可膨胀的囊，所述可膨胀的囊具有由密封的连续地基本平的周边包围的所述可膨胀的隔室；以及
(d)从所述可膨胀的囊移除所述第一材料层和第二材料层。
11.如权利要求10所述的方法，还包括如下步骤：通过在所述可膨胀的囊的所述周边将所述可膨胀的囊固定到鞋类物品，来将所述可膨胀的囊结合到所述鞋类物品中。
12.如权利要求10所述的方法，其中所述隔离材料是可固化的释放涂层，并且其中将隔离材料定位在第一膜和第二膜之间的步骤包括如下子步骤：将所述释放涂层施加到所述第一膜，将所述释放涂层固化到所述第一膜，以及将所述固化的释放涂层夹在所述第一膜和第二膜之间。
13.如权利要求12所述的方法，其中所述释放涂层利用网屏、模板或型板而被施加到所述第一膜。
14.如权利要求12所述的方法，其中所述释放涂层通过施加紫外光而被固化。
15.如权利要求10所述的方法，其中所述第一材料层和第二材料层是聚四氟乙烯涂覆的玻璃纤维增强布。
16.如权利要求10所述的方法，其中所述第一材料层和第二材料层中的至少一个材料层被纹理化。
17.如权利要求10所述的方法，其中所述附着步骤通过旋转层压、通过在压板之间热压或通过施加真空和热来实现。
18.如权利要求10所述的方法，还包括如下步骤：将充注设备和抽放设备联接到所述可膨胀的囊。
19.如权利要求10所述的方法，其中所述第一膜或第二膜中的一个膜是由聚合物层和衬底组成的层压物。
20.如权利要求10所述的方法，其中所述隔离材料包括至少两个释放涂层，并且其中将隔离材料定位在第一膜和第二膜之间的步骤包括如下子步骤：将第一释放涂层施加到所述第一膜，将第二释放涂层施加到所述第二膜，固化所述释放涂层中的至少一个释放涂层，以及将所述释放涂层夹在所述第一膜和第二膜之间。
21.如权利要求20所述的方法，其中施加于所述第二膜的所述释放涂层是不连续的涂层。
22.如权利要求10所述的方法，其中所述隔离材料是涂料、墨、纸、织品、光敏剂、金属丝、箔或颗粒物。
23.一种根据权利要求1所述的方法形成的可膨胀的物品。
24.一种根据权利要求10所述的方法形成的可膨胀的囊。
25.一种可膨胀的鞋类物品，包括：
(a)鞋底；以及
(b)附接到所述鞋底的鞋帮，所述鞋帮包括可膨胀的囊，所述可膨胀的囊包括：
(i)第一膜；
(ii)释放剂，所述释放剂以与所述可膨胀的囊的可膨胀的隔室的形状对应的图案施加并固化到所述第一膜；以及
(iii)第二膜，所述第二膜附着到所述第一膜，使得所述释放剂被布置在所述第一膜和所述第二膜之间，且所述第一膜和所述第二膜在所述释放剂附近不附着，从而形成具有外周边缘的所述可膨胀的隔室，
其中所述可膨胀的囊没有升高的焊接线或升高的附着接缝，并且其中所述可膨胀的囊的外表面的至少一部分被纹理化。
26.如权利要求25所述的可膨胀的鞋类物品，其中所述可膨胀的囊的所述外表面基本上全部被纹理化。
27.如权利要求26所述的可膨胀的鞋类物品，其中所述可膨胀的囊的所述纹理化的外表面对应于在所述第一膜和第二膜彼此附着的同时与所述第一膜或所述第二膜中的至少一个膜的所述外表面邻近地定位的纹理化材料层的纹理。
28.如权利要求27所述的可膨胀的鞋类物品，其中所述材料层是聚四氟乙烯涂覆的玻璃纤维增强布。
29.如权利要求25所述的可膨胀的鞋类物品，其中所述可膨胀的囊包括从所述可膨胀的隔室的所述外周边缘延伸到所述可膨胀的囊的边缘的基本平的附着的附接边沿，以便于所述可膨胀的囊至所述鞋类物品的所述鞋帮的附接。
30.如权利要求25所述的可膨胀的鞋类物品，其中所述固化的释放涂层通过施加紫外光而被硅强化和固化。
31.如权利要求25所述的可膨胀的鞋类物品，其中所述膜中的至少一个膜是结合到衬底的聚合物层。
32.如权利要求25所述的可膨胀的鞋类物品，还包括充注设备和抽放设备。
33.一种可膨胀的鞋类物品，包括：
(a)鞋帮；
(b)附接到所述鞋帮的鞋底；以及
(c)附接到所述鞋类物品的可膨胀的囊，所述可膨胀的囊包括：
(i)第一单层膜，所述第一单层膜具有内表面和纹理化的外表面；
(ii)释放剂，所述释放剂以与所述可膨胀的囊的可膨胀的隔室的形状对应的图案施加并固化到所述第一单层膜的所述内表面；
(iii)第二单层膜，所述第二单层膜具有内表面和纹理化的外表面，所述第二单层膜以与所述第一单层膜面对的关系布置并附着到所述第一单层膜，使得所述释放剂被布置在所述第一单层膜的所述内表面和所述第二单层膜的所述内表面之间，所述释放剂防止所述第一单层膜在施加所述释放剂的区域中附着到所述第二单层膜，从而形成所述可膨胀的囊的所述可膨胀的隔室。
34.如权利要求33所述的可膨胀的鞋类物品，其中通过在将所述第一单层膜附着到所述第二单层膜期间与所述第一单层膜和第二单层膜的所述外表面邻近地布置的纺织材料，将所述第一单层膜和第二单层膜的所述纹理化的外表面的纹理赋予所述第一单层膜和第二单层膜。
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US20120084999A1 (en) 2012-04-12
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