Method Of Manufacturing A Contoured Fluid-Filled Chamber With Tensile Structures

Abstract

In one method of manufacturing a fluid-filled chamber, two polymer layers are located between two mold portions, the surfaces of the mold portions cooperatively defining a peripheral cavity with first and second regions, an inward extent of the first region exceeding an inward extent of the second region. A tensile structure may be positioned between the polymer layers and the mold portions may be compressed together. Part of a peripheral portion of the chamber may be formed by drawing first and second areas of the chamber against the first and second regions of the peripheral cavity, respectively. After pressurization, the first region of the peripheral cavity may have a greater extent of outward protrusion than the second region of the peripheral cavity. Accordingly, an asymmetric medio-lateral shape may be imparted to the chamber without the use of a tensile structure that is itself tapered or contoured.

1 - 13 . (canceled) 
     
     
         14 . A method of manufacturing a fluid-filled chamber, the method comprising:
 locating a first polymer layer and a second polymer layer between a first mold portion and a second mold portion, a first surface of the first mold portion and a first surface of the second mold portion cooperatively defining a peripheral cavity with a first region and a second region, an inward extent of the first region exceeding an inward extent of the second region;   positioning a tensile structure between the first polymer layer and the second polymer layer;   securing the tensile structure to the first polymer layer and the second polymer layer;   sealing the first polymer layer to the second polymer layer to form the chamber;   forming at least part of a peripheral portion of the chamber by drawing a first area of the chamber against the first region of the peripheral cavity, and drawing a second area of the chamber against the second region of the peripheral cavity; and   pressurizing the chamber.   
     
     
         15 . The method of manufacturing of  claim 14 , wherein the tensile structure has a first height adjacent to the first area of the chamber and a second height adjacent to the second area of the chamber, the second height being substantially the same as the first height 
     
     
         16 . The method of manufacturing of  claim 14 , wherein the tensile structure includes a first tensile member adjacent to the first area and a second tensile member adjacent to the second area. 
     
     
         17 . The method of manufacturing of  claim 14 , wherein the first area of the chamber and the second area of the chamber are located substantially opposite each other on the chamber. 
     
     
         18 . The method of manufacturing of  claim 17 , wherein one of the first area of the chamber and the second area of the chamber is located on a lateral side of the chamber. 
     
     
         19 . The method of manufacturing of  claim 17 , wherein the first area of the chamber and the second area of the chamber are located in a midfoot region of the chamber. 
     
     
         20 . The method of manufacturing of  claim 14 , wherein the tensile structure includes a textile tensile member. 
     
     
         21 . The method of manufacturing of  claim 14 , wherein the first surface of the first mold portion is substantially flat. 
     
     
         22 . A method of manufacturing an article of footwear, the method comprising:
 locating a first polymer layer and a second polymer layer between a pair of mold portions, each mold portion having a molding surface, at least one of the molding surfaces including a peripheral indentation with a first region having a first inward extent and a second region having a second inward extent, the first inward extent exceeding the second inward extent;   positioning a tensile structure between the mold portions;   compressing the mold portions together to secure the tensile structure to each of the polymer layers, to seal the polymer layers to each other, and to form a chamber;   forming at least part of a peripheral portion of the chamber by drawing a first area of the chamber against the first region of the peripheral indentation, and drawing a second area of the chamber against the second region of the peripheral indentation;   pressurizing the chamber to form a window portion around at least part of a periphery of the tensile structure, the window portion having a first area with a first extent of outward protrusion and a second area with a second extent of outward protrusion, the first extent of outward protrusion exceeding the second extent of outward protrusion.   incorporating the chamber into the article of footwear.   
     
     
         23 . The method of manufacturing of  claim 22 , wherein the tensile structure has a first height adjacent to the first area of the window portion and a second height adjacent to the second area of the window portion, the second height being substantially the same as the first height. 
     
     
         24 . The method of manufacturing of  claim 22 , wherein the tensile structure includes a first tensile member adjacent to the first area and a second tensile member adjacent to the second area. 
     
     
         25 . The method of manufacturing of  claim 22 , wherein the first area of the chamber and the second area of the chamber are located substantially opposite each other on the chamber. 
     
     
         26 . The method of manufacturing of  claim 25 , wherein one of the first area of the chamber and the second area of the chamber is located on a lateral side of the chamber. 
     
     
         27 . The method of manufacturing of  claim 25 , wherein the first area of the chamber and the second area of the chamber are located in a midfoot region of the chamber. 
     
     
         28 . The method of manufacturing of  claim 22 , wherein the tensile structure includes a textile tensile member. 
     
     
         29 . The method of manufacturing of  claim 22 , wherein one of the first mold portion and the second mold portion has a substantially flat molding surface.