Flexible fluid-filled chamber with tensile member

1. A method of making an article of footwear having an upper and a sole structure secured to the upper, the method comprising:

forming a chamber for receiving a pressurized fluid by:

assembling a stacked arrangement of chamber components including:

a first chamber barrier layer;

a second chamber barrier layer; and

a tensile member extending between the first chamber barrier layer and the second chamber barrier layer, the tensile member including a first tensile member layer, a second tensile member layer, and a plurality of tethers connecting the first tensile member layer to the second tensile member layer, wherein the second tensile member layer includes a first section and a second section separate from the first section;

bonding the first chamber barrier layer to the second chamber barrier layer to form peripheral portions of the chamber and to define an interior void between the first chamber barrier layer and the second chamber barrier layer; and

extending a portion of the second chamber barrier layer toward the first tensile member layer between the first section of the second tensile member layer and the second section of the second tensile member layer, pressing the portion of the second chamber barrier layer against the first tensile member layer; and

joining the portion of the second chamber barrier layer to the first tensile member layer between the first section of the second tensile member layer and the second section of the second tensile member layer;

bonding the first tensile member layer to the first chamber barrier layer;

bonding the second tensile member layer to the second chamber barrier layer;

inflating the chamber with a pressurized fluid;

incorporating the chamber into the sole structure; and

attaching the sole structure to the upper.

2. The method of claim 1 , wherein the steps of bonding the first chamber barrier layer to the second chamber barrier layer to form peripheral portions of the chamber and joining a portion of the second chamber barrier layer to the first tensile member layer are performed simultaneously in a first die set as part of a first process.

3. The method of claim 2 , wherein the first die set includes a first die including a first peripheral die projection and a second die including a second peripheral die projection, configured to mate with the first peripheral die projection; and

wherein bonding the first chamber barrier layer to the second chamber barrier layer to form peripheral portions of the chamber includes:

placing a portion of the first chamber barrier layer and a portion of the second chamber barrier layer between the first peripheral die projection and the second peripheral die projection; and

applying pressure to the first chamber barrier layer and the second chamber barrier layer between the first peripheral die projection and the second peripheral die projection.

4. The method of claim 3 , wherein the second die includes a projection; and

wherein joining a portion of the second chamber barrier layer to the first tensile member layer involves extending a portion of the second chamber barrier layer toward the first tensile member layer using the projection by advancing the first die and the second die toward one another to extend the projection between the first section of the second tensile member layer and the second section of the second tensile member layer and press the portion of the second chamber barrier layer toward and against the first tensile member layer.

5. The method of claim 4 , wherein the second die includes a first recessed portion adjacent the projection, the method further including:

drawing the second chamber barrier layer against the second die by creating a reduced pressure using a vacuum, so that the second chamber barrier layer extends into the first recessed portion adjacent the projection.

6. The method of claim 5 , wherein the second die includes a second recessed portion adjacent the projection and located on an opposite side of the projection from the first recessed portion, and

wherein drawing the second chamber barrier layer against the second die extends the second chamber barrier layer into the second recessed portion of the second die.

7. The method of claim 4 , wherein the projection is an elongate projection; and

wherein the step of joining the portion of the second chamber barrier layer to the first tensile member layer by extending the portion of the second chamber barrier layer toward the first tensile member layer using the elongate projection forms an elongate flex groove in the chamber.

8. The method of claim 2 , wherein the steps of bonding the first tensile member layer to the first chamber barrier layer and bonding the second tensile member layer to the second chamber barrier layer are performed simultaneously in a second die set as part of a second process.

9. The method of claim 8 , wherein the first process is a thermoforming process; and

wherein the second process utilizes radiofrequency welding to perform the bonding steps of the second process.

10. The method of claim 1 , wherein the second tensile member layer is discontinuous such that the first tensile member layer section is separated from the second tensile member layer section by a gap.

11. The method of claim 1 , wherein the portion of the second chamber barrier layer is joined to a first side of the first tensile member layer and the first chamber barrier layer is bonded to a second side of the first tensile member layer.

12. A method of making a sole structure for an article of footwear, including forming a chamber for receiving a pressurized fluid, comprising:

assembling a stacked arrangement of chamber components including:

a first chamber barrier layer;

a second chamber barrier layer; and

a tensile member extending between the first chamber barrier layer and the second chamber barrier layer, the tensile member including a first tensile member layer, a second tensile member layer, and a plurality of tethers connecting the first tensile member layer to the second tensile member layer, wherein the second tensile member layer is discontinuous such that a first section of the second tensile member layer is separated from a second section of the second tensile member layer by a gap;

bonding the first chamber barrier layer to the second chamber barrier layer to form peripheral portions of the chamber and to define an interior void between the first chamber barrier layer and the second chamber barrier layer; and

extending a portion of the second chamber barrier layer toward the first tensile member layer in the gap between the first section of the second tensile member layer and the second section of the second tensile member layer, pressing the portion of the second chamber barrier layer against the first tensile member layer; and

joining the portion of the second chamber barrier layer to the first tensile member layer between the first section of the second tensile member layer and the second section of the second tensile member layer;

bonding the first tensile member layer to the first chamber barrier layer;

bonding the second tensile member layer to the second chamber barrier layer; and

inflating the chamber with a pressurized fluid.

13. The method of claim 12 , wherein the steps of bonding the first chamber barrier layer to the second chamber barrier layer to form peripheral portions of the chamber and joining a portion of the second chamber barrier layer to the first tensile member layer are performed simultaneously in a first die set as part of a first process.

14. The method of claim 13 , wherein the first die set includes a first die and a second die;

wherein the second die includes a projection; and

wherein joining a portion of the second chamber barrier layer to the first tensile member layer involves extending a portion of the second chamber barrier layer toward the first tensile member layer using the projection by advancing the first die and the second die toward one another to extend the projection into the gap between the first section of the second tensile member layer and the second section of the second tensile member layer and press the portion of the second chamber barrier layer toward and against the first tensile member layer.

15. The method of claim 14 , wherein the projection is an elongate projection; and

wherein the step of joining the portion of the second chamber barrier layer to the first tensile member layer by extending the portion of the second chamber barrier layer toward the first tensile member layer using the elongate projection forms an elongate flex groove in the chamber.

16. The method of claim 13 , wherein the steps of bonding the first tensile member layer to the first chamber barrier layer and bonding the second tensile member layer to the second chamber barrier layer are performed simultaneously in a second die set as part of a second process.

17. The method of claim 16 , wherein the first process is a thermoforming process; and

wherein the second process utilizes radiofrequency welding to perform the bonding steps of the second process.

18. The method of claim 12 , wherein the portion of the second chamber barrier layer is joined to a first side of the first tensile member layer and the first chamber barrier layer is bonded to a second side of the first tensile member layer.

19. A method of making a sole structure for an article of footwear, including forming a chamber for receiving a pressurized fluid, comprising:

assembling a stacked arrangement of chamber components including:

a first chamber barrier layer;

a second chamber barrier layer; and

a tensile member extending between the first chamber barrier layer and the second chamber barrier layer, the tensile member including a first tensile member layer, a second tensile member layer, and a plurality of tethers connecting the first tensile member layer to the second tensile member layer, wherein the second tensile member layer is discontinuous such that a first section of the second tensile member layer is separated from a second section of the second tensile member layer by a gap;

bonding the first chamber barrier layer to the second chamber barrier layer to form peripheral portions of the chamber and to define an interior void between the first chamber barrier layer and the second chamber barrier layer; and

extending a portion of the second chamber barrier layer toward the first tensile member layer in the gap between the first section of the second tensile member layer and the second section of the second tensile member layer, pressing the portion of the second chamber barrier layer against the first tensile member layer; and

joining the portion of the second chamber barrier layer to the first tensile member layer; and

inflating the chamber with a pressurized fluid.

20. The method of claim 19 , wherein the projection is an elongate projection; and

wherein the step of joining the portion of the second chamber barrier layer to the first tensile member layer by extending the portion of the second chamber barrier layer toward the first tensile member layer using the elongate projection forms an elongate flex groove in the chamber.

21. The method of claim 20 , wherein the first process is a thermoforming process.

22. The method of claim 21 , further including a second process involving bonding the first chamber barrier layer to the first tensile member layer and bonding the second chamber barrier layer to the second tensile member layer;

wherein the bonding steps of the second process are performed by radiofrequency welding.

23. The method of claim 19 , wherein the portion of the second chamber barrier layer is joined to a first side of the first tensile member layer and the first chamber barrier layer is bonded to a second side of the first tensile member layer.