阅读说明：本技术 具有拉伸部件的缓冲物品和制造缓冲物品的方法 (Cushioning article with tensile member and method of making a cushioning article ) 是由 佩奇.J.贝利 杰里米.L.康奈尔 杰森.R.米克 于 2018-05-17 设计创作，主要内容包括：缓冲物品包括彼此结合并闭合内部空腔的第一和第二聚合物片。聚合物片将气体保留在内部空腔中。设置在内部空腔中的拉伸部件包括第一拉伸层、第二拉伸层以及跨越内部空腔并将第一拉伸层连接至第二拉伸层的多个系绳。向内突出的结合部将第一聚合物片连接到第一拉伸层,从第一聚合物片向第二聚合物片向内突出,并部分地横穿多个系绳。第一聚合物片被气体从邻近向内突出的结合部的第一拉伸层移位。还公开了一种制造缓冲物品的方法。(The cushioning article includes first and second polymeric sheets bonded to one another and closing the interior cavity. The polymer sheet retains the gas in the internal cavity. The tensile member disposed in the internal cavity includes a first tensile layer, a second tensile layer, and a plurality of tethers spanning the internal cavity and connecting the first tensile layer to the second tensile layer. An inwardly projecting bond joins the first polymeric sheet to the first tensile layer, projects inwardly from the first polymeric sheet toward the second polymeric sheet, and partially traverses the plurality of tethers. The first polymer sheet is displaced by the gas from the first tensile layer adjacent the inwardly projecting bonds. A method of making a cushioning article is also disclosed.)

1. A mold for cushioning an article, the mold comprising:

a mold insert having a plurality of protrusions arranged in a first pattern having a closed shape that results in a pattern of bonds that form inwardly projecting bonds of the cushioning article.

2. The mold of claim 1, further comprising:

a first mold portion and a second mold portion, at least one of the first mold portion and the second mold portion being translatable toward the other of the first mold portion and the second mold portion to close a mold cavity between the first mold portion and the second mold portion; and

wherein the mold insert is securable to the first mold portion in the mold cavity.

3. The mold of claim 2, wherein the cushioning article comprises a polymeric sheet, a tensile member, and a weld-resistant material disposed on the tensile member; wherein the polymer sheet is disposed adjacent to the mold insert in the mold cavity and between the mold insert and the tensile member;

wherein the polymer sheet is insert molded against the mold to at least partially form the cushioning article, wherein the polymer sheet is bonded to the tensile member at the inwardly projecting bonds and is not bonded to the tensile member at the weld-resistant material.

4. The mold of claim 3, wherein the mold is configured to maintain a pressure or vacuum in the mold cavity to conform the polymer sheet to the mold insert.

5. The mold of any of claims 2-4, wherein the first mold portion has a recess, and the mold insert fits within the recess such that a surface of the mold insert comprising the plurality of protrusions is flush with a surface of the first mold portion adjacent to the recess.

6. The mold of claim 5, wherein the first mold portion has a recess into which the mold insert fits;

wherein the first mold portion has an opening in the recess and the mold insert has an opening that aligns with the opening in the first mold portion when the mold insert is in the recess; and the mold further comprises:

a fastener received in an opening of the mold insert and extending into an opening of the first mold portion to secure the mold insert to the first mold portion.

7. The mold of claim 5, wherein the mold insert is a first mold insert, and the mold further comprises:

a second mold insert securable to the second mold portion in the mold cavity; wherein the second mold insert has a plurality of protrusions arranged in another pattern having a closed shape that results in another pattern of bonds that forms inwardly projecting bonds of the cushioning article that is opposite to the pattern of bonds that results from the first pattern of closed shapes of the first mold insert.

8. The mold of claim 5, wherein the mold insert is a first mold insert, the cushioning article is a first cushioning article, and the mold further comprises:

a different mold insert having a plurality of protrusions shaped, sized, or positioned differently than the plurality of protrusions of the first mold insert;

wherein the different mold insert is securable to the first mold portion in the mold cavity in place of the first mold insert; and

wherein the plurality of protrusions of the different mold inserts result in a bond pattern of the inwardly projecting bonds of the second cushioning article that is different from the bond pattern of the inwardly projecting bonds of the first cushioning article.

9. The mold defined in any one of claims 1-4, wherein the closed shape is a polygon.

10. The mold defined in any one of claims 1-4, wherein a plurality of adjacent projections of the plurality of projections are arranged longitudinally along a common axis such that the pattern of joints establishes a bending axis of the cushioning article.

Technical Field

The present teachings generally include cushioning articles having tensile members, and methods of making cushioning articles having inwardly projecting bonds.

Background

An article of cushioning (e.g., a sole component of an article of footwear) is generally configured to provide cushioning, motion control, and/or resiliency. Some cushioning articles utilize a sealed internal cavity filled with a gas to resiliently resist compressive loads. The tensile member may be disposed in the interior cavity and may limit outward expansion of the cushioning article.

Drawings

FIG. 1 is a schematic illustration of a plan view of a cushioning article according to the present teachings.

Fig. 2 is a schematic illustration of a bottom view of the cushioning article of fig. 1.

Figure 3 is a schematic illustration of a cross-sectional view of the cushioning article of figure 1 taken along line 3-3 of figure 1.

Figure 4 is a schematic illustration of a close-up cross-sectional view of a portion of the cushioning article of figure 3.

Figure 5 is a schematic illustration of a close-up cross-sectional view of the cushioning article of figure 4 in a first stage of compression under load.

Figure 6 is a schematic illustration of a close-up cross-sectional view of the cushioning article of figure 4 in a second stage of compression under load.

Figure 7 is a schematic illustration of a close-up cross-sectional view of the cushioning article of figure 4 in a third stage of compression under load.

Figure 8 is a schematic illustration of a cross-sectional view of the cushioning article of figure 1 taken along line 8-8 of figure 1.

Figure 9 is a schematic illustration of a medial side view of an article of footwear having a sole structure that includes the cushioning article of figure 1 shown in phantom lines.

FIG. 10 is a schematic illustration of a plan view of a cushioning article according to an alternative aspect of the present teachings.

Figure 11 is a schematic illustration of a bottom view of the cushioning article of figure 10.

Figure 12 is a schematic illustration of a partial cross-sectional view of the cushioning article of figure 10, taken along line 12-12 of figure 10.

Fig. 13 is a schematic illustration of an inside view of the cushioning article of fig. 1.

Fig. 14 is a schematic illustration of an inside view of the cushioning article of fig. 10.

Figure 15 is a schematic illustration of a cross-sectional exploded view of the components of the cushioning article and a mold for making the cushioning article of figure 1.

Fig. 16 is a schematic view of a component of the cushioning article of fig. 1 in the mold of fig. 16, with the mold in a closed position.

FIG. 17 is a schematic perspective view of a mold portion for making a cushioning component.

Fig. 18 is a schematic perspective view of the mold section of fig. 17 with a first mold insert secured thereto.

Fig. 19 is a schematic perspective view of a second mold insert for use with the mold section of fig. 17.

Fig. 20 is a flow chart of a method of manufacturing a buffered article.

FIG. 21 is a schematic illustration of a plan view of a cushioning article according to an alternative aspect of the present teachings.

Figure 22 is a schematic illustration of a bottom view of the cushioning article of figure 21.

Figure 23 is a schematic illustration of a cross-sectional view of the cushioning article of figure 21 taken along line 23-23 of figure 21.

Figure 24 is a schematic illustration of an inside view of the cushioning article of figure 21.

Detailed Description

The cushioning article includes a bladder that surrounds the internal cavity and retains gas in the internal cavity. The tensile member is disposed in the interior cavity and includes a tensile layer and a plurality of tethers connecting the tensile layer. The tensile layer is connected to an inner surface of the bladder such that the tether spans the interior cavity. The bladder has a plurality of bonds arranged in a closed shape around a domed portion of the bladder. A plurality of bonds bond the inner surface of the bladder to the tensile member. The dome portion of the bladder is not bonded to the tensile member and is therefore displaced from the tensile member by the gas.

In one or more embodiments, the bladder includes a first polymeric sheet and a second polymeric sheet bonded to each other at an outer peripheral flange and enclosing an internal cavity. The stretch layer includes a first stretch layer attached to the first polymer sheet and a second stretch layer attached to the second polymer sheet. At least one of the first polymeric sheet and the second polymeric sheet includes a domed portion.

The plurality of bonds may protrude inward into the interior cavity and partially traverse the plurality of tethers such that the bladder narrows at the plurality of bonds. The plurality of bonds define a slot at the outer surface of the airbag such that the cushioning article hinges along the slot when the inflation pressure of the gas in the interior cavity is sufficient to pull on the plurality of tethers.

The plurality of bonds may be a first plurality of bonds in a first region of the bladder, and the bladder may have a second plurality of bonds arranged in a closed shape in a second region of the bladder. The portion of the bladder surrounded by the closed shape in the second region may be bonded to the tensile member.

The cushioning article may be used in a variety of applications, such as, but not limited to, a sole component of an article of footwear. In such embodiments, the first region may be distal (i.e., ground-engaging side) of the bladder and the second region may be proximal (i.e., foot-facing side) of the bladder. In other embodiments, the first zone and the second zone are both distal to the bladder or both proximal to the bladder. In other embodiments, the plurality of bonds is a first plurality of bonds in a first region of the bladder, and the bladder has a second plurality of bonds arranged in a closed shape in a second region of the bladder. The portion of the bladder surrounded by the closed shape in the second region is not bonded to the tensile member and forms a dome portion that is displaced from the tensile member by the gas. For example, both the proximal and distal sides of the cushioning article may have domed portions.

The cushioning article includes a first polymeric sheet and a second polymeric sheet bonded to each other and enclosing an interior cavity. The first polymeric sheet and the second polymeric sheet retain a gas in the internal cavity. The tension member is disposed in the interior cavity. The tensile member includes a first tensile layer, a second tensile layer, and a plurality of tethers spanning from the first tensile layer across the interior cavity to the second tensile layer and connecting the first tensile layer to the second tensile layer. An inwardly projecting bond joins the first polymeric sheet to the first tensile layer, projects inwardly from the first polymeric sheet toward the second polymeric sheet, and partially traverses the plurality of tethers. The first polymer sheet is displaced by the gas from the first tensile layer adjacent the inwardly projecting bonds. The inwardly projecting bonds are spaced from the second polymeric sheet such that the interior cavity narrows at the inwardly projecting bonds and gas in the interior cavity is in fluid communication across the inwardly projecting bonds. Thus, the consistency and responsiveness of the tether to return the interior cavity to its original shape under dynamic compressive loading is combined with the stage cushioning and the elasticity of the articulated cushioning component, where articulation occurs when the tether is aligned across by the inwardly projecting joints.

In one or more embodiments, the cushioning article is a sole component for an article of footwear, and the inwardly projecting bonds form bending axes of the sole component. Accordingly, the cushioning component may be articulated at an inwardly projecting junction, and the bending axis may be aligned with a desired bending area of the foot (e.g., such as the metatarsal and phalangeal joints).

In one or more embodiments, a portion of the interior cavity on a first side of the inwardly projecting junction is in fluid communication with a portion of the interior cavity on a second side of the inwardly projecting junction, wherein the second side is opposite the first side. Thus, for example, when a cushioning article is included in a sole structure, during a heel or heel strike of the article of footwear, gas in the interior cavity may be displaced over the inwardly projecting bonds.

In one or more embodiments, the inflation pressure of the gas in the interior cavity is sufficient to pull the plurality of tethers taut at the inwardly projecting bonds, and the inwardly projecting bonds define a slot at an outer surface of the first polymeric sheet such that the cushioning article is divided into a first article portion on one side of the slot and a second article portion on the other side of the slot, and the first article portion is hinged relative to the second article portion along the slot.

In one or more embodiments, the first tensile layer is spaced a first distance from the second tensile layer at a location adjacent to the inwardly projecting bonds, and the inwardly projecting bonds are spaced a second distance from the second tensile layer. The second distance is 50% to 80% of the first distance. Narrowing the interior cavity by this ratio can provide an optimal hinge area, which helps cushion the elasticity of the article.

Because the inwardly projecting bonds at least partially traverse the plurality of tethers, in one or more embodiments, the plurality of tethers includes tethers aligned with the inwardly projecting bonds and tethers displaced from the inwardly projecting bonds. The tethers aligned with the inwardly projecting bonds are shorter and/or thicker than tethers displaced from the inwardly projecting bonds. The tethers initially all have the same length and width prior to the manufacture of the cushioning article and the formation of the inwardly projecting bonds. Deformation of the tether during manufacture at the inwardly projecting bond helps to cushion articulation and elasticity of the article.

In one or more embodiments, the inwardly projecting bonds define a closed shape that surrounds a portion of the first polymeric sheet displaced from the first tensile layer such that the portion of the first polymeric sheet has a domed surface extending away from the first tensile layer.

In some embodiments, the second polymeric sheet is recessed inwardly toward the inwardly projecting bonds of the first polymeric sheet when the interior cavity is inflated. In other embodiments, the second polymeric sheet also has inwardly projecting bonds.

In some embodiments, the inwardly projecting bonds may be first inwardly projecting bonds, the portion of the first polymeric sheet surrounded by the closed shape being a first portion of the first polymeric sheet in a first region of the first polymeric sheet, an inner surface of a second portion of the first polymeric sheet in a second region of the first polymeric sheet spaced apart from the first region being bonded to an outer surface of the first tensile layer; the cushioning article may also further include a second inwardly projecting bond joining the first polymeric sheet to the first tensile layer and projecting from the first polymeric sheet toward the second polymeric sheet in the second region and partially across the tensile member. The second inwardly projecting bond can be spaced apart from the second polymeric sheet such that the interior cavity narrows at the second inwardly projecting bond and the gas in the interior cavity is in fluid communication across the second inwardly projecting bond.

A method of manufacturing a cushioning article, the method comprising disposing a weld-resistant material on at least one of an inner surface of a first polymer sheet and an outer surface of a first tensile layer of a tensile member. The tensile member includes a first tensile layer, a second tensile layer, and a plurality of tethers connecting the first tensile layer to the second tensile layer. The method further includes conforming the first polymeric sheet and the second polymeric sheet to the features of the mold. The first polymeric sheet is conformed in a manner that the first polymeric sheet is pressed towards the second polymeric sheet at the protrusions of the mold arranged in a closed shape, and the protrusions are directly external to the plurality of tethers. The method further includes thermally bonding a first stretch layer to the first polymeric sheet and thermally bonding a second stretch layer to a second polymeric sheet opposite the first stretch layer. The stretch layer is thermally bonded to the polymer sheet in a manner that creates a plurality of bonds at the protrusions that join the first polymer sheet to the first stretch layer and partially traverse the plurality of tethers. The plurality of bonds project toward the second polymeric sheet and are spaced apart from the second tensile layer and the second polymeric sheet. Due to the weld-resistant material, the first polymer sheet is separated from the first tensile layer adjacent to the inwardly protruding bonds such that portions of the first polymer sheet surrounded by the plurality of bonds forming the closed shape may be displaced from the first tensile layer. For example, when inflated, a portion of the first polymer surrounded by the bonds that form the closed shape forms a domed surface.

In one or more embodiments, the method further includes bonding the first polymeric sheet to the second polymeric sheet at the peripheral bond such that the first polymeric sheet and the second polymeric sheet at least partially surround the interior cavity containing the tensile member. A plurality of tethers span the interior cavity from the first tensile layer to the second tensile layer. The plurality of junctions project inwardly such that the interior cavity narrows at the inwardly projecting junctions.

In one or more embodiments, the method further comprises inflating and sealing the internal cavity. The cushioning article is articulated by inflating the interior cavity in a manner that raises the portion of the first polymeric sheet surrounded by the closed shape away from the tensile member to form a dome portion, and tensioning the plurality of tethers at the plurality of bonds to form a plurality of grooves on the exterior surface of the first polymeric sheet at the plurality of bonds. For example, the cushioning article may be a sole component of an article of footwear and the channels may form bending axes of the sole component.

In one or more embodiments, the components of the mold include a first mold portion and a second mold portion. At least one of the first mold portion and the second mold portion is translatable relative to the other of the first mold portion and the second mold portion between an open position and a closed position. Bonding the first and second polymeric sheets at the peripheral bond includes compressing the first and second polymeric sheets between the first and second mold portions in the closed position.

In one or more embodiments, the mold part having the plurality of protrusions is one of the first mold portion and the second mold portion. Optionally, in other embodiments, the mold component having the plurality of protrusions is a mold insert. This makes it possible to easily change the pattern of the bonded portions of the cushioning article manufactured according to the method by changing the mold insert to a different mold insert having a different protrusion pattern. For example, the method may further comprise securing the mold insert to a mold portion of the mold prior to conforming the first and second polymeric sheets to the mold part, and wherein the mold part having the plurality of protrusions is the mold insert. In some embodiments, the mold insert is a first mold insert, the mold portion is a first mold portion, the plurality of bonds is a first plurality of bonds, and the method further comprises securing a second mold insert to a second mold portion of the mold, wherein the second mold insert has a second plurality of protrusions directly opposite the first plurality of protrusions and external to the plurality of tethers. In such embodiments, conforming the first and second polymer sheets and thermally bonding the first stretch layer to the first polymer sheet and the second stretch layer to the second polymer sheet creates a second plurality of bonds on the second plurality of protrusions, the second plurality of bonds traversing the stretch member and directly opposing the first plurality of bonds. The second plurality of bonds project toward the first plurality of bonds and the first polymeric sheet and are spaced apart from the first plurality of bonds, the first tensile layer, and the first polymeric sheet.

In one or more embodiments, the cushioning article is a first cushioning article, and the method further comprises manufacturing a second cushioning article by removing the mold insert from the mold portion and securing a second mold insert having a second plurality of protrusions to the mold portion. The second plurality of protrusions may be shaped, sized, or positioned differently than the first plurality of protrusions. The method further includes conforming the subsequent first polymer sheet and the subsequent second polymer sheet to the second mold insert and another component of the mold, respectively, with the subsequent tensile component between the subsequent first polymer sheet and the subsequent second polymer sheet. The subsequent first and second polymer sheets are adapted in a manner that presses the subsequent first polymer sheet toward the subsequent second polymer sheet at a second plurality of protrusions, wherein the second plurality of protrusions are directly outward of the subsequent tensile member, thereby creating a second plurality of bonds at the second plurality of protrusions that partially traverse the subsequent tensile member. Due to the second mold insert, the mold provides a different bond pattern for the second cushioning article than the first cushioning article.

In one or more embodiments, the first polymeric sheet and the second polymeric sheet are conformed to the components of the mold by vacuum and/or compression. Additionally, in one or more embodiments, the thermal bonding of the first tensile layer to the first polymer sheet and the thermal bonding of the second tensile layer to the second polymer sheet includes heating the first polymer sheet and the second polymer sheet, heating at least one of the mold parts, or radio frequency welding.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the methods for carrying out the present teachings when taken in connection with the accompanying drawings.

Referring to the drawings, wherein like reference numbers refer to like parts throughout the several views. FIG. 1 illustrates a cushioning article 10 that may be manufactured according to the method 210 of FIG. 20, the cushioning article 10 having features that provide a desired combination of cushioning and resiliency. The cushioning article 10 is shown and described as being used in a sole structure 12 in an article of footwear 14 shown in figure 9. Cushioning article 10 is a full length cushioning article for sole structure 12 in that it has forefoot region 17A, midfoot region 17B, and heel region 17C. Forefoot region 17A may be generally associated with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 17B may be generally associated with an arch of the foot. Heel region 17C may generally be associated with a heel that includes a heel bone. Cushioning article 10 has an exterior side 19 and an interior side 21. In particular, lateral side 19 and medial side 21 may be opposite sides of cushioning article 10 and may extend along forefoot region 17A, midfoot region 17B, and heel region 17C. In the embodiment of the cushioning article 10 shown in fig. 1 and 2, the first polymeric sheet 16 is formed proximal to the bladder 23 (i.e., the side closest to the foot when assembled in the article of footwear). The second polymeric sheet 18 is formed on the distal side of the bladder 23 (i.e., the side of the bladder facing the ground).

In fig. 9, the cushioning article 10 is shown at least partially encased in a foam sole layer 11, and the cushioning article 10 and sole layer 11 together serve as a midsole for the sole structure 12. Sole structure 12 may also include an outsole, an insole, and other sole components. Accordingly, the cushioning article 10 is a sole component. However, the cushioning article 10 or other cushioning article manufactured according to method 210 may be used in other articles, such as athletic apparel, athletic equipment, furniture, and floor mats. For example, the cushioning article may be used in a backpack strap, a helmet pad, a shin guard, a baseball glove, a seat pad, or a floor pad.

Referring to fig. 1-3, the cushioning article 10 includes a bladder 23 having a first polymeric sheet 16 and a second polymeric sheet 18 bonded to each other at a peripheral bond 20 to enclose an interior cavity 22. When the first and second polymeric sheets 16, 18 are bonded to each other at the peripheral bond 20 and any inflation ports 82 are sealed, the first and second polymeric sheets 16, 18 retain fluid in the internal cavity 22. As used herein, the "fluid" filling the internal cavity 22 may be a gas, such as air, nitrogen, another gas, or a combination thereof.

The first and second polymeric sheets 16, 18 may be a variety of polymeric materials capable of elastically retaining a fluid, such as nitrogen, air, or another gas. Examples of polymeric materials for the first and second polymeric sheets 16, 18 include thermoplastic urethanes, polyurethanes, polyester fibers, polyester urethanes, and polyether urethanes. Also, the first and second polymeric sheets 16, 18 may each be formed from layers of different materials including polymeric materials. In one embodiment, each of the first and second polymeric sheets 16, 18 is formed from a film having one or more layers of thermoplastic polyurethane and one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein, such as an elastomeric microlayer membrane comprising alternating layers of a gas barrier material and an elastomeric material, as disclosed in U.S. patent nos. 6,082,025 and 6,127,026 to Bonk et al, which are hereby incorporated by reference in their entirety. Alternatively, the layers may include ethylene vinyl alcohol copolymer, thermoplastic polyurethane, and regrind material of ethylene vinyl alcohol copolymer and thermoplastic polyurethane. Other suitable materials for the first and second polymer sheets 16, 18 are disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy, and are incorporated herein by reference in their entirety. Further suitable materials for the first and second polymeric sheets 16, 18 include thermoplastic films comprising crystalline materials, as disclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy, and polyurethanes comprising polyester polyols, as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868 and 6,321,465 to Bonk et al, and incorporated herein by reference in their entirety. Engineering properties such as tensile strength, elongation properties, fatigue properties, dynamic modulus, and loss tangent may be considered in selecting a material for cushioning article 10. For example, the thicknesses of the first and second polymer sheets 16, 18 used to form the cushioning article 10 may be selected to provide these characteristics.

As best shown in fig. 3, the cushioning article 10 includes a tensile member 30 disposed within the interior cavity 22. The tensile member 30 includes a first tensile layer 32, a second tensile layer 34, and a plurality of tethers 36 spanning from the first tensile layer 32 to the second tensile layer 34 across the internal cavity 22. A tether 36 connects the first tensile layer 32 to the second tensile layer 34. In fig. 3, only some of the tethers 36 are denoted by reference numerals. The tether 36 may also be referred to as a fabric tensile member or wire and may be in the form of a braided wire connecting the first tensile layer 32 and the second tensile layer 34. Tensile member 30 may be formed as a unitary one-piece textile element having a spaced apart woven textile. It should be understood that first tensile layer 32 and second tensile layer 34 may be permeable to the gas in the internal cavity. As such, the internal cavity 22 extends through the first tensile layer 32 and the second tensile layer 34 between and around the tethers 36 from the inner surface of the first polymeric sheet 16 to the inner surface of the second polymeric sheet 18. The tensile layers 32, 34 are not subjected to the outward force of the gas in the internal cavity where the tensile layers are not bonded to the first and second polymeric sheets 16, 18. Thus, the tethers 36B extending between the portions of the tensile layers 32, 34 that are not bonded to the polymer sheets 16, 18 (e.g., the portions of the tensile layers 32, 34 that are inside the dome portions) may not be taut. However, the tethers 36A extending between portions of the tensile layers 32, 34 bonded to the polymer sheets 16, 18 (e.g., at the inwardly projecting bonds 50) are tensioned when subjected to sufficient inflation pressure of the interior cavity 22.

As best shown in fig. 15, a weld-resistant material 48 is applied to selected areas of the outer surfaces 45, 47 of the first and second tensile layers 32, 34, respectively. For example, the weld-resistant material may be inkjet printed throughout, in addition to the raised areas of the mold components used during thermoforming of the cushioning article 10 that result in the inwardly protruding bonds 50 of the first and second polymeric sheets 16, 18, as further explained herein. The inwardly projecting bonds 50 of the first polymeric sheet 16 are also referred to as a first plurality of bonds. Alternatively, if the solder resist material is not activated, the solder resist material may be applied even where the joint 50 is desired. If the weld-resistant material 48 is activated, the weld-resistant material 48 prevents the inner surfaces 42, 46 of the first and second polymer sheets 16, 18 from bonding to the outer surfaces 45, 47 of the tensile member 30 during the manufacturing method 210 described herein. First tensile layer 32 is bonded to inner surface 42 of first polymer sheet 16 at inwardly projecting bonds 50. As best shown in fig. 3, the second tensile layer 34 is bonded to the inner surface 46 of the second polymeric sheet 18 at inwardly projecting bonds 50. The inwardly projecting bonds 50 of the second polymeric sheet 18 are also referred to as a second plurality of bonds. The first plurality of bonds 50 are in a first region of the bladder 23 (e.g., proximal in each of the forefoot, midfoot, and heel regions), and the second plurality of bonds 50 are in a second region of the bladder 23 (e.g., distal in each of the forefoot, midfoot, and heel regions).

The tether 36 limits the distance between the first and second polymer sheets 16, 18 to the maximum spaced position shown in fig. 3 for a given inflation pressure of the gas in the interior cavity 22. The outward force of the pressurized gas in the interior cavity 22 on the inner surfaces 42, 46 of the first and second polymeric sheets 16, 18 places the tethers 36A at the inwardly projecting bonds 50 in tension, and the tethers 36 prevent the tensile layers 32, 34 and the polymeric sheets 16, 18 from moving further outward from one another. However, the tether 36 does not exhibit resistance to compression when under a compressive load. When pressure is applied to the cushioning article 10, for example due to dynamic impact forces of the wearer during running or other activities, the cushioning article 10 is compressed and the polymeric sheets 16, 18 move closer together as the tethers 36 collapse (e.g., relax), which is proportional to the pressure applied to the first and second polymeric sheets 16, 18 proximate a particular tether 36.

The tethers 36 of the tensile member 30 may all be an initial length, and may all be substantially the same length, prior to the tethers 36 being joined to the first and second polymeric sheets 16, 18 according to the method 210 disclosed herein, and the first and second tensile layers 32 and 34, respectively, joined by the tethers 36 may have generally flat outer surfaces 45, 47 directly above the tethers 36, as shown in fig. 15. In fig. 15, the tether 36 is shown in a relaxed state because fig. 15 shows the tension member 30 prior to being secured within the sealed pressurized interior cavity 22.

According to the method 210 provided herein, although the tethers 36 are initially of the same length and prior to the manufacture of the cushioning article 10, the outer surfaces 45, 47 of the first and second tensile layers 32, 34 and the outer surfaces 49, 54 of the first and second polymeric sheets 16, 18, respectively, are generally flat (i.e., not contoured) directly above the tethers 36, the method of manufacture 210 creates inwardly projecting bonds 50 that join the first polymeric sheet 16 to the first tensile layer 32, the first tensile layer 32 projecting from the first polymeric sheet 16 toward the second polymeric sheet 18 directly into the cavity 32 in the areas occupied by some of the tethers 36. In practice, as shown in fig. 3, there are a plurality of inwardly projecting engaging portions 50.

Each bond 50 in the first polymeric sheet 16 is formed by a respective protrusion 51 of a mold part 53A (best shown in fig. 15 and 18, with the plurality of protrusions 51 arranged in a closed shape) that is in contact with the first polymeric sheet 16 during the manufacturing method 210 disclosed herein. Each bond 50 in the second polymeric sheet 18 is formed by a respective protrusion 51 of a mold part 53B (a plurality of protrusions 51 are also shown arranged in a closed shape) in contact with the second polymeric sheet 18 during the manufacturing method 210 disclosed herein (see fig. 15). Fig. 18 shows a representative mold part 53A having a first pattern of protrusions 51 that results in a bond pattern 55A that forms the inwardly projecting bonds 50 of the cushioning article 10 shown in fig. 1. The mold part 53B is identical to the mold part 53A and produces the same bond pattern 55A on the second polymeric sheet 18. The mold part 53A is a first mold insert and may also be referred to as a shim. The mold part 53B is a second mold insert. When the bonds 50 project inwardly from the outer surfaces 49, 54 as shown, the bonds 50 are indicated by dashed lines in fig. 1 and 2.

Bonds 50 result in recessed channels 52 on outer surface 49 of first polymeric sheet 16 and outer surface 54 of second polymeric sheet 18. For clarity, only some of the bonds 50 and some of the troughs 52 are shown in FIGS. 1 and 2. As best shown in fig. 1 and 2, the inwardly projecting bonds 50 on the first polymeric sheet 16 define a closed shape that surrounds a portion of the first polymeric sheet 16. The inwardly projecting bonds 50 on the second polymeric sheet 18 define a closed shape that surrounds a portion of the second polymeric sheet 18. In the illustrated embodiment, the closed shape is a polygon. For example, one closed shape is a pentagon, and is represented in fig. 1 by the number of bonds 50A, 50B, 50C, 50D, and 50E to the bonds 50 that surround and define the closed shape. Corresponding slots 52 are numbered 52A, 52B, 52C, 52D, and 52E.

Due to the pressure of the gas in internal cavity 22, portion 16A of first polymer sheet 16 that is unbonded (i.e., not bonded) to first tensile layer 32 and is surrounded by bonds 50A, 50B, 50C, 50D, 50E that define the closed shape is displaced (i.e., lifted away from the first tensile layer 32) such that portion 16A of first polymer sheet 16 has a domed surface 49A that extends away from first tensile layer 32. The closed shape and dome surface 49A shown is only one of many closed shapes and many dome surfaces formed at the outer surface 49 of the first polymeric sheet 16. Other portions having domed surfaces 49B, 49C, 49D, 49E are shown in fig. 3 and may be referred to as dome portions. As is evident from the plan view of fig. 1, first polymer sheet 16 actually has the shape of a plurality of circular bubbles extending over each of forefoot region 17A, midfoot region 17B, and heel region 17C of cushioning article 10. As used herein, "dome-shaped" refers to circular, and need not be hemispherical.

Similarly, referring to fig. 2, one closed shape at the second polymeric sheet 18 is a pentagon, represented in fig. 2 by the bonds 50 numbered 50F, 50G, 50H, 50I, and 50J that surround and define the closed shape. Corresponding slots 52 are numbered 52F, 52G, 52H, 52I, and 52J. As best shown in fig. 3, due to the pressure of the gas in the internal cavity 22, the portion 18A of the second polymeric sheet 18 surrounded by the closed shape-defining bonds 50F, 50G, 50H, 50I, 50J is displaced from the second tensile layer 34 such that the portion 18A of the second polymeric sheet 18 has a domed surface 54A extending away from the second tensile layer 34. The closed shape and portion of the second polymeric sheet 18 having the domed surface 54A shown is but one of many closed shapes and many portions having domed surfaces formed at the outer surface 54 of the second polymeric sheet 18. Other portions having domed surfaces 4B, 54C, 54D, 54E are shown in fig. 3. As is evident from the bottom view of fig. 2, the second polymeric sheet 18 actually has a plurality of rounded bubble shapes extending over each of the forefoot region 17A, midfoot region 17B, and heel region 17C of the cushioning article 10.

As shown in fig. 3, each inwardly projecting bond 50 partially traverses the plurality of tethers 36. In other words, the bonds 50 are directly outside of the various tethers 36 and project inwardly on these tethers 36. The tethers 36 may be arranged in rows, each row extending laterally between the tensile layers 32, 34, or in any other manner in which the tethers 36 extend between the tensile layers 32, 34. Various tethers 36 are aligned with the joints 50. The inwardly projecting bonds 50 may traverse different rows of tethers 36 such that different tethers from different rows are aligned with the inwardly projecting bonds 50, or the inwardly projecting bonds 50 may be directly aligned with a single row. Some of the inwardly projecting bonds 50 may be between the rows of tethers.

Referring to fig. 4, the plurality of tethers 36 include tethers 36A aligned with the inwardly projecting bonds 50 and tethers 36B displaced from the inwardly projecting bonds 50. The tethers 36A aligned with the inwardly projecting bonds 50 are deformed by heating, by compressing the covering material of the first tensile layer 32 and the second tensile layer 34, and/or by coating the tethers 36A with the covering material of the first tensile layer 32 such that the tethers 36A are shorter and/or thicker at the inwardly projecting bonds 50 than elsewhere. Such a tether is indicated in fig. 4 with reference numeral 36A and may be referred to as a modified tether 36A. However, unless otherwise specified, reference herein to tether 36 includes tether 36A and tether 36B.

As shown in fig. 3, when the interior cavity 22 is inflated, the modified tether 36A creates a recessed groove 52 in the outer surface 49 of the first polymeric sheet 16. The inwardly projecting bonds 50 define a groove 52 on an outer surface 49 of the first polymeric sheet 16 and an outer surface 54 of the second polymeric sheet 18 when the inflation pressure of the gas in the interior cavity 22 against the inner surfaces of the polymeric sheets 16, 18 is sufficient to cause the polymeric sheets 16, 18 to tighten the tethers 36A. With respect to the leftmost channel 52 as shown in fig. 4, at each channel 52, the buffered article 10 may be divided into a first article portion 61 on one side of the channel 52 and a second article portion 62 on the other side of the channel 52. First article portion 61 is hinged relative to second article portion 62 along slot 52. In other words, outer surface 49 of first polymeric sheet 16 on a first side of inwardly projecting bonds 50 (the first side being represented in fig. 4 as portion 49D of outer surface 49) is non-planar with outer surface 49 of first polymeric sheet 16 on a second side of inwardly projecting bonds 50 (the second side being represented in fig. 4 as portion 49C of outer surface 49) that is opposite the first side. The outer surface 54 of the second polymeric sheet 18 on a first side of the inwardly projecting bonds 50 (the first side being represented in fig. 4 as portion 54D of the outer surface 54) is non-planar with the outer surface 54 of the second polymeric sheet 18 on a second side of the inwardly projecting bonds 50 (the second side being represented in fig. 4 as portion 54C of the outer surface 54) that is opposite the first side.

The channel 52 may serve as a bending axis for the cushioning article 10. For example, when the article of cushioning 10 is included in the sole structure 12 of the article of footwear 14 in fig. 9, the inwardly projecting bonds 50 and the formed channels 52 may form a bending axis of the sole structure 12. Joints 50 may be configured such that a number of joints 50 fall longitudinally near or along a common axis to form bending axes that may be aligned with joints of the foot (e.g., metatarsal and phalangeal joints), thereby increasing the flexibility of sole structure 12. Various bending axes F1, F2 are shown in fig. 1. The curved axes increase the elasticity of the cushioning article 10. In some embodiments, some bonds 50 may be aligned in a straight line from the inside to the outside of the cushioning article, thereby creating a bending axis that extends laterally across the entire cushioning article.

Referring to fig. 3 and 4, each inwardly projecting bond 50 at the first polymeric sheet 16 is spaced apart from the second polymeric sheet 18 and each inwardly projecting bond 50 at the second polymeric sheet 18 is spaced apart from the first polymeric sheet 16, thereby narrowing, but not closing, the internal cavity 22 at the inwardly projecting bonds 50. Thus, gas in the interior cavity 22 may be in fluid communication across any inwardly projecting bonds 50 (i.e., between a bond 50 on the first polymeric sheet 16 and a corresponding bond 50 on the second polymeric sheet 18). As shown in fig. 4, first stretch layer 32 is spaced apart from second stretch layer 34 by a first distance D1 at a location adjacent to inwardly projecting bonds 50, and inwardly projecting bonds 50 at first polymer sheet 16 and first stretch layer 32 are spaced apart from inwardly projecting bonds 50 at second polymer sheet 18 and second stretch layer 34 by a second distance D2. The first distance D1 may be the distance between the tensile layers 32, 34 at tether 36B, which tether 36B is not a modified tether 36A. The second distance D2 may be the minimum distance between the corresponding inwardly projecting bonds 50 at the engineered tether 36A (i.e., the distance at the narrowest portion of the interior cavity 22 between the corresponding bonds 50 on the first and second polymer sheets 16, 18). In one embodiment, the manufacturing method 210 may be controlled such that the second distance D2 is between 50% and 80% of the first distance D1. A bond 50 within this depth range may produce the most desirable amount of articulation. For example, factors that may affect the extent to which bonds 50 and their protrusion toward the opposing first or second polymeric sheets 16, 18 may be controlled to provide a desired ratio of second distance D2 to first distance D1. These factors may include the depth of the protrusions 51 forming the bonds 50, the temperature of the mold insert 53 or other mold component, the temperature of the components of the cushioning article 10, the vacuum and/or inflation pressure in the mold cavity during manufacture, the power of the welding frequency if radio frequency welding is used, and other factors.

As shown in fig. 4, therefore, the portion 22A of the internal cavity 22 at a first side of the respective inwardly projecting junction 50 is in fluid communication with the portion 22B of the internal cavity 22 at a second side of the respective inwardly projecting junction 50, wherein the second side is opposite the first side. The illustrated modified tether 36A, which extends below the respective junction 50 between the two portions 22A, 22B, is narrow in diameter and allows gas to flow around and between the tether 36A from the portion 22A to the portion 22B, and vice versa. This allows gas to be displaced from portion 22A to portion 22B and from portion 22B to portion 22A when a compressive force is applied to cushioning article 10, such as when article of footwear 14 collides with ground G in fig. 9. For example, as the heel rolls forward to the toes during foot strike, gas may be displaced from the rear portion in the cushioning article 10 to a more forward portion in the cushioning article 10. Thus, the supportive cushioning provided by the interior cavity 22 can be provided in the areas most needed during use of the cushioning article 10.

Figures 5-7 illustrate stages of compression of the cushioning article 10 under an applied compressive force F normal to the domed surfaces of the first and second polymers 16, 18, such as being subjected to dynamic compressive loading during foot travel when the cushioning article is a sole component of the sole structure 12 of figure 9. As illustrated by the changes to the cushioning article 10 in fig. 5-6, during initial loading, the portions having the domed surfaces 49B, 49C, 49D and 54B, 54C, 54D begin to flatten and as the volume of the internal cavity 22 decreases, the gas in the internal cavity 22 becomes more pressurized, and under continued loading, the domed surfaces may completely flatten and the first and second polymer sheets 16, 18 contact the first and second tension members 32, 34 between the bonds 50. With further loading, the shortened tether 36A will collapse. When the dynamic compressive force F is removed, the tether 36A will return to a taut state and the portions of the first and second polymeric sheets 16, 18 between the closed shapes of the bonds 50 will return to their dome shapes.

Fig. 10-11 illustrate another embodiment of a cushioning article 110. Cushioning article 110 has many of the same features as cushioning article 10, and these features are shown with like reference numbers and as described with respect to cushioning article 10. The sheets 16, 18 form a bladder 123 with a first polymeric sheet formed proximal to the bladder 123 and a second polymeric sheet 18 forming the distal side of the bladder 123. In cushioning article 110, weld-resistant material is applied only on first and second polymer sheets 16, 18 prior to representative separation line 113 and/or on stretch layers 32, 34 that do not require bonding. Thus, as shown in fig. 12 and 14, only in a first region of the first polymeric sheet 16 (which is the region before the parting line 113), the first and second polymeric sheets 16, 18 have portions with inner surfaces 42, 46 surrounded by and displaced from the outer surfaces 45, 47 of the adjacent first and second tensile layers 32, 34 by a first plurality of bonds 50 arranged in a closed shape, forming dome surfaces 49F, 49G, 54F, 54G, respectively, and so forth.

In a second region of the first polymer sheet 16, which is a region behind the separation line 113 in fig. 10, 11, 12, and 14, the inner surface 42 of the first polymer sheet 16 is bonded to the outer surface 45 of the first tensile layer 32 at the surface bond 40, and the inner surface 46 of the second polymer sheet 18 is bonded to the outer surface 47 of the second tensile layer 34 at the surface bond 44. A mold is used such that the protrusions 51 contact only the first polymeric sheet 16 in the second region. A second plurality of inwardly projecting bonds 50 arranged in a closed shape are formed at the first polymeric sheet 16 in the second region but are not formed in the second polymeric sheet 18 in the second region. When the interior cavity 22 is inflated, the engineered tethers 36A at the inwardly projecting bonds 50 create concave troughs 52 in the outer surface 49 of the first polymeric sheet 16 and the outer surface 54 of the second polymeric sheet 18. When the inflation pressure of the gas in the interior cavity 22 is sufficient to pull the plurality of tethers 36A taut at the inwardly projecting bonds 50, the inwardly projecting bonds 50 define grooves 52 at the outer surface 49 of the first polymeric sheet 16 and at the outer surface 54 of the second polymeric sheet 18. Although first and second pluralities of bonds 50 are shown on first polymeric sheet 16 on a proximal side, cushioning article 110 may be used in an article of footwear where the first polymeric sheet is on a distal side.

The tension of the reformed tether 36A also causes a recess 56 in the outer surface 54 of the second polymeric sheet 18 opposite each inwardly projecting bond 50 on the first polymeric sheet 16. As the interior cavity 22 inflates, the second polymeric sheet 18 is recessed inwardly at each recess 56 toward the respective trough 52 and inwardly projecting bond 50. The channels 52 are generally deeper than the recesses 56, which results in the possibility that the cushioning article 10 may articulate in the second region even in the absence of compressive loading, as the cushioning article 10 bends slightly upward at each channel 52. In other words, the physical deformation of first polymer sheet 16 and first tensile layer 32, in combination with the tension of modified tether 36A, will result in groove 52 being deeper than recess 56 created by the tension of only shortened modified tether 36A. Thus, the second region of cushioning article 10 may have an articulated shape, such as shown in FIG. 14, which bends slightly upward from horizontal line H when not subjected to a load at channel 52. In addition, channel 52 and recess 56 together facilitate articulation of cushioning article 10 at channel 52, as the overall thickness of cushioning article 10 is reduced at channel 52, reducing the bending stiffness of the cushioning article at channel 52. Conversely, when not under load, cushioning articles 10 having channels 52 on both sides maintain a higher level and less articulation than cushioning articles 110 due to inwardly projecting bonds 50 at both first and second polymeric sheets 16, 18, but, similar to cushioning articles 110, promote articulation at channels 52.

Due to the surface bonds 40, any spheres or arches of the polymer sheet 16 in the closed shape surrounded by the inwardly projecting bonds 50 are reduced and do not include any displacement of the first polymer sheet 16 from the first tensile layer 32. In fig. 14, the first and second stretch layers 32, 34 are shown in phantom lines, with the phantom lines in the second region following the contour of the first and second polymer sheets 16, 18 and are intended to indicate that the inner surfaces 42, 46 are bonded to the outer surfaces 45, 47 throughout the second region. As shown in fig. 12, at the inwardly protruding first bonds 50K, the interior cavity 22 narrows but does not close, so that gas can pass over the bonds 50K and the corresponding bonds 50 on the second polymer 18 to communicate. At the inwardly projecting second bonds 50L in the second region, the interior cavity 22 narrows but does not close so that gas can pass over the bonds 50L and the corresponding bonds 50 of the second polymer sheet 18 to communicate.

Fig. 15 illustrates in exploded view the components of cushioning article 10, with the components located between the components of mold 66. More specifically, the components of the mold 66 (also referred to herein as mold components) include a first mold portion 66A, a second mold portion 66B, a first mold insert 53A, and a second mold insert 53B. The components of the mold necessary to make cushioning article 110 are the same, except that second mold insert 53B will not have protrusions 51, because no inwardly protruding bonds are created on second polymer sheet 18 in cushioning article 110. Alternatively, the second mold portion 66B may be modified such that a mold insert is not required and the mold surface that contacts the outer surface 54 of the second polymeric sheet 18 is free of protrusions 51. Fig. 16 shows the component of the cushioning article 10 positioned in a mold cavity 68 of a mold 66 defined by the mold components, with the mold 66 in a closed position. Although the polymer sheets 16, 18 are in contact with the tensile members 32, 34 in the mold 66, the weld-resistant material prevents the polymer sheets 16, 18 from bonding to the tensile members 32, 34 provided with the weld-resistant material.

Fig. 21-24 illustrate another embodiment of a cushioning article 310. Cushioning article 310 has many of the same features as cushioning articles 10 and 110, and these features are shown with the same reference numbers and are described with respect to cushioning article 310. Referring to fig. 23, on cushioning article 310, a weld-resistant material is applied only on the inner surface of second polymeric sheet 18 and/or on the inner surface of tensile layer 34. Thus, as shown in fig. 23, the first polymeric sheet 16 is proximal to the cushioning article 310 and has a plurality of bonds 50 (referred to as a second plurality of bonds) in a second region of the bladder 323, wherein the second region is the entire forefoot region 17A, midfoot region 17B, and heel region 17C (defining a closed shape) on the distal side of the bladder 323, and the portion surrounded by the closed shape has a surface bond 40 with the first tensile layer 32. The second polymeric sheet 18 has portions with a first plurality of bonds 50, the first plurality of bonds 50 arranged in a closed shape, surrounding portions of the interior surface 46 displaced from the exterior surface 47 of the adjacent second tensile layer 34, forming domed surfaces 54F, 54G, 54H, 54I, 54J, etc. in a first region of the second polymeric sheet 18 that is the entire forefoot region 17A, midfoot region 17B, and heel region 17C on the distal side of the bladder 323.

In a second region of the first polymeric sheet 16, i.e., in a region behind the separation line 113 in fig. 10, 11, 12, and 14, the inner surface 42 of the first polymeric sheet 16 is bonded to the outer surface 45 of the first tensile layer 32 at a surface bond 40, and the inner surface 46 of the second polymeric sheet 18 is bonded to the outer surface 47 of the second tensile layer 34 at a surface bond 44. A mold is used such that the protrusions 51 contact only the first polymeric sheet 16 in the second region. The inwardly projecting bonds 50 are formed in the first polymeric sheet 16 in the second region and not in the second polymeric sheet 18 in the second region. When the interior cavity 22 is inflated, the engineered tethers 36A at the inwardly projecting bonds 50 create concave grooves 52 in the outer surface 49 of the first polymeric sheet 16 and the outer surface 54 of the second polymeric sheet 18. When the inflation pressure of the gas in the interior cavity 22 is sufficient to pull on the plurality of tethers 36A at the inwardly projecting bonds 50, the inwardly projecting bonds 50 define grooves 52 on the outer surface 49 of the first polymeric sheet 16 and the outer surface 54 of the second polymeric sheet 18.

A method 210 of manufacturing a buffered article, such as buffered article 10, 110 or 310, is shown in the flow chart of fig. 20 and described with reference to fig. 15 and 16. The method 210 may begin with block 211 by disposing a weld-resistant material on an inner surface of the first polymeric sheet 16 or on an outer surface of the first tensile layer 32. In manufacturing cushioning article 110, the weld-resistant material will be disposed only in front of separation line 113, e.g., in a first region of first polymeric sheet 16. In making the cushioning article 10, the method further includes providing 212 a weld-resistant material on an inner surface of the second polymeric sheet 18 or on an outer surface of the second tensile layer 34. In manufacturing cushioning article 110, block 212 may be omitted for certain areas of polymer sheet 18, as discussed herein. Block 211 may be omitted when cushioning article 310 is manufactured. The solder-resistant material provided in the frames 211 and 212 is not provided at a position where the bonding portion 50 is required. For example, the weld-resistant material may be disposed in front of the separation line 113 as described, but avoiding areas of the sheets 16, 18 and tensile layers 32, 34 where bonding is desired. This may be accomplished by properly placing the solder resistant material by ink-jet printing the correct pattern on the surface of the sheets 16, 18 and/or the tensile layer. Alternatively, if the locations of the joints need not be activated, a solder-resistant material may be provided at these locations.

As best shown in fig. 18, in block 213, a first mold insert 53A having a first pattern of protrusions 55A (i.e., a pattern of protrusions 51 arranged in a closed shape) is secured to a first mold portion 66A. For example, as shown in fig. 15, the first mold insert 53A has an opening 70 that receives a fastener 72. Fasteners 72 extend into openings 74 in first mold portion 66A to secure first mold insert 53A to first mold portion 66A. The opening 74 is in a groove 75 of the first mold portion 66A and the mold insert 53A fits within the groove 75 such that the surface 76 is flush with a surface 78 of the adjacent first mold portion 66A. The openings 70, 74 and fasteners 72 may be threaded, for example. Thus, when arranged as described in block 212, the mold insert 53A is positioned in the mold cavity 68 and partially defines the mold cavity 68.

When the cushioning article 10 or 310 is manufactured, in block 214, the second mold insert 53B having the plurality of protrusions 51 arranged in the closed shape will be secured to the second mold portion 66B in the same manner as the first mold insert 53A is secured to the first mold portion 66A. For some configurations, the first mold portion 66A and the second mold portion 66B may be configured with a plurality of protrusions 51 arranged in a closed shape such that the use of the mold inserts 53A, 53B is not required. However, the use of the mold inserts 53A, 53B allows the same mold portions 66A, 66B to be used to manufacture cushioning articles having different bonding patterns simply by changing either or both of the mold inserts 53A, 53B to mold inserts having alternative protrusion patterns. When making cushioning article 110, no protrusions are necessary near second polymeric sheet 18 behind line 113 because no inwardly projecting bonds 50 are created in this region of second polymeric sheet 18. Thus, in making cushioning article 110, second mold portion 66B, which is configured to align behind line 113, may be provided without protrusions and with a surface configured to shape the outer surface of second polymer sheet 18.

Next, in block 215, the components of the cushioning article 10 (or the cushioning article 110 or 310), the mold components 53A, 53B, 66A, 66B, or both, may be preheated prior to placing the components of the cushioning article 10 in the open mold cavity 68 to help expedite subsequent thermoforming by the combination blocks 218, 220.

In block 216, the first and second polymeric sheets 16, 18 and the tensile member 30 are then placed in the mold cavity 68 with the first tensile layer 32 placed adjacent the first polymeric sheet 16, the second tensile layer 34 placed adjacent the second polymeric sheet 18, and the plurality of tethers 36 connecting the first tensile layer to the second tensile layer. Frame 216 may include placing the first and second polymer sheets 16, 18 and the tensile member 30 between the open mold portions 66A, 66B. As shown in fig. 15, this may be accomplished through the use of a shuttle frame (not shown) that controls the alignment of the various components of the cushioning article 10, 110 or 310 with each other and with the mold components 66A, 66B, 53A, 53B, respectively. When the cushioning article 110 is manufactured, the respective tensile layers 32, 34 of the tensile member 30 may have been bonded, such as by lamination or by use of an adhesive, to the respective tensile layers 32, 34 after the separation line 113 when the first and second polymeric sheets 16, 18 are placed in the mold cavity 68. Alternatively, as shown in fig. 15, the first and second polymeric sheets 16, 18 may not have been bonded to the tensile member 30. Once the component of the cushioning article 10, 110, or 310 is placed in the mold cavity 68, one or both of the mold components 66A, 66B are translated toward the other mold component to close the mold cavity 68.

Next, in block 218, the first and second polymeric sheets 16, 18 are conformed to the components of the mold 66 as shown in fig. 16. For example, the outer surface 49 of the first polymeric sheet 16 conforms to the surface 76 of the mold insert 53A. Surface 76 includes a plurality of protrusions 51. A portion of the outer surface 49 of the first polymeric sheet 16 conforms directly to the mold surface 78 of the first mold portion 66A adjacent the first mold insert 53A. The first polymeric sheet 16 is adapted with a surface 76 comprising a plurality of protrusions 51 at the plurality of protrusions 51, the plurality of protrusions 51 being directly exterior to some of the plurality of tethers 36, depressing the first polymeric sheet 16 toward the second polymeric sheet 18. In block 218, as shown in fig. 16, the outer surface 54 of the second polymeric sheet 18 is also conformed to the surface 77 of the second mold insert 53B and to the mold surface 79 of the second mold portion 66B, the second mold portion 66B being adjacent to the second mold insert 53B. Conforming the polymer sheets 16, 18 to the surfaces of the mold inserts 53A, 53B and mold portions 66A, 66B may include applying a vacuum to the mold cavity 68 to draw the polymer sheets 16, 18 against the surfaces 76, 77, 78, 79. Alternatively or additionally, conforming the polymer sheets 16, 18 to the surface may include pressurizing the mold cavity 68, thereby pressing the polymer sheets 16, 18 against the surfaces 76, 77, 78, 79.

After or concurrently with conforming the first and second polymeric sheets 16, 18 to the surfaces 76, 77, 78, 79 in block 218, the first tensile layer 32 may be thermally bonded to the first polymeric sheet 16 and the second tensile layer 34 opposite the first tensile layer 32 may be thermally bonded to the second polymeric sheet 18 in block 220. In addition to applying vacuum and/or pressure to mold cavity 68, the heating of polymer sheets 16, 18, tensile layers 32, 34, and/or mold members 53A, 53B, 66A, 66B can thermally bond at surface bonds 40, 44 and inwardly projecting bonds 50. When the components of the cushioning article 10 are cooled, the bonds 40, 44, 50 remain. The adaptation in frame 218 and the thermal bonding in frame 220 may be referred to as thermoforming and creates inwardly projecting bonds 50 where the first polymer 16 and the first tensile layer 32 are joined and partially traverse the protrusions 51 of the plurality of tethers 36, while the inwardly projecting bonds 50 project toward the second polymer sheet 18 but are still spaced apart from the second tensile layer 34 and the second polymer sheet 18 as described in connection with fig. 3.

The thermal bonding of block 220 may include heating first polymer sheet 16 and second polymer sheet 18 prior to placing first polymer sheet 16 and second polymer sheet 18 in mold cavity 68. Alternatively or additionally, thermal bonding may include heating one or more of the mold parts 53A, 53B, 66A, 66B, or radio frequency welding via the mold 66.

After or concurrently with block 220, the method 210 may include block 222, bonding the first polymeric sheet 16 to the second polymeric sheet 18 at the peripheral bond 20 such that the first and second polymeric sheets 16, 18 at least partially surround the interior cavity 22 housing the tensile member 30. For example, as shown in fig. 16, joining the first and second polymeric sheets 16, 18 at the peripheral bond 20 in block 222 may include compressing the first and second polymeric sheets 16, 18 between the first and second mold portions 66A, 66B in the closed position. The outer perimeter of the first and second polymer sheets 16, 18 may be left a small portion that is not bonded, such as at the inflation ports 82 molded into the sheets at the frames 218 and 220.

After block 222, the mold cavity 68 may be opened in block 224 by translating one or both of the mold portions 66A, 66B away from each other. The buffered article 10 may then be removed from the mold cavity 68 in block 226.

In block 228, the interior cavity 22 may be inflated to a desired inflation pressure, for example, through the inflation port 82 of fig. 1. For example, the fill tube may fit into the inflation port 82, or may be integrally formed from the sheets 16, 18 at the inflation port 82. Excess material in the sheets 16, 18 around the peripheral bond 20 may be trimmed before or after the interior cavity 22 is inflated in block 228. Gas (such as air) may be dispensed from a pressurized source or pumped from a pressurized source through the inflation port 82 into the interior cavity 22. In some embodiments, the internal cavity 22 is not inflated, but simply maintains the gas at atmospheric pressure.

The internal cavity 22 is sealed in block 230. In the illustrated embodiment, this may be accomplished by sealing the inflation port 82, such as by thermally bonding the sheets 16, 18 to one another at the inflation port 82, or plugging the inflation port 82. In fig. 1, the sheets 16, 18 and any fill tubes have been trimmed and the inflation port 82 sealed. Once block 230 is complete, the cushioning article 10, 110, or 310 is fully manufactured and ready to be assembled in the article of footwear 14. If the interior cavity 22 is inflated to a sufficient pressure, the portions of the polymeric sheets 16 and/or 18 of the cushioning article 10, 110, or 310 that form the dome portions with the dome surfaces 49A-49D, 54A-54J, etc. and the plurality of tethers 36A at the bonds 50 are tensioned, forming slots 52 at the outer surface 49 of the first polymeric sheet 16 and the inwardly projecting bonds 50 in the outer surface 54 of the second polymeric sheet 18, thereby causing the cushioning article 10, 110, or 310 to articulate together as discussed with respect to FIG. 6, wherein the slots 52 form a bending axis.

It should be understood that although the mold component having the protrusions 51 forming the inwardly projecting bonds 50 in fig. 15-16 is mold insert 53A and/or 53B, one or both of the mold portions 66A, 66B may have one or more protrusions and the use of a mold insert is not required. However, the use of mold inserts may allow for the production of cushioning articles having different bond patterns at a lower tooling cost. For example, the same mold portions 66A, 66B may be used with different tool inserts having different protrusion patterns to produce cushioning articles having different bonding patterns. For example, fig. 19 shows a different mold insert 53AA having a different pattern 55AA of protrusions 51. The shape, size, or location of the protrusions 51 of the mold insert 53AA is different from the protrusions 51 of the first mold insert 53A such that the pattern of the protrusions 51 of the mold insert 53AA is different from the first pattern of protrusions of the mold insert 53A.

After manufacturing a cushioning article having a first bond pattern (i.e., a first pattern of inwardly-protruding bonds corresponding to a first pattern of protrusions of the first mold insert 53A), the method 210 may include block 232: the first mold insert 53A is removed from the mold cavity 68. Then, as described with respect to the mold insert 53A, in block 234, the different mold insert 53AA can be secured to the mold portion 66A using the fasteners 72 extending through the openings 70, 74. The mold insert 53B may also be replaced by a different mold insert having a different pattern of protrusions. Now placing mold insert 53AA in mold cavity 68, and possibly a different mold insert secured to mold portion 66B and placed in cavity 68, blocks 211 through 230 of method 210 may now be repeated to produce a second cushioning article that is a full-length sole component having a different bond pattern than the first full-length sole component produced using mold inserts 53A, 53B, the different bond pattern being the pattern of inwardly projecting bonds 50 as described herein, but corresponding, for example, to a different pattern of projections of a different mold insert 53 AA.

For example, in repeating blocks 211 through 230, block 216 is repeated by placing a subsequent first polymer sheet, a subsequent second polymer sheet, and a subsequent tensile member in the mold cavity 68, wherein the subsequent tensile member is between the subsequent first polymer sheet and the subsequent second polymer sheet. Block 218 is repeated by adapting a subsequent first polymer sheet to a different mold insert 53AA and a subsequent second polymer sheet to a different mold insert or another mold component (e.g., a mold component similar to mold component 66B), respectively, to adapt the first polymer sheet and the second polymer sheet in a manner that presses the subsequent first polymer sheet toward the subsequent second polymer sheet at the second protrusion 51 (i.e., at one of the protrusions 51 of the different mold insert 53 AA), wherein the second protrusion is directly outward of the subsequent tensile component. For example, block 220 is repeated by thermally bonding a first tensile layer of a subsequent tensile member to a subsequent first polymeric sheet and thermally bonding a second tensile layer of the subsequent tensile member to a subsequent second polymeric sheet to create an inwardly projecting second bond 50 at the second protrusion, the second bond 50 partially traversing the subsequent tensile member. Because the mold inserts 53AA are different, the same mold portions and mold cavities may provide a different bond pattern for the second cushioning article than the first cushioning article, and simply remove the first mold insert 53A and replace it with a different mold insert 53AA, and possibly replace the second mold insert 53B with a different mold insert when manufacturing cushioning articles (e.g., cushioning article 10) having an inwardly projecting bond 50 at the second polymeric sheet 18.

To facilitate and clarify the description of the various embodiments, various terms are defined herein. The following definitions apply throughout the specification (including claims) unless otherwise indicated. Additionally, all references cited are incorporated herein in their entirety.

"article of footwear," "article of footwear," and "footwear" may be considered machine and manufacturing. Assembled ready-to-wear articles of footwear (e.g., shoes, sandals, boots, etc.) and individual components of the articles of footwear (e.g., midsoles, outsoles, uppers, etc.) have been considered prior to final assembly into a wearable article of footwear and are referred to herein in singular or plural form as "articles of footwear" or "footwear".

The terms "a," "an," "the," "at least one," and "one or more" are used interchangeably to indicate the presence of at least one item. There may be a plurality of such items, unless the context clearly dictates otherwise. Unless otherwise indicated explicitly or clearly by context (including the appended claims), all numbers in this description of a parameter (e.g., quantity or condition) are to be understood as modified in all instances by the term "about", whether or not "about" actually appears before the value. "about" means that the numerical value allows some slight imprecision (with some approach to exactness in the value; about or reasonably close to the value; close). If the imprecision provided by "about" is not otherwise understood in the art with this ordinary meaning, then "about" as used herein indicates variations that can result from at least the ordinary methods of measuring and using these parameters. As used in the specification and the appended claims, a value is considered "approximately" equal to a specified value if, unless otherwise specified, the value is neither greater than nor less than five percent of the specified value. Additionally, disclosure of ranges should be understood to specifically disclose all values within the range and further divided ranges.

The terms "comprises," "comprising," and "having" are intended to be inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of the steps, processes, and operations may be altered, where possible, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any and all combinations of the associated listed items. The term "any" should be understood to include any possible combination of the referenced items, including "any one" of the referenced items. The term "any" should be understood to include any possible combination of the recited claims of the appended claims, including "any one" of the recited claims.

For consistency and convenience, directional adjectives corresponding to the indicated embodiments may be employed throughout the detailed description. Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," "top," "bottom," and the like may be used to describe graphically related features and are not meant to limit the scope of the invention as defined by the claims.

The term "longitudinal" refers to a direction extending along the length of a component. For example, a longitudinal direction of the article of footwear extends between a forefoot region and a heel region of the article of footwear. The terms "forward" or "front" are used to refer to a general direction from the heel region to the forefoot region, and the terms "rearward" or "rear" are used to refer to the opposite direction, i.e., from the forefoot region to the heel region. In some cases, a component may be identified with a longitudinal axis and a front-to-back longitudinal direction along the axis. The longitudinal direction or longitudinal axis may also be referred to as the anterior-posterior direction or anterior-posterior axis.

The term "transverse" refers to a direction extending along the width of the component. For example, the lateral direction of the article of footwear extends between the lateral side and the medial side of the article of footwear. The transverse or lateral axis may also be referred to as a lateral or side axis or a medial-lateral or medial-lateral axis.

The term "perpendicular" refers to a direction that is substantially perpendicular to both the transverse and longitudinal directions. For example, where the sole structure rests flat on the ground, the vertical direction may extend upward from the ground. It will be understood that each of these directional adjectives may apply to various components of the sole structure. The terms "upward" or "upwardly" refer to a vertical direction pointing toward the top of the component, which may include the instep, fastening area, and/or the upper. The terms "downward" or "downward" refer to a vertical direction opposite to the upward direction, which is directed toward the bottom of the component and may generally be directed toward the bottom of the sole structure of the article of footwear.

The "interior" of an article of footwear, such as a shoe, refers to the portion of the space occupied by the wearer's foot when the article of footwear is worn. The "medial" side of a component refers to the side or surface of the component that faces (or will face) the article of footwear in the assembled article of footwear. The "lateral side" or "exterior" of a component refers to the side or surface of the component that faces away from (or will face away from) the article of footwear in the assembled article of footwear. In some cases, other components may be located between the medial side of the component and the space on the medial side of the assembled article of footwear. Similarly, other components may be located between the lateral side of the component and the space on the lateral side of the assembled article of footwear. Further, the terms "inwardly" and "inwardly" refer to a direction toward the interior of a footwear component or article, such as a shoe, and the terms "outwardly" and "outwardly" refer to a direction toward the exterior of a footwear component or article, such as a shoe. Additionally, the term "proximal" refers to a direction closer to the center of the footwear component or closer to the foot toward the foot when the user inserts the foot into the article of footwear. Likewise, the term "distal" refers to a direction away from the center of the footwear component or away from the foot when the user inserts the foot into the article of footwear. Thus, the terms proximal and distal may be understood as opposing terms describing relative spatial positions.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be combined with or substituted for any other feature or element in any other embodiment unless specifically limited. Therefore, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the appended claims.

While several modes for carrying out many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary of the scope of the entire alternative embodiments that one of ordinary skill in the art would recognize as being structurally and/or functionally equivalent or otherwise evident based on the content included therein, and not limited to those explicitly depicted and/or described.