CUSHIONING COMPONENT FOR A WEARABLE ARTICLE

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. Provisional Application No. 63/735,460, filed Dec. 18, 2024, which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure generally relates to a cushioning component for a wearable article that includes a bladder and a core of at least one polymeric sheet disposed in the bladder.

BACKGROUND

Wearable articles, such as articles of footwear, often include cushioning components. Some cushioning components are configured as fluid-filled bladders that enclose an interior cavity to retain a gas in the interior cavity, providing cushioning when loaded.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary rather than to limit the scope of the disclosure.

FIG. 1 is a plan view of a bottom side of a polymeric sheet with anti-weld material disposed thereon.

FIG. 2 is a plan view of an opposing top side of the polymeric sheet of FIG. 1 with anti-weld material disposed thereon in a different pattern than on the side shown in FIG. 1.

FIG. 3 is a plan view of a top side of another polymeric sheet with anti-weld material disposed thereon and with an opposite second side not having any anti-weld material disposed thereon.

FIG. 4 is a plan view of a portion of a core formed from the polymeric sheets of FIGS. 1-3, showing the polymeric sheet of FIGS. 1-2 as a lower core sheet and representing bonded areas at the top side of the polymeric sheet of FIG. 2 in solid and bonded areas at the bottom side of the polymeric sheet of FIG. 2 in dashed lines.

FIG. 5 is a plan view of a portion of the core formed from the polymeric sheets of FIGS. 1-3 showing the polymeric sheet of FIG. 3 as an upper core sheet and representing bonded areas at the top side of the upper core sheet in solid and bonded areas at the bottom side of the upper core sheet in dashed lines.

FIG. 6 is a cross-sectional view of a cushioning component including the core of FIG. 5 at a cross-section taken at lines 6-6 in FIG. 7 along a longitudinal axis and including a bladder having first and second barrier sheets, with the cushioning component in an uninflated state.

FIG. 7 is a plan view of the cushioning component of FIG. 6 in an uninflated state.

FIG. 8 is a plan view of the cushioning component of FIGS. 6-7 in an inflated state.

FIG. 9 is a medial side view of an article of footwear including the cushioning component of FIG. 8.

FIG. 10 is a fragmentary and perspective cross-sectional view of a portion of the cushioning component of FIG. 8 taken at lines 10-10 in FIG. 8 and showing extensions of the core.

FIG. 11 is a fragmentary and perspective cross-sectional view of a portion of a cushioning component configured as in FIG. 10 but having an alternate configuration of extensions of the core.

FIG. 12 is a fragmentary and perspective cross-sectional view of a portion of the cushioning component configured as in FIG. 10 but having another alternate configuration of extensions of the core.

FIG. 13 is a fragmentary and perspective cross-sectional view of a portion of the cushioning component configured as in FIG. 10 but having another alternate configuration of extensions of the core.

FIG. 14 is a plan view of a bottom side of a polymeric sheet with anti-weld material disposed thereon.

FIG. 15 is a plan view of an opposing top side of the polymeric sheet of FIG. 14 with anti-weld material disposed thereon in a different pattern than on the side shown in FIG. 14.

FIG. 16 is a plan view of a top side of another polymeric sheet with anti-weld material disposed thereon and with an opposite second side not having any anti-weld material disposed thereon.

FIG. 17 is a plan view of a cushioning component including a bladder having first and second barrier sheets and a core from the polymeric sheets of FIGS. 14-16 and in an uninflated state.

FIG. 18 is a perspective view of the cushioning component of FIG. 17 in an inflated state.

FIG. 19 is a fragmentary and perspective cross-sectional view of a portion of the cushioning component of FIG. 18 taken at lines 19-19 in FIG. 18 and showing extensions of the core.

FIG. 20 is a side view of a sole structure including the cushioning component of FIG. 18 and a foam layer overlaying the cushioning component.

FIG. 21 is a cross-sectional view of a cushioning component taken at lines 21-21 in FIG. 23, showing the cushioning component in an inflated state and including a bladder and a single-sheet core.

FIG. 22 is a cross-sectional view of the cushioning component of FIG. 21 taken at lines 22-22 in FIG. 21.

FIG. 23 is a side view of the cushioning component of FIGS. 21-22.

DESCRIPTION

The present disclosure generally relates to an article of footwear that includes a sole structure that has a cushioning component. The cushioning component includes a bladder and a core disposed in the bladder and bonded to inner sides of barrier sheets of the bladder to act as a tensile component. Providing a tensile component within a bladder may be useful in restraining the bladder when inflated, preventing it from adopting a ball-like shape. A tensile component such as the core according to the present disclosure enables bonding the at least one polymeric sheet of the core to the barrier sheets at bonds having patterns that result in technical advantages both in performance aspects of the cushioning component and ease of manufacturing the cushioning component.

More specifically, the bladder may include a first barrier sheet and a second barrier sheet. The first barrier sheet and the second barrier sheet may together define an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet. The first barrier sheet and the second barrier sheet may be sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity. The core may be disposed in the interior cavity and may be spaced entirely inward of the peripheral bond. The core may include at least one polymeric sheet traversing the interior cavity between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonds to tether the first barrier sheet to the second barrier sheet. The at least one polymeric sheet of the core may be displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet. The at least one polymeric sheet of the core may include a medial edge and a lateral edge at which the plurality of bonds terminate, and may include one or more extensions extending laterally outward from the medial edge or from the lateral edge into a peripheral portion of the interior cavity. The one or more extensions may be not bonded to the first barrier sheet in the peripheral portion and not bonded to the second barrier sheet in the peripheral portion.

The plurality of bonds may be arranged such that the gas in the interior cavity is in fluid communication around the at least one polymeric sheet of the core without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity. In other words, the at least one polymeric sheet does not subdivide the interior cavity into separate, sealed chambers.

In an example, the at least one polymeric sheet of the core may include a first polymeric sheet and a second polymeric sheet. The first polymeric sheet includes a first set of the extensions and the second polymeric sheet include a second set of the extensions. In an implementation, none of the extensions of the first set are bonded to any of the extensions of the second set. In another implementation, at least one of the extensions of the first polymeric sheet is bonded to at least one of the extensions of the second polymeric sheet. For example, all of the extensions of the first polymeric sheet may be bonded to the extensions of the second polymeric sheet, or only some of the extensions of the first polymeric sheet may be bonded to the extensions of the second polymeric sheet.

In an aspect, the one or more extensions may include multiple extensions. The bladder may include a forefoot region, a midfoot region, and a heel region. The extensions may be disposed in at least two of the forefoot region, the midfoot region, and the heel region.

In an example, the one or more extensions may include multiple extensions, and at least some of the extensions may have different shapes.

In an example, the one or more extensions may include multiple extensions, and the multiple extension may be aligned with the plurality of bonds at the medial edge of the core and at the lateral edge of the core.

In an implementation, the one or more extensions may have an aperture.

In an aspect, the bladder may include a forefoot region, a midfoot region, and a heel region, and the core may not be bonded to the inner surface of the first barrier sheet in the heel region. For example, the inner surface of the first barrier sheet may not be bonded to the surface of the first polymeric sheet in the heel region inward of the peripheral bond such that the bladder is taller in the heel region than in the midfoot region and the forefoot region. In an implementation, the bladder may be at least twice as tall in the heel region than in the forefoot region.

In an example, the bladder may include a forefoot region, a midfoot region, and a heel region. The article of footwear may further include a foam midsole layer extending in the midfoot region and in the forefoot region and overlaying a top side of the bladder. In an implementation, the foam midsole layer does not overlay at least a rear half of the heel region.

In an implementation, anti-weld material may be disposed on the core at the unbonded areas. By utilizing anti-weld material disposed on the at least one polymeric sheet, the patterns of bonds of the core to the inner surfaces of the barrier sheets (and the bonds of adjacent polymeric sheets in embodiments in which the core includes more than one polymeric sheet) are controlled to determine the final geometry of the completed cushioning component, including height differentials in different regions of an article of footwear, toe spring, etc.

Moreover, utilizing anti-weld material enables ease in manufacturing. For example, when the anti-weld material is blocker ink, patterns may be digitally implemented relatively easily in comparison to other tensile components that require specific molds or mold inserts to control bond formation of barrier sheets to internally placed polymeric sheets. The anti-weld material may be deposited so that it extends to an outer perimeter of the core at the inner surfaces of the barrier sheets, and so that the patterns of bonds of the core do not result in any sealed chambers within the bladder that are not in fluid communication with the interior cavity. In this way, the core itself controls the final geometry of the inflated cushioning component but does not affect the cushioning response of the cushioning component under dynamic loading. Additionally, by utilizing anti-weld material, the cushioning component may be relatively flat prior to inflation. Stated differently, the core may lay flat within the bladder with the unbonded areas contacting the opposing inner surfaces when the interior cavity of the bladder is uninflated.

In an example, the opposing inner surfaces of the bladder may include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet and the core is a multi-sheet core. The at least one polymeric sheet of the core may include a first polymeric sheet and a second polymeric sheet. The first polymeric sheet may be disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet may be disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces the first inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces the second inner surface of the second barrier sheet. The first side of the first polymeric sheet may be directly bonded to the first inner surface of the first barrier sheet at a first set of bonds of the plurality of bonds, the second side of the second polymeric sheet may be directly bonded to the second inner surface of the second barrier sheet at a second set of bonds of the plurality of bonds, the second side of the first polymeric sheet may be directly bonded to the first side of the second polymeric sheet at a third set of bonds of the plurality of bonds, the bonds of the third set may alternate with the bonds of the first set along a length of the first polymeric sheet, and the bonds of the third set may alternate with the bonds of the second set along a length of the second polymeric sheet.

In an example, an article of footwear may include a sole structure having a cushioning component. The cushioning component may include a bladder including a first barrier sheet and a second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity. The cushioning component may also include a core disposed in the interior cavity and spaced inward of the peripheral bond, the core including a first polymeric sheet and a second polymeric sheet, the first polymeric sheet disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces an inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces an inner surface of the second barrier sheet. The first side of the first polymeric sheet may be directly bonded to the inner surface of the first barrier sheet at a first set of spaced bonds, the second side of the second polymeric sheet may be directly bonded to the inner surface of the second barrier sheet at a second set of spaced bonds, and the second side of the first polymeric sheet may be directly bonded to the first side of the second polymeric sheet at a third set of spaced bonds. The first barrier sheet is thereby tethered to the second barrier sheet by the core, and the core is displaced from the opposing inner surfaces by the gas at unbonded areas of the core. The core may include a medial edge and a lateral edge at which the first, second, and third sets of spaced bonds terminate. The first polymeric sheet may include a first set of extensions extending laterally outward from the medial edge or from the lateral edge into a peripheral portion of the interior cavity and not bonded to the first barrier sheet in the peripheral portion and not bonded to the second barrier sheet in the peripheral portion. The second polymeric sheet may include a second set of extensions extending laterally outward from the medial edge or from the lateral edge into the peripheral portion of the interior cavity and bonded to the first set of extensions. In an example, the second set of extensions are not bonded to the first barrier sheet and are not bonded to the second barrier sheet.

In an implementation, the first set of extensions and the second set of extensions may be laterally aligned with some of the bonds at the medial edge of the core and at the lateral edge of the core. In the same implementation or in a different implementation, at least one of the extensions of the first set may be bonded to at least one of the extensions of the second set.

In an aspect, the bladder may include a forefoot region, a midfoot region, and a heel region, and the core is not bonded to the first barrier sheet in the heel region.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings. It should be understood that even though in the following Figures embodiments may be separately described, single features thereof may be combined to additional embodiments.

FIGS. 1-3 show polymeric sheets 10 and 11 used to form a core 12 shown in FIG. 6. The core 12 is included in a cushioning component 14 shown in FIGS. 6-10. More specifically, the cushioning component 14 is included in a sole structure 70 of an article of footwear 72 as shown in FIG. 9. As further explained herein, the cushioning component 14 includes a bladder 20 and the core 12 is disposed in the bladder 20 and bonded to inner surfaces 17, 19 of barrier sheets 16, 18 of the bladder 20 to act as a tensile component. Providing a tensile component within a bladder may be useful in restraining the bladder when inflated, preventing it from adopting a ball-like shape. A tensile component such as the core 12 according to the present disclosure enables bonding the polymeric sheets 10, 11 to the barrier sheets 16, 18 at bonds having patterns that result in technical advantages both in performance aspects of the cushioning component 14 and ease of manufacturing the cushioning component 14.

FIG. 1 is a plan view of a bottom side of the polymeric sheet 11 with anti-weld material 24 disposed thereon. The polymeric sheet 11 is referred to herein as a second polymeric sheet. The side of the polymeric sheet shown in FIG. 1 is a second side 13 and is also referred to as a bottom side or distal side as it is disposed further from the foot when the core 12 is incorporated in the sole structure 70 of the article of footwear 72. The second side 13 interfaces with and is bonded to the inner surface 19 of the second barrier sheet 18 as shown in FIG. 6 and discussed herein.

FIG. 2 is a plan view of an opposing first side 15 of the second polymeric sheet 11 with anti-weld material 24 disposed thereon in a different pattern than on the second side 13 shown in FIG. 1. The first side 15 is also referred to as the top side or as the proximal side of the second polymeric sheet 11 as it is disposed closer to the foot when the core 12 is incorporated in the sole structure 70 of the article of footwear 72.

As best shown in FIGS. 4-9, each of the core 12, the cushioning component 14, and the article of footwear 72 includes a forefoot region, a heel region, and a midfoot region. These regions are referred to as a forefoot region 50, a midfoot region 52, and a heel region 54 with respect to the cushioning component 14, the sole structure 70, and the article of footwear 72. However, because the core 12 is of a shorter length than each of the cushioning component 14, the sole structure 70, and article of footwear 72, the forefoot region, midfoot region, and heel region of the core 12 are referred to as 50A, 52A, and 54A, respectively. The forefoot region 50 and 50A generally includes portions of the article of footwear 72 or the core 12 corresponding with the toes and the joints connecting the metatarsals with the phalanges of a wearer's foot. The midfoot region 52 and 52A generally includes portions of the article of footwear 72 or the core 12 corresponding with the arch area of the foot, and the heel region 54 and 54A corresponds with rear portions of the foot, including the calcaneus bone. Each of the core 12, the cushioning component 14, the sole structure 70, and the article of footwear 72 include a medial side 80 and a lateral side 82 that extend through each of forefoot region 50 and 50A, the midfoot region 52 and 52A, and the heel region 54 and 54A and fall on opposite sides of a longitudinal midline (e.g., longitudinal axis LA) of the cushioning component 14 in FIG. 7. The forefoot region 50 and 50A, the midfoot region 52 and 52A, the heel region 54 and 54A, the medial side 80, and the lateral side 82 are not intended to demarcate precise areas of footwear 72, the core 12, the cushioning component 14, or the sole structure 70, but are instead intended to represent general areas of the article of footwear 72, the core 12, the cushioning component 14, and the sole structure 70 to aid in the following discussion.

FIG. 3 is a plan view of a first side 22 of the first polymeric sheet 10 with anti-weld material 24 disposed thereon. The opposite second side 26 does not have any anti-weld material disposed thereon. The first polymeric sheet 10 is stacked on the second polymeric sheet 11 when the core 12 is assembled such that the second side 26 interfaces with and is bonded to the first side 15 of the second polymeric sheet 11 and the first side 22 interfaces with and is bonded to the inner surface 17 of the first barrier sheet 16 as shown in FIG. 6 and discussed herein.

The anti-weld material 24 is disposed on the polymeric sheets 10, 11 of the core 12 at areas that will be unbonded areas when the core 12 is thermally processed. By utilizing anti-weld material 24 disposed on the polymeric sheets 10, 11, the patterns of bonds of the core 12 to the inner surfaces 17, 19 of the barrier sheets 16, 18 (and the bonds of the second side 26 of the first polymeric sheet 10 to the first side 15 of the second polymeric sheet 11), as well as the extensions 56A, 56B, 58A, and 58B are controlled to determine the final geometry of the completed cushioning component 14, including height differentials in different regions (e.g., forefoot region 50 and heel region 54) of an article of footwear 72, toe spring, etc. As shown in FIG. 6, portions of one or both of the inner surfaces 17, 19 that are outward of the outer perimeter 34 of the core 12 and inward of where the peripheral bond 38 is formed may also be preprinted or otherwise prepared with anti-weld material 24 or otherwise processed so that these portions of the inner surfaces 17, 19 will not bond to one another.

The anti-weld material 24 may be disposed on the polymeric sheets 10 and 11 (and on the portions of the inner surfaces 17, 19 of the first barrier sheet 16 and/or second barrier sheet 18 shown in FIG. 6) via a computer-controlled printer head or heads (not shown) according to a stored algorithm representing a predetermined printing pattern. As used herein, the anti-weld material 24 may be blocker ink, and may also be referred to as anti-weld ink. For example, when the anti-weld material is blocker ink, it may be printed according to a different predetermined programmed pattern for the first side 22 of the first polymeric sheet 10, the first side 15 of the second polymeric sheet 11 and the second side 13 of the second polymeric sheet 11 at all selected locations where bonds of the polymeric sheets 10, 11 of the core 12 to one another or to the barrier sheets 16, 18 are not desired. After trimming the sheets 10, 11 to establish the outer perimeters 34B, 34A and when bonded to one another such as by thermal processing, adjacent surfaces of the stacked, flat polymeric sheets 10, 11 and barrier sheets 16, 18 are bonded to one another except where the anti-weld material 24 is disposed. Accordingly, the patterns of anti-weld material 24 determine corresponding patterns of resulting bonds in the finished cushioning component 14.

The predetermined pattern of anti-weld material 24 on the second side 13 of the second polymeric sheet 11 in FIG. 1 is referred to as a second predetermined pattern and results in a second set of bonds 46 as well as extensions 56A, 58A as discussed with respect to FIGS. 4 and 6-10. The predetermined pattern of anti-weld material 24 on the first side 15 of the second polymeric sheet 11 in FIG. 2 is referred to as a third predetermined pattern and results in a third set of bonds 47 as well as bonds 59 of the extensions 56A as discussed with respect to FIGS. 4-10. The predetermined pattern of anti-weld material 24 on the first side 22 of the first polymeric sheet 10 is referred to as a first predetermined pattern and results in a first set of bonds 44 as well as extensions 56B, 58B as discussed with respect to FIGS. 5-10. The extensions 56B, 58B of the first polymeric sheet 10 may be referred to as a first set of extensions. The extensions 56A, 58A of the second polymeric sheet 11 may be referred to as a second set of extensions.

With reference to FIG. 1, the anti-weld material 24 is disposed on the second side 13 of the second polymeric sheet 11 in the second predetermined pattern at spaced regions A, B, C, D, E, F, G, H, I, J, K, and L of deposited anti-weld material 24 as well as over the entire extensions 56B. The spaced regions H, I, J, and K include the extensions 58B. That is, anti-weld material 24 covers the extensions 58B. Areas of the second side 13 of the second polymeric sheet 11 between any adjacent two of the spaced regions A, B, C, D, E, F, G, H, I, J, K, and L are free from anti-weld material 24. More specifically, area 13A between adjacent regions A and B is free from anti-weld material 24, area 13B between adjacent spaced regions B and C is free from anti-weld material 24, area 13C between adjacent spaced regions C and D is free from anti-weld material 24, area 13D between adjacent spaced regions D and E is free from anti-weld material 24, area 13E between adjacent spaced regions E and F is free from anti-weld material 24, area 13F between adjacent spaced regions F and G is free from anti-weld material 24, area 13G between adjacent spaced regions G and H is free from anti-weld material 24, area 13H between adjacent spaced regions H and I is free from anti-weld material 24, area 13I between adjacent spaced regions I and J is free from anti-weld material 24, area 13J between adjacent spaced regions J and K is free from anti-weld material 24, and area 13K between adjacent spaced regions K and L is free from anti-weld material 24. The areas 13A, 13B, 13C, 13D, 13E, 13F, 13G, 13H, 13I, 13J, and 13K will become a second set of bonds 46 shown in FIG. 6, each corresponding with one of the areas 13A-13K. The areas 13A and 13K are indicated in FIG. 6 and the remaining areas at bonds 46 are not numbered in FIG. 6 for clarity in the drawing but correspond with areas 13B-13J in order from area 13A to area 13K.

Each of the areas 13A-13K has a wavy shape such that the second set of bonds 46 are wavy bonds as further described with respect to FIG. 7. The second polymeric sheet 11 is trimmed to an outer perimeter 34A shown in FIGS. 4 and 6 after printing the anti-weld material 24 such that the areas A-L of anti-weld material 24 extend to the perimeter 34A and the areas 13A-13K and corresponding resulting bonds 46 also extend to the perimeter 34A at both the medial and lateral sides 80, 82.

As best shown in FIGS. 4 and 8, the extensions 56A and 58A are disposed in a midfoot region 52A and a heel region 54A of the core 12 and in a corresponding midfoot region 52 and heel region 54 of the bladder 20 and cushioning component 14. No extensions are disposed in the forefoot region 50A of the core 12 and the corresponding forefoot region 50 of the cushioning component 14 in the implementation shown. In other implementations, extensions could be disposed in another two of the regions and not in the third region (e.g., only in the forefoot region 50A and the heel region 54A and not in the midfoot region 52A, or only in the forefoot region 50A and the midfoot region 52A and not in the heel region 54A, or disposed in all of the region 50A, 52A, and 54A, or disposed in only any one of the regions 50A, 52A, and 54A).

As shown, the extensions 56A have a different shape than the extensions 58A and also extend further laterally outward than the extensions 58A. Additionally, as indicated in FIG. 4, the extensions 56A are aligned with the plurality of bonds 46 at a medial edge 34C of the core 12 and at a lateral edge 34D of the core 12. The extensions 58A are aligned with the plurality of bonds 47 at the medial edge 34C and the lateral edge 34D. Similarly, the extensions 56B have a different shape than the extensions 58B and also extend further laterally outward than the extensions 58B. Additionally, as indicated in FIG. 5, the extensions 56B are aligned with the plurality of bonds 44 at a medial edge 34C of the core 12 and at a lateral edge 34D of the core 12. The extensions 58B are aligned with the plurality of bonds 47 at the medial edge 34C and the lateral edge 34D. The extensions 56A have the same shape as the extensions 56B. The extensions 58A have the same shape as the extensions 58B.

The medial edge 34C and the lateral edge 34D of the core 12 are each part of the outer perimeters 34A and 34B of the respective polymeric sheets 10, 11 of the core 12. The outer perimeter 34A includes the medial edge 34C and lateral edge 34D of the first polymeric sheet 10 and the extensions 56A, 58A extending therefrom. The outer perimeter 34B includes the medial edge 34C and the lateral edge 34D of the second polymeric sheet 11 and the extensions 56A, 58A extending therefrom.

With reference to FIG. 2, the anti-weld material 24 is disposed on the first side 15 of the second polymeric sheet 11 in the third predetermined pattern at spaced regions M, N, O, P, Q, R, S, T, U, V, and W of deposited anti-weld material 24. The regions S, T, U, and V include portions of the extensions 56A that are covered with anti-weld material. Anti-weld material 24 is also disposed on the extensions 58A except on regions 59A near the tips of each extension 58A, that will result in bonds 59 of the extensions 58A. Areas of the first side 15 of the second polymeric sheet 11 between any adjacent two of the spaced regions M, N, O, P, Q, R, S, T, U, V, and W are free from anti-weld material 24. More specifically, area 15M between adjacent regions M and N is free from anti-weld material 24, area 15N between adjacent spaced regions N and O is free from anti-weld material 24, area 15O between adjacent spaced regions O and P is free from anti-weld material 24, area 15P between adjacent spaced regions P and Q is free from anti-weld material 24, area 15Q between adjacent spaced regions Q and R is free from anti-weld material 24, area 15R between adjacent spaced regions R and S is free from anti-weld material 24, area 15S between adjacent spaced regions S and T is free from anti-weld material 24, area 15T between adjacent spaced regions T and U is free from anti-weld material 24, area 15U between adjacent spaced regions U and V is free from anti-weld material 24, and area 15V between adjacent spaced regions V and W is free from anti-weld material 24. The areas 15M, 15N, 15O, 15P, 15Q, 15R, 15S, 15T, 15U, and 15V will become a third set of bonds 47 shown in FIG. 6, each corresponding with one of the areas 15M-15V. The areas 15M and 15V are indicated in FIG. 6 and the remaining areas at bonds 47 are not numbered in FIG. 6 for clarity in the drawing but correspond with areas 15N-15U in order from area 15M to area 15V.

Each of the areas 15M-15V has a wavy shape such that the third set of bonds 47 are wavy bonds as further described with respect to FIGS. 4-5 and 7-8. The second polymeric sheet 11 is trimmed to an outer perimeter 34A shown in FIGS. 4 and 6 and after printing the anti-weld material 24 such that the areas M-W of anti-weld material 24 extend to the medial and lateral edges 34C, 34D, the areas 15M-15V and corresponding resulting bonds 47 also extend to the medial and lateral edges 34C, 34D, and the extensions 56A, 58A extend laterally outward from the medial and lateral edges 34C, 34D.

With reference to FIG. 3, the anti-weld material 24 is disposed on the first side 22 of the first polymeric sheet 10 in the first predetermined pattern at spaced regions X, Y, Z, A1, B1, C1, D1, E1, F1, G1, and H1 of deposited anti-weld material 24. The regions D1, E1, F1, and G1 include the extensions 58B that are covered with anti-weld material. Anti-weld material 24 is also disposed on the entire extensions 56B on the first side 22. Areas of the first side 22 of the first polymeric sheet 10 between any adjacent two of the spaced regions X, Y, Z, A1, B1, C1, D1, E1, F1, G1, and H1 are free from anti-weld material 24. More specifically, area 22A between adjacent regions X and Y is free from anti-weld material 24, area 22B between adjacent spaced regions Y and Z is free from anti-weld material 24, area 22C between adjacent spaced regions Z and A1 is free from anti-weld material 24, area 22D between adjacent spaced regions A1 and B1 is free from anti-weld material 24, area 22E between adjacent spaced regions B1 and C1 is free from anti-weld material 24, area 22F between adjacent spaced regions C1 and D1 is free from anti-weld material 24, area 22G between adjacent spaced regions D1 and E1 is free from anti-weld material 24, area 22H between adjacent spaced regions E1 and F1 is free from anti-weld material 24, area 22I between adjacent spaced regions F1 and G1 is free from anti-weld material 24, and area 22J between adjacent spaced regions G1 and H1 is free from anti-weld material 24. The areas 22A, 22B, 22C, 22D, 22E, 22F, 22G, 22H, 22I, and 22J will become a first set of bonds 44 shown in FIG. 6, each corresponding with one of the areas X-H1. The areas 22A and 22J are indicated in FIG. 6 and the remaining areas at bonds 44 are not numbered in FIG. 6 for clarity in the drawing but correspond with areas 22B-22I in order from area 22A to area 22J. Area 77 shown on the polymeric sheet 10 in FIG. 3 just above the deposited anti-weld material 24 that will be part of the core 12 once the first polymeric sheet 10 is trimmed (see the outer perimeter 34B after trimming represented in phantom at the top of the first predetermined pattern in FIG. 3) will become a foremost bond 77A of the first polymeric sheet 10 to the first barrier sheet 16 after trimming the polymeric sheet 10 to the outer perimeter 34B and then thermally processing the cushioning component 14.

Each of the areas 22A-22J has a wavy shape such that the first set of bonds 44 are wavy bonds as further described with respect to FIG. 7. The first polymeric sheet 10 is trimmed to an outer perimeter 34B shown in FIGS. 5 and 6 and after printing the anti-weld material 24 such that the areas X-H1 of anti-weld material 24 extend to the medial and lateral edges 34C, 34D and the areas 22A-22J and corresponding resulting bonds 44 also extend to the medial and lateral edges 34C, 34D. The extensions 56B, 58B extend laterally outward from the medial and lateral edges 34C, 34D.

FIG. 4 is a plan view of the top side of a portion of the core 12 formed from the polymeric sheets of FIGS. 1-3, not showing the first polymeric sheet 10 or the barrier sheets 16, 18 to which the core 12 is bonded, but showing only the second polymeric sheet 11 as the lower core sheet when the core 12 is assembled in order to illustrate the relative locations of the third set of bonds 47, the second set of bonds 46, and the bonds 59. The bonded areas at the top side (first side 15) include the third set of bonds 46 where the first side 15 of the second polymeric sheet 11 of the core 12 bonds to the bottom side (second side 26) of the first polymeric sheet 10 (not shown in FIG. 4), the bonds 59 where the extensions 56A and bonded to the extensions 58B, and are represented in solid. The bonded areas at the opposite bottom side 13 (second side) of the second polymeric sheet 11 are represented with dashed lines and are the second set of bonds 46 wherein the second side 13 of the second polymeric sheet 11 is bonded to the inner surface 19 of the second barrier sheet 18. The areas 15M-15V corresponding with each of the third set of bonds 47 and the areas 13A-13K corresponding with each of the second set of bonds 46 are also indicated with reference numbers. FIG. 4 shows that the bonds 47 of the third set of bonds are offset from the bonds 46 of the second set of bonds in the longitudinal direction of the core 12 (e.g., from a forefoot region 50A of the core 12 to a heel region 54A of the core 12). Stated differently, each bond 47 of the third set of bonds is disposed between two adjacent bonds 46 of the second set of bonds without overlapping with the second set of bonds 46. In this manner, the second polymeric sheet 11 will extend in the vertical direction as shown in FIG. 9 between adjacent bonds 46 and 47 when the interior cavity 21 of the bladder 20 is inflated, tethering the second barrier sheet 18 to the first polymeric sheet 10. The bonded areas of the top side 15 of the second polymeric sheet 11 also include the bonds 59.

FIG. 4 also shows that the plurality of bonds 46 and the plurality of bonds 47 extend to and terminate at the medial edge 34C and the lateral edge 34D. Some of the extensions 56A and 58A extend laterally outward from the medial edge 34C and some of the extensions 56A and 58A extend laterally outward from the lateral edge 34D. As shown in FIGS. 8-10, for example, the extensions 56A, 58A, 56B, and 58B extend into a peripheral portion 21A of the interior cavity 21 of the bladder 20. In the example shown, the extensions 56A, 58A, 56B, and 58B do not extend to the peripheral bond 38 but instead may be said to float in the peripheral portion 21A. The extensions 56A and 56B are bonded to one another at the bonds 59 and thus extend toward one another until meeting at the bond 59 and float together in the peripheral portion 21A. No portion of any of the extensions 56A, 58A, 56B, and 58B is bonded to either of the barrier sheets 16, 18, enabling the extensions 56A, 58A, 56B, and 58B to float in the peripheral portion 21A. As shown, the extension 56A and 58A are aligned with the plurality of bonds 46 and 47, respectively, at the medial edge 34C of the core 12 and at the lateral edge 34D of the core 12. The extensions 56B and 58B are aligned with the plurality of bonds 44 and 47, respectively. Stated differently, and as used herein, the extensions are aligned with bonds when they are disposed directly laterally outward of the bonds in a transverse direction of the core 12, at the medial edge 34C of the core 12 or at the lateral edge 34D of the core 12.

FIG. 4 also illustrates that the bonds 46 of the second set of bonds and the bonds 47 of the third set of bonds are wavy bonds. Stated differently, each of the bonds 46 and each of the bonds 47 has waves having peaks P1 and valleys V1 extending in a fore-aft direction when the core 12 is disposed in the article of footwear 72. For example, bond 47 at area 15N is illustrated having three peaks P1 and two valleys V1. Adjacent bond 46 at area 13C also has three peaks P1 and three valleys V1. Some of the bonds 46, 47 have partial peaks or partial valleys near the perimeter 34A. The peaks and valleys of the other bonds 46 and 47 are not labeled for clarity in the drawings. The number of peaks P1 and valleys V1 of each bond 46 and each bond 47 depends upon the width of the core 12 at the particular bond as spacing between peaks P1 and valleys V1 of each of the bonds 46 and 47 is maintained as relatively equal. By utilizing wavy bonds, the fore-aft extent of each bond (e.g., the longitudinal distance between a peak P1 and a valley V1 of the bond) is increased relative to a straight bond of the same width. This may increase the robustness of the bond and its ability to withstand repeated stresses, such as lateral forces, reducing the likelihood of delamination.

FIG. 5 is a plan view of a portion of the core 12 showing only the polymeric sheet 10 of FIG. 3 as an upper core sheet and representing bonded areas at the first side 22 of the polymeric sheet 10 in solid and bonded areas at the bottom side 26 of the polymeric sheet 10 in dashed lines in order to illustrate the relative locations of the third set of bonds 47, the first set of bonds 44, and the bonds 59. The bonded areas at the top side (first side 22) are the first set of bonds 44 where the first side 22 of the first polymeric sheet 10 of the core 12 bonds to the inner surface 17 of the first barrier sheet 16. The bonded areas at the opposite bottom side 26 (second side) of the first polymeric sheet 10 are represented with dashed lines and are the third set of bonds 47 wherein the second side 26 of the first polymeric sheet 10 is bonded to the first side 15 of the second polymeric sheet 11 and also the bonds 59 where the extension 56A are bonded to the extensions 56B. The areas 15M-15V corresponding with each of the third set of bonds 47 and the areas 22A-22J corresponding with each of the first set of bonds 44 are also indicated with reference numbers. FIG. 5 shows that the bonds 47 of the third set of bonds are offset from the bonds 44 of the first set of bonds in the longitudinal direction of the core 12 (e.g., from a forefoot region 50A of the core 12 to a heel region 54A of the core 12). Stated differently, each bond 47 of the third set of bonds is disposed between two adjacent bonds 44 of the first set of bonds without overlapping with the first set of bonds 44. In this manner, the first polymeric sheet 10 will extend in the vertical direction as shown in FIG. 9 between adjacent bonds 44 and 47 when the interior cavity 21 of the bladder 20 is inflated, tethering the first barrier sheet 16 to the first polymeric sheet 10 and tethering the second polymeric sheet 11 to the first polymeric sheet 10.

FIG. 5 also illustrates that the bonds of the first set of bonds 44 and the bonds of the third set of bonds 47 are wavy bonds. Stated differently, each of the bonds 44 and each of the bonds 47 has waves having peaks P1 and valleys V1 extending in a fore-aft direction when the core is disposed in the article of footwear 72. For example, bond 44 at area 22B is illustrated having three peaks P1 and three valleys V1. Adjacent bond 47 at area 15O also has three peaks P1 and has three valleys V1. The peaks and valleys of the other bonds 44 and 47 are not labeled for clarity in the drawings. Some of the bonds 44, 47 have partial peaks or partial valleys near the outer perimeter 34B. The number of peaks P1 and valleys V1 of each bond 44 and each bond 47 depends upon the width of the core 12 at the particular bond as spacing between peaks P1 and valleys V1 of each of the bonds 44 and 47 is maintained as relatively equal.

Referring again to FIG. 6, after trimming the first polymeric sheet 10 and the second polymeric sheet 11 to establish the respective outer perimeters 34B, 34A, including the medial and lateral edges 34C, 34 D and the extensions 56A, 58A, 56B, and 58B, the first polymeric sheet 10 is stacked on the second polymeric sheet 11 with the second side 13 of the second polymeric sheet 11 adjacent to the inner surface 19 of the second barrier sheet 18 and the first side 22 of the first polymeric sheet 10 adjacent to the inner surface 17 of the first barrier sheet 16. The aligned outer perimeters 34B and 34A of the stacked polymeric sheets 10 and 11 establish and may together be referred to as an outer perimeter 34 of the core 12. In this relative positioning, the barrier sheets 16, 18 and the polymeric sheets 10, 11 are thermally processed to form the bonds 38, 44, 46, 47, and 59 discussed herein. The first barrier sheet 16 and the second barrier sheet 18 together define the interior cavity 21 between the opposing inner surfaces 17, 19 of the first barrier sheet 16 and the second barrier sheet 18.

As shown in FIG. 6, the cushioning component 14 is relatively flat prior to inflation. Stated differently, the core 12 lays flat within the bladder 20 with the unbonded areas contacting the opposing inner surfaces 17, 19 when the interior cavity 21 of the bladder 20 is uninflated. The unbonded areas are as discussed with respect to FIGS. 1-5 and are where anti-weld material 24 is shown in FIG. 6. Only some of the areas with anti-weld material 24 are indicated with a reference number in FIG. 6 for clarity in the drawing.

Traditional tensile components may include a first polymeric sheet bonded only to the inner surface of the first barrier sheet, a second polymeric sheet bonded only to the inner surface of the second barrier sheet, and a plurality of tethers extending from the first polymeric sheet to the second polymeric sheet. Due to this configuration, such traditional tensile components are not relatively flat or sheet-like prior to inflating the interior cavity of a bladder in which they are disposed and are not amendable to heat pressing either to create a core of multiple polymeric sheets or to bond a core of a single polymeric sheet or multiple polymeric sheets to the inner surfaces of the barrier sheets.

As indicated in FIG. 6, the polymeric sheets 10 and 11 are each shown as having the same thickness T1. The barrier sheets 16 and 18 are each shown as having the same thickness T2. The thickness T1 is not greater than the thickness T2. Maintaining a sheet thickness of each polymeric sheet 10 and 11 not greater than that of each of the barrier sheets 16 and 18 helps to ensure the flexibility of the core 12 to function as a tether that collapses back toward the relatively flat state of FIG. 6 easily under compressive loading.

As shown in FIGS. 6-9, the first barrier sheet 16 and the second barrier sheet 18 are sealed to one another along the peripheral bond 38 to enclose the interior cavity 21 and retain a gas in the interior cavity. The barrier sheets 16, 18 of the bladder 20 can be formed from a variety of materials including various polymers that can resiliently retain a fluid such as air or another gas. The polymeric sheets 10 and 11 may be formed of the same material or materials as the barrier sheets 16, 18 as described herein, or may be formed of a polymeric material that does not necessarily retain fluid, as, unlike the barrier sheets 16, 18, the polymeric sheets 10 and 11 function as tethers but do not seal any interior cavity as do the barrier sheets 16, 18. Examples of polymeric materials for the barrier sheets 16, 18 and the polymeric sheets 10 and 11 can include thermoplastic urethane, polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Moreover, the barrier sheets 16, 18 and the polymeric sheets 10 and 11 can be formed of layers of different materials. In one embodiment, the barrier sheets 16, 18 and/or the polymeric sheets 10 and 11 are formed from thin films having one or more thermoplastic polyurethane layers with one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein as disclosed in U.S. Pat. No. 6,082,025, which is incorporated by reference in its entirety. The barrier sheets 16, 18 and the polymeric sheets 10 and 11 may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. Pat. Nos. 5,713,141 and 5,952,065 to Mitchell et al. which are incorporated by reference in their entireties. Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. The barrier sheets 16, 18 and the polymeric sheets 10 and 11 may also each be a flexible microlayer membrane that includes alternating layers of a gas barrier material and an elastomeric material, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk et al. which are incorporated by reference in their entireties. Additional suitable materials for the barrier sheets 16, 18 and the polymeric sheets 10 and 11 are disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy which are incorporated by reference in their entireties. Further suitable materials for the barrier sheets 16, 18 and the polymeric sheets 10 and 11 include thermoplastic films containing a crystalline material, as disclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy, and polyurethane including a polyester polyol, as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk et al. which are incorporated by reference in their entireties. In selecting materials for the barrier sheets 16, 18 and the polymeric sheet 10, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thickness of the barrier sheets 16, 18 and the polymeric sheets 10 and 11 can be selected to provide these characteristics.

As shown in FIG. 7, each bond 44, 46, and 47 of the plurality of wavy bonds extends continuously from the medial edge 34C of the core 12 to the lateral edge 34D of the core 12. The medial edge 34C is a portion of the perimeter 34 at a medial side 80 of the longitudinal axis LA. The longitudinal axis LA is also referred to herein as a longitudinal midline. The lateral edge 34D is a portion of the perimeter 34 at a lateral side 82 of the longitudinal axis LA. The medial side 80 and lateral side 82 also described the respective sides of the cushioning component 14 and the article of footwear 72 as well as its other components. By depositing the anti-weld material 24 so that it extends to the medial and lateral edges 34C, 34D of the core 12 at the inner surfaces 17, 19 of the barrier sheets 16, 18 and between the polymeric sheets 10, 11 (on the first side 15 of the second polymeric sheet 11), on all of the extensions 56A, 56B, 58A, and 58B except at the regions 59A (unbonded areas), and by ensuring that the outer perimeter 34 of the core 12 is entirely inward of the peripheral bond 38 of the barrier sheets 16, 18 as shown in FIG. 7, for example, ensures that the resulting pattern of bonds 44, 46, 47, and 59 of the core 12 does not result in any sealed chambers within the bladder 20 that are not in fluid communication with the interior cavity 21. In this way, the core 12 itself controls the final geometry of the inflated cushioning component 14 but does not affect the cushioning response of the cushioning component 14 under dynamic loading.

FIG. 7 illustrates the relative alignment of the sets of bonds 44, 46, and 47 and of the extensions 56B, 58B afforded by the precise predetermined patterns of the anti-weld material 24 disposed on the first side 22 of the first polymeric sheet 10, on the second side 13 of the second polymeric sheet 11, and on the first side 15 of the second polymeric sheet 11, respectively. In FIG. 7, the bonds 44 of the first set are indicated with solid lines. The bonds 46 of the second set are indicated with dashed lines as are the bonds 59. The bonds 47 of the third set are indicated with a combination of dashed and dotted lines. It is clear from the FIG. 5 and FIG. 7 that the bonds 47 of the third set alternate with the bonds 44 of the first set along a length of the core 12 (e.g., along a length of the first polymeric sheet 10 of the core 12) and hence along a length of the resulting cushioning component 14. It is also clear from FIGS. 4 and 7 that the bonds 47 of the third set alternate with the bonds 46 of the second set along a length of the core 12 (e.g., along a length of the second polymeric sheet 11 of the core 12) and hence along a length of the resulting cushioning component 14. With this configuration, as best indicated in FIGS. 7 and 9, at least some of the bonds 46 of the second set are aligned with the at least some of the bonds 44 of the first set. More specifically, the bonds 44 of the first set are disposed vertically above the bonds 46 of the second set with a bond 47 of the third set offset from and vertically at a height between that of bond 44, 46 of each vertically-stacked set of bonds 44, 46.

Additionally, as best shown in FIGS. 7 and 9, at least some of the bonds 46 of the second set are wider in a fore-aft direction of the core 12, of the cushioning component 14, and of the article of footwear 72 than the bonds 44 of the first set with which the at least some of the bonds 46 of the second set are aligned. In the example shown, all of the bonds 46 of the second set are aligned with the bonds 44 of the first set, and each bond 46 of the second set is wider than the respective bond 44 of the first set with which the bond 46 of the second set is aligned. The bonds 46 of the second set that are wider than the bonds 44 of the first set are thus in both the forefoot region 50 and the heel region 54 as well as in the midfoot region 52 of the article of footwear 72. In other examples, the bonds 46 of the second set may be wider than the bonds 44 of the first set only in the forefoot region 50 or only in the heel region 54, for example.

By providing wider bonds 46 that are disposed closer to the ground surface GS when the cushioning component 14 is incorporated into the article of footwear 72 as shown in FIG. 9, when inflated, the side with the narrower (e.g., shorter) bonds (e.g., the second barrier sheet 18 at the foot-facing side of the cushioning component 14) will allow for more pillowing between the bonds 44 of the first set than between the bonds 46 of the second set when inflated. The side with more pillowing (e.g., the first barrier sheet 16 at the foot-facing side) will contract more in overall length as the path of the material of the barrier sheet 16 at the foot-facing side (e.g., the footbed side) is distributed vertically and horizontally. Accordingly, the first barrier sheet 16 at the foot-facing side with narrower bonds 44 will become more concave after inflation than the second barrier sheet 18 with the wider bonds 46 and may cause the overall shape of the cushioning component 14 to curve upwards at the forefoot region 50 and at the heel region 54 at the ground-facing side (e.g., at the second barrier sheet 18). Providing the narrower bonds 44 of the first set on the footbed side and the wider bonds 46 of the second set on the ground-facing side thus helps to shape the inflated cushioning component 14 to promote toe spring.

FIG. 9 shows that the tension created in the bonded polymeric sheets 10, 11 of the core 12 by the inflation of the interior cavity 21 causes portions of the first barrier sheet 16 inward of the outer perimeter 34 of the core 12 to be pulled downward at the bonds 44, as also indicated by the contoured exterior surface 39 of the first barrier sheet 16 in FIG. 8. Because the outer perimeter 34 of the core 12 is entirely inward of the peripheral bond 38, the barrier sheets 16, 18 will not be tethered together at a peripheral portion 21A of the interior cavity 21 outward of the outer perimeter 34 of the core 12 and inward of the peripheral bond 38. The distance between the inner surfaces 17 and 19 and the resulting height of the cushioning component 14 may thus be greatest outward of the core 12. The top exterior surface 39 is only partly shown and is represented with hidden lines in FIG. 9 where the first barrier sheet 16 is pulled downward by the first polymeric sheet 10 at the bonds 44.

Similarly, tension created in the bonded polymeric sheets 10, 11 of the core 12 by the inflation of the interior cavity 21 causes portions of the second barrier sheet 18 inward of the outer perimeter 34 of the core 12 to be pulled upward at the bonds 46, as indicated by the contoured exterior surface 41 of the second barrier sheet 18 in FIG. 9. The pattern of anti-weld material 24 disposed on the polymeric sheets 10 and 11 the resulting patterns of bonds 44, 46 of the polymeric sheets 10 and 11, respectively, of the core 12 to the barrier sheets 16, 18 can be selected to control the resulting contours of the exterior surfaces 39, 41 of the barrier sheets 16, 18.

FIG. 9 also shows the extensions 56A and 56B bonded to one another at bonds 59, and the extensions 58A and 58B not bonded to one another. The extensions 58B are vertically aligned with the extensions 58A (i.e., directly above the extensions 58A when the article of footwear 72 is disposed in the upright position shown in FIG. 9, resting with the outsole 73 on the ground surface GS), and float over the extensions 58A in the peripheral portion 21A of the interior cavity 21.

FIG. 9 shows the sole structure 70 also includes another midsole layer 71, such as a foam midsole layer, which is secured to and overlies the cushioning component 14 (e.g., secured to the first barrier sheet 16). The sole structure 70 also includes an outsole 73 secured to the bottom of the cushioning component 14 (e.g., to the second barrier sheet 18). A footwear upper 75 is secured to the sole structure 70 to support a foot over the cushioning component 14. The sole structure 70 is a non-limiting example, and the cushioning component 14 may be used in a sole structure with a different configuration than in FIG. 9.

Additionally, FIGS. 6, 7, and 9 best show that the bonds 47 of the third set are offset from the bonds 46 of the second set and from the bonds 44 of the first set, and each bond 46 of the second set is wider than adjacent bonds 47 of the third set. Furthermore, in an example, each bond 47 of the third set is not narrower than adjacent bonds 44 of the first set.

As shown in FIG. 9, some or all of the wavy bonds 46 of the second set progressively decrease in width from the heel region 54 to the forefoot region 50 of the article of footwear 72. For example, the bonds 46 generally decrease in width from a bond 46A in the heel region 54 to a bond 46B in the forefoot region 50 in FIG. 9. In some implementations, the bond 44 may also similarly decrease in width from the heel region 54 to the forefoot region 50.

Moreover, the bonds 44 are spaced closer to one another in the forefoot region 50 than in the heel region 54, and the bonds 46 are spaced closer to one another in the forefoot region 50 than in the heel region 54. This may also be illustrated by the bonds 46 of the second set of bonds and the bonds 47 of the third set of bonds. For example, the plurality of wavy bonds includes a first group of bonds (e.g., adjacent bonds 47C and 47D) in the forefoot region 50 and a second group of bonds (e.g., adjacent bonds 47A and 47B) in the heel region 54. Spacing between the adjacent bonds 47C and 47D of the first group of bonds is less than spacing between the adjacent bonds 47A and 47B of the second group of bonds such that the opposing inner surfaces 17, 19 of the barrier sheets 16, 18 are held closer to one another in the forefoot region 50 than in the heel region 54. This configuration also results in toe spring, which is the gradual increasing elevation of the second barrier sheet 18 away from the ground surface GS in the forefoot region 50 in a forward direction when in a steady state position (e.g., unloaded or at least not under a dynamic compressive load) as shown in FIG. 9. This pre-shaping of the cushioning component 14 with a toe spring via the bond placement helps to create a forward foot roll and easier toe-off during a forward motion of the wearer.

Referring to FIGS. 6-8, in addition to bond placement to promote toe spring, the medial and lateral edges 34C, 34D of the core 12 are spaced further inward of the peripheral bond 38 in the heel region 54 than in the forefoot region 50. This is best shown in FIG. 7 where a distance D1A from the lateral edge 34D of the core 12 to the peripheral bond 38 in the heel region 54 is greater than a distance D2A from the lateral edge 34D of the core 12 to the peripheral bond 38 in the forefoot region 50. This creates a larger and taller peripheral portion of the interior cavity 21 around the core 12 in the heel region 54 than in the forefoot region 50, as best shown in FIG. 9, which causes the cushioning component 14 to nest around the heel where the bonds 44 on the first barrier sheet 16 tend to pull the barrier sheet 16 down inward of peripheral portion 21A of the interior cavity 21 that is disposed outward of the core 12. Stated differently, as best shown in FIG. 8, the first barrier sheet 16 may recess slightly downward between the medial side 80 and the lateral side 82 above the core 12 in the heel region 54, helping to cup the heel.

FIG. 10 is a fragmentary and perspective cross-sectional view of a portion of the cushioning component 14 of FIG. 8 taken at lines 10-10 in FIG. 8 and showing some of the extensions 56A, 56B, 58A, and 58B of the core 12. As shown, the extensions 56A and 56B are directly bonded to one another at the bonds 59 while the extensions 58A and 58B are not directly bonded to one another. As such, some (but not all) of the extensions of the first set are directly bonded to some of the extensions of the second set.

FIG. 11 is a fragmentary and perspective cross-sectional view of a portion of an alternative cushioning component 14A configured as described with respect to the cushioning component 14 in FIG. 10 but having an alternate configuration of extensions of the core 12. Specifically, the extensions 56B and 56A are directly bonded to one another at bonds 59B. All of the extensions 56B and 58B of the first set are bonded to the respective extensions 56A and 58A of the second set in the example shown. All of the extensions 56A are directly bonded to the extensions 56B at bonds 59, and all of the extensions 58A are directly bonded to the extensions 58B at bonds 59B. In FIG. 2, for example, the anti-weld ink 24 is not disposed on the extensions 58A in order to result in bonds 59B shown in FIG. 11.

FIG. 12 is a fragmentary and perspective cross-sectional view of a portion of an alternative cushioning component 14B configured as described with respect to the cushioning component 14 in FIG. 10 but having an alternate configuration of extensions of the core 12. Specifically, the extensions 58B and 56B are directly bonded to one another at bonds 59B but the extensions 56A are not directly bonded to the extensions 56B. As such, some (but not all) of the extensions of the first set are directly bonded to some of the extensions of the second set.

FIG. 13 is a fragmentary and perspective cross-sectional view of a portion of an alternative cushioning component 14C configured as described with respect to the cushioning component 14 in FIG. 10 but having an alternate configuration of extensions of the core 12. Specifically, the extensions 58B and 56B are not directly bonded to one another and the extensions 56A are not directly bonded to the extensions 56B. In fact, none of the extensions 56B, 58B of the first set are bonded to any of the extensions 56A, 58A of the second set.

FIGS. 14-16 show predetermined patterns of anti-weld material 24 like those of FIGS. 1-3 but to result in a different second set of extensions 156A and first set of extensions 156B. The predetermined pattern of anti-weld material 24 on the second side 13 of the second polymeric sheet 11 in FIG. 14 is referred to as a second predetermined pattern and results in the second set of bonds 46. The entire extensions 156A at the second side 13 are covered with anti-weld material 24. The predetermined pattern of anti-weld material 24 on the first side 15 of the second polymeric sheet 11 in FIG. 15 is referred to as a third predetermined pattern and results in the third set of bonds 47 as well as bonds 159 of the extensions 156A. The extensions 156A at the first side 15 are covered with anti-weld material 24 except at bonding areas 159A. The predetermined pattern of anti-weld material 24 on the first side 22 of the first polymeric sheet 10 shown in FIG. 16 is referred to as a first predetermined pattern and results in the first set of bonds 44. The areas D1, E1, F1, G1, and H1 are replaced by a single larger area D2 such that there are only six unbonded areas 22A, 22B, 22C, 22D, 22E, and 22F on the first side 22, and only six resulting bonds 44 in the forefoot region 50 and the midfoot region 52 as shown in FIG. 17, with no bonds 44 in the heel region 54. Much of the core 112 is thus not bonded to the inner surface 17 of the first barrier sheet 16 in the midfoot region 52 and is not bonded to the inner surface 17 at all in the heel region 54, as indicated in FIGS. 17 and 18. The extensions 156B at the first side 22 of the first polymeric sheet 10 are covered with anti-weld material 24. No anti-weld material 24 is disposed on the second side 26 of the first polymeric sheet 10. The extensions 156A are bonded to the extensions 156B at bonds 159 at the bonding areas 159A. The extensions 156B of the first polymeric sheet 10 may be referred to as a first set of extensions. The extensions 156A of the second polymeric sheet 11 may be referred to as a second set of extensions.

When the sheets 10, 11 are trimmed, stacked, and thermally bonded with barrier sheets 16, 18 as discussed, an alternative cushioning component 114 results, shown in FIGS. 17-20, including a bladder 120 and a core 112 with the first set of extensions 156B bonded to the second set of extensions 156A at the bonds 159 and only at the bonds 159, the first set of bonds 44 securing the first polymeric sheet 10 to the first barrier sheet 16 (but only in the forefoot region 50 and the midfoot region 52), the second set of bonds 46 securing the second polymeric sheet 11 to second barrier sheet 18 as in the core 12, and the third set of bonds 47 securing the first polymeric sheet 10 to the second polymeric sheet 11 as in the core 12. The extensions 156A and 156B extend laterally outward from the medial edge 34C and the lateral edge 34D of the core 112 into the peripheral portion 21A of the interior cavity 21 and are not bonded to the first barrier sheet 16 in the peripheral portion 21A and are not bonded to the second barrier sheet 18 in the peripheral portion 21A. As with the core 12, gas in the interior cavity 21 is in fluid communication around the sheets 10, 11 of the core 112 without the sheets 10, 11 (including the extensions 156A, 156B thereof) creating any sealed chambers within the bladder 120 that are not in fluid communication with the interior cavity 21. In other words, the core 112 does not subdivide the interior cavity 21 into separate, sealed chambers.

As shown, the extensions 156A and the extensions 156B have the same shape. Additionally, as indicated by FIGS. 14-17, legs 162 of the extensions 156B are aligned with the bonds 44, legs 162 of the extensions 156A are aligned with the bonds 46, and the center strips 161 of the extensions 156A are aligned with the bonds 47 at the medial edge 34C of the core 112 and at the lateral edge 34D of the core 112. FIG. 19 provides a close-up view of some of the bonded extensions 156A, 156B.

The medial edge 34C and the lateral edge 34D of the core 112 are each part of the outer perimeters 34A and 34B of the respective polymeric sheets 10, 11 of the core 112. The outer perimeter 34A includes the medial edge 34C and lateral edge 34D of the first polymeric sheet 10 and the extensions 156A extending therefrom. The outer perimeter 34B includes the medial edge 34C and the lateral edge 34D of the second polymeric sheet 11 and the extensions 156B extending therefrom.

Each extension 156A and each extension 156B has a pair of apertures 160 such that a center strip 161 of the extension 156A or 156B is disposed between the apertures 160 and legs 162 of the extensions 156A or 156B border the apertures 160. Only one of the extensions 156A and one of the extensions 156B has the apertures 160 and center strip 161 indicated with reference numbers in FIGS. 14-16 for clarity in the drawings. In FIG. 17, only some of the extensions 156A, 156B are labeled, and each are bonded to one another at bonds 159 (resulting from the unbonded areas 159A) like those shown in FIG. 19. In other examples, the center strip 161 could be eliminated in some or all of the extensions 156A, 156B such that the extension 156A, 156B has only one larger aperture. In still other examples, there could be more than two apertures in some or all of the extensions 156A, 156B. In any of these examples, the aperture or apertures could have a shape other than the triangular shapes shown. In other examples, there could be no aperture or apertures in some or all of the extensions 156A, 156B.

Because the inner surface 17 of the first barrier sheet 16 is not bonded to the first side 22 of the first polymeric sheet 10 in the heel region 54 inward of the peripheral bond 38, the bladder 120 is taller in the heel region 54 than in the midfoot region 52 and the forefoot region 50. In the example shown in FIG. 18, the bladder 120 is at least twice as tall in the heel region 54 than in the forefoot region 50 as indicated by a comparison of a height H2A in the heel region 54 to a height H2B in the forefoot region 50, where the heights H2A and H2B are measured at a longitudinal midline LM of the bladder 120 from the first barrier sheet 16 to the second barrier sheet 18.

In an example, a sole structure 170 for an article of footwear is shown in FIG. 20 that includes the cushioning component 114 and a foam midsole layer 171 that may be used in the article of footwear 72 of FIG. 9 in place of the cushioning component 14 and foam midsole layer 71. Specifically, due to the height differential between the heights H2A and H2B of the heel region 54 and the forefoot region 50 of bladder 120, the foam midsole layer 171 extends in the midfoot region 52 and in the forefoot region 50, overlaying a top side of the bladder 120 (e.g., overlaying the first barrier sheet 16). The foam midsole layer 171 does not overlay the heel region 54 in the example shown. In other examples, the foam midsole layer 171 could be extended to overlay a front half 54AA of the heel region 54 but not a rear half 54BB of the heel region 54. By terminating the foam midsole layer 171 in the midfoot region 52, or at least forward of the rear half 54B of the heel region 54, the foam midsole layer 171 adds height in the forefoot region 50 but not in at least the rear half 54BB of the heel region 54, and thus helps to lessen the height differential of the forefoot region 50 relative to the heel region 54.

FIGS. 21-23 show an alternative cushioning component 214 in an inflated state. The cushioning component includes a bladder 220 that utilizes the first and second barrier sheets 16, 18 sealed to one another at a peripheral bond 38 as previously described and a single-sheet core 212 bonded to the opposing inner surfaces 17, 19 at a pattern of bonds 44 and 46, respectively. The core 212 is disposed in the interior cavity and spaced entirely inward of the peripheral bond. The core 212 includes only the single polymeric sheet 10 traversing the interior cavity 21 between and directly bonded to the opposing inner surfaces 17, 19 at the bonds 44, 46 to tether the first barrier sheet 16 to the second barrier sheet 18. The four edges 234A, 234B, 234C, and 234D of the outer perimeter 234 of the core 212 are shown entirely inward of the peripheral bond in FIGS. 21 and 22. The polymeric sheet 10 is displaced from the opposing inner surfaces 17, 19 by the gas at unbonded areas of the at least one polymeric sheet 10 (e.g., all areas where blocker ink 24 is disposed on the first and second sides 22, 26 of the polymeric sheet 10.

As best shown in FIG. 22, the polymeric sheet 10 includes the medial edge 234C and the lateral edge 234D at which the plurality of bonds 44, 46 terminate, and includes extensions 256 extending laterally outward from the medial edge 234C and from the lateral edge 234D into the peripheral portion 21A of the interior cavity 21 and not bonded to the first barrier sheet 16 in the peripheral portion 21A and not bonded to the second barrier sheet 18 in the peripheral portion 21A. Because no portion of any of the extensions 256 is bonded to either of the barrier sheets 16, 18, the extensions 56A, 58A, 256 float in the peripheral portion 21A.

FIG. 23 shows that the tension created in the polymeric sheet 10 by the inflation of the interior cavity 21 causes portions of the first barrier sheet 16 inward of the outer perimeter 234 of the core 212 to be pulled downward at the bonds 44, as indicated by the contoured exterior surface 250 of the first barrier sheet 16. Because the outer perimeter 234 of the core 212 is entirely inward of the peripheral bond 38, the barrier sheets 16, 18 will not be tethered together at a peripheral portion of the interior cavity 21 outward of the outer perimeter 234 of the core 212 and inward of the peripheral bond 38. The distance between the inner surfaces 17 and 19 and the resulting height of the cushioning component 214 may thus be greatest outward of the core 212. The top exterior surface 250 is represented with hidden lines where the first barrier sheet 16 is pulled downward by polymeric sheet 10 at the bonds 44.

Similarly, tension created in the polymeric sheet 10 by the inflation of the interior cavity 21 causes portions of the second barrier sheet 18 inward of the outer perimeter 234 of the core 212 to be pulled upward at the bonds 46, as indicated by the contoured exterior surface 252 of the second barrier sheet 18. The pattern of blocker ink 24 printed on the polymeric sheet 10 and the resulting patterns of bonds 44, 46 of the polymeric sheet 10 of the core 212 to the barrier sheets 16, 18 can be selected to control the resulting contours of the exterior surfaces 250, 252 of the barrier sheets 16, 18.

The following Clauses provide example configurations of an article of footwear having a cushioning component as disclosed herein.

Clause 1. An article of footwear comprising: a sole structure having a cushioning component including: a bladder including a first barrier sheet and a second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity; and a core disposed in the interior cavity and spaced entirely inward of the peripheral bond, the core including at least one polymeric sheet traversing the interior cavity between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonds to tether the first barrier sheet to the second barrier sheet, the at least one polymeric sheet displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet; and wherein the at least one polymeric sheet of the core includes a medial edge and a lateral edge at which the plurality of bonds terminate, and includes one or more extensions extending laterally outward from the medial edge or from the lateral edge into a peripheral portion of the interior cavity, the one or more extensions not bonded to the first barrier sheet in the peripheral portion and not bonded to the second barrier sheet in the peripheral portion.

Clause 2. The article of footwear of clause 1, wherein the plurality of bonds are configured such that the gas in the interior cavity is in fluid communication around the at least one polymeric sheet without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity.

Clause 3. The article of footwear of any of clauses 1-2, wherein: the at least one polymeric sheet of the core includes a first polymeric sheet and a second polymeric sheet; and the first polymeric sheet includes a first set of the extensions and the second polymeric sheet includes a second set of the extensions.

Clause 4. The article of footwear of clause 3, wherein at least one of the extensions of the first polymeric sheet is bonded to at least one of the extensions of the second polymeric sheet.

Clause 5. The article of footwear of clause 4, wherein all of the extensions of the first polymeric sheet are bonded to the extensions of the second polymeric sheet.

Clause 6. The article of footwear of clause 4, wherein only some of the extensions of the first polymeric sheet are bonded to the extensions of the second polymeric sheet.

Clause 7. The article of footwear of any of clauses 1-2, wherein: the one or more extensions include multiple extensions; the bladder includes a forefoot region, a midfoot region, and a heel region; and the extensions are disposed in at least two of the forefoot region, the midfoot region, and the heel region.

Clause 8. The article of footwear of any of clauses 1-2, wherein: the one or more extensions include multiple extensions; and at least some of the extensions have different shapes.

Clause 9. The article of footwear of any of clauses 1-2, wherein: the one or more extensions include multiple extensions; and the multiple extensions are aligned with the plurality of bonds at the medial edge of the core and at the lateral edge of the core.

Clause 10. The article of footwear of any of clauses 1-2, the one or more extensions have an aperture.

Clause 11. The article of footwear of any of clauses 1-2, wherein: the bladder includes a forefoot region, a midfoot region, and a heel region; and the core is not bonded to the first barrier sheet in the heel region.

Clause 12. The article of footwear of clause 11, wherein the inner surface of the first barrier sheet is not bonded to the first polymeric sheet in the heel region inward of the peripheral bond such that the bladder is taller in the heel region than in the midfoot region and the forefoot region.

Clause 13. The article of footwear of clause 12, wherein the bladder is at least twice as tall in the heel region than in the forefoot region.

Clause 14. The article of footwear of any of clauses 1-2, wherein the bladder includes a forefoot region, a midfoot region, and a heel region; and the article of footwear further comprising a foam midsole layer extending in the midfoot region and in the forefoot region and overlaying a top side of the bladder.

Clause 15. The article of footwear of clause 14, wherein the foam midsole layer does not overlay at least a rear half of the heel region.

Clause 16. The article of footwear of any of clauses 1-2, wherein anti-weld material is disposed on the core at the unbonded areas.

Clause 17. The article of footwear of clause 1, wherein: the opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the at least one polymeric sheet of the core includes a first polymeric sheet and a second polymeric sheet, the first polymeric sheet disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces the first inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces the second inner surface of the second barrier sheet; and the first side of the first polymeric sheet is directly bonded to the first inner surface of the first barrier sheet at a first set of bonds of the plurality of bonds, the second side of the second polymeric sheet is directly bonded to the second inner surface of the second barrier sheet at a second set of bonds of the plurality of bonds, the second side of the first polymeric sheet is directly bonded to the first side of the second polymeric sheet at a third set of bonds of the plurality of bonds, the bonds of the third set alternating with the bonds of the first set along a length of the core, and the bonds of the third set alternating with the bonds of the second set along the length of the core.

Clause 18. An article of footwear comprising: a sole structure having a cushioning component including: a bladder including a first barrier sheet and a second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity; and a core disposed in the interior cavity and spaced inward of the peripheral bond, the core including a first polymeric sheet and a second polymeric sheet, the first polymeric sheet disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces an inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces an inner surface of the second barrier sheet; wherein the first side of the first polymeric sheet is directly bonded to the inner surface of the first barrier sheet at a first set of spaced bonds, the second side of the second polymeric sheet is directly bonded to the inner surface of the second barrier sheet at a second set of spaced bonds, the second side of the first polymeric sheet is directly bonded to the first side of the second polymeric sheet at a third set of spaced bonds, the first barrier sheet thereby tethered to the second barrier sheet by the core, and the core displaced from the opposing inner surfaces by the gas at unbonded areas of the core; wherein the core includes a medial edge and a lateral edge at which the first, second, and third sets of spaced bonds terminate; wherein the first polymeric sheet includes a first set of extensions extending laterally outward from the medial edge or from the lateral edge into a peripheral portion of the interior cavity, the first set of extensions not bonded to the first barrier sheet in the peripheral portion and not bonded to the second barrier sheet in the peripheral portion; and wherein the second polymeric sheet includes a second set of extensions extending laterally outward from the medial edge or from the lateral edge into the peripheral portion of the interior cavity and bonded to the first set of extensions.

Clause 19. The article of footwear of clause 18, wherein: the first set of extensions and the second set of extensions are laterally aligned with some of the bonds at the medial edge of the core and at the lateral edge of the core; and/or at least one of the extensions of the first set is bonded to at least one of the extensions of the second set.

Clause 20. The article of footwear of clause 18, wherein: the bladder includes a forefoot region, a midfoot region, and a heel region; and the core is not bonded to the first barrier sheet in the heel region.

To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Additionally, all references referred to are incorporated herein in their entirety.

An “article of footwear”, a “footwear article of manufacture”, and “footwear” may be considered to be both a machine and a manufacture. Assembled, ready to wear footwear articles (e.g., shoes, sandals, boots, etc.), as well as discrete components of footwear articles (such as a midsole, an outsole, an upper component, etc.) prior to final assembly into ready-to-wear footwear articles, are considered and alternatively referred to herein in either the singular or plural as “article(s) of footwear”.

“A”, “an”, “the”, “at least one”, and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.

The terms “comprising”, “including”, and “having” are 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. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of” is understood to include any possible combination of referenced items, including “any one of” the referenced items. The term “any of” is understood to include any possible combination of referenced claims of the appended claims, including “any one of” the referenced claims.

For consistency and convenience, directional adjectives may be employed throughout this detailed description corresponding to the illustrated embodiments. Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may be used descriptively relative to the figures, without representing limitations on the scope of the invention, as defined by the claims.

The term “longitudinal” particularly refers to a direction extending a length of a component. For example, a longitudinal direction of a shoe extends between a forefoot region and a heel region of the shoe. The term “forward” or “anterior” is used to particularly refer to the general direction from a heel region toward a forefoot region, and the term “rearward” or “posterior” is used to particularly refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

The term “transverse” particularly refers to a direction extending a width of a component. For example, a transverse direction of a shoe extends between a lateral side and a medial side of the shoe. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

The term “vertical” particularly refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole. The term “upward” or “upwards” particularly refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term “downward” or “downwards” particularly refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.

The “interior” of an article of footwear, such as a shoe, particularly refers to portions at the space that is occupied by a wearer's foot when the shoe is worn. The “inner side” of a component particularly refers to the side or surface of the component that is (or will be) oriented toward the interior of the component or article of footwear in an assembled article of footwear. The “outer side” or “exterior” of a component particularly refers to the side or surface of the component that is (or will be) oriented away from the interior of the shoe in an assembled shoe. In some cases, other components may be between the inner side of a component and the interior in the assembled article of footwear. Similarly, other components may be between an outer side of a component and the space external to the assembled article of footwear. Further, the terms “inward” and “inwardly” particularly refer to the direction toward the interior of the component or article of footwear, such as a shoe, and the terms “outward” and “outwardly” particularly refer to the direction toward the exterior of the component or article of footwear, such as the shoe. In addition, the term “proximal” particularly refers to a direction that is nearer a center of a footwear component, or is closer toward a foot when the foot is inserted in the article of footwear as it is worn by a user. Likewise, the term “distal” particularly refers to a relative position that is further away from a center of the footwear component or is further from a foot when the foot is inserted in the article of footwear as it is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposing terms to describe 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 used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, 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 attached claims.

While several modes for carrying out the 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 entire range of alternative embodiments that an ordinarily skilled artisan would recognize as implied by, structurally and/or functionally equivalent to, or otherwise rendered obvious based upon the included content, and not as limited solely to those explicitly depicted and/or described embodiments.