Article of footwear with first and second outsole components and method of manufacturing an article of footwear

A sole structure for an article of footwear comprises a midsole including a polymeric bladder element enclosing a fluid-filled interior cavity, a first outsole component secured to a bottom surface and to a side surface of the polymeric bladder element, and a second outsole component. The first outsole component includes a first base, and a wall integral with the first base. The second outsole component includes a second base secured to the first base, and a wall integral with the second base and secured to the outer surface of the wall of the first outsole component. A method of manufacturing the article of footwear includes thermoforming the bladder element and the first outsole component, and securing the second outsole component to the first outsole component.

TECHNICAL FIELD

The present teachings generally relate to an article of footwear including a sole structure, and to a method of manufacturing the article of footwear.

BACKGROUND

Footwear typically includes a sole structure configured to be located under a wearer's foot to space the foot away from the ground or floor surface. Athletic footwear in particular sometimes utilizes polyurethane foam, rubber, or other resilient materials in the sole structure to provide cushioning.

DESCRIPTION

A sole structure for an article of footwear includes a midsole having a polymeric bladder element enclosing a fluid-filled interior cavity, a first outsole component, and a second outsole component. The first outsole component is secured to a bottom surface and to a side surface of the polymeric bladder element. The first outsole component includes a first base, and a wall integral with the first base. The second outsole component includes a second base secured to the first base, and a wall integral with the second base and secured to the outer surface of the wall of the first outsole component.

In an embodiment, the first outsole component may be a first material, such as a thermoplastic polyurethane, and the second outsole component may be a second material, such as rubber.

In an embodiment, the bladder element has an arcuate tubular portion in a forefoot region of the sole structure. The side surface of the bladder element is at an inner curved wall of the bladder element at the arcuate tubular portion. In this configuration, the wall of the second outsole component supports and reinforces the inner curved wall of the bladder element, such as during dorsiflexion of the forefoot region.

In an embodiment, the first base has integral tread elements protruding at a first portion of a bottom surface of the first base, but a second portion of the bottom surface is free of any tread elements. The wall of the first outsole component has an outer surface adjacent the second portion of the bottom surface. The second base of the second outsole component is secured to the second portion of the bottom surface of the first base. Accordingly, the first tread elements do not interfere with the second base. Moreover, a ground-engaging surface of the sole structure includes the integral tread elements of the first outsole component and includes the second outsole component. The second outsole component may also have tread elements that are included in the ground-engaging surface.

In an embodiment, the first outsole component is a first material and the second outsole component is a second material different than the first material. For example, the first outsole component may be a thermoplastic polyurethane, and the second outsole component may be rubber. The second material may be selected to provide durability to the ground-engaging surface and reinforcing support to tune the cushioning response of the first outsole component.

In an embodiment, the outer surface of the wall of the first outsole component has a recess adjacent the second portion of the bottom surface of the first outsole component. The wall of the second outsole component may be secured to the outer surface of the wall of the first outsole component in the recess. The wall of the second outsole component is thus nested in the recess, which protects the wall of the second outsole component from forces that could cause delamination. In one embodiment, the wall of the second outsole component has a first thickness, the recess has a first depth, and the first thickness is greater than the first depth so that the second outsole component protrudes outward of the first outsole component at the wall of the first outsole component.

In an embodiment, the wall of the first outsole component is an outer wall of the first outsole component and the wall of the second outsole component is an outer wall of the second outsole component. The first outsole component has an inner wall integral with the first base, and the recess extends only partway up the outer wall of the first outsole component, along the bottom surface of the base, and up the inner wall of the first outsole component. The second outsole component has an inner wall integral with the second base and secured to an outer surface of the inner wall of the first outsole component. The inner wall of the second outsole component extends further upward along the first outsole component than the outer wall of the second outsole component.

In an embodiment, the polymeric bladder element is configured so that at least a portion of the fluid-filled interior cavity has a U shape with an arcuate portion at an outer periphery of the sole structure. The first outsole component has a U shape corresponding to the U shape of the fluid-filled interior cavity with the wall of the first outsole component at the arcuate portion of the fluid-filled interior cavity.

In an embodiment, the second outsole component has a plurality of integral second tread elements protruding from a bottom surface of the second outsole component. The first tread elements and the second tread elements establish a ground-engaging surface of the sole structure.

The article of footwear may include an upper. The midsole, the first outsole component, and the second outsole component may be configured as a forefoot sole structure secured to a forefoot region of the upper, and the sole structure may also include a heel sole structure secured to a heel region of the upper. The heel sole structure may include a midsole with a polymeric bladder element enclosing a separate fluid-filled interior cavity isolated from the fluid-filled interior cavity of the polymeric bladder element of the forefoot sole structure, a first outsole component secured to a bottom surface of the bladder element of the heel sole structure, and a second outsole component secured to the first outsole component of the heel sole structure.

A method of manufacturing an article of footwear comprises placing a preformed first outsole component into a thermoforming mold. The preformed first outsole component has a base with integral tread elements protruding from a first portion of a bottom surface of the base, and with a second portion of the bottom surface free of any tread elements. The first outsole component also has a wall integral with the base and adjacent the second portion of the bottom surface. The method includes placing polymeric material in the thermoforming mold with the first outsole component, and closing the thermoforming mold to enclose the polymeric material and the first outsole component in a mold cavity. A vacuum is applied to conform a first portion of the polymeric material to a first mold surface of the thermoforming mold and to conform a second portion of the polymeric material to an upper surface of the first outsole component and to a second mold surface of the thermoforming mold, with an interior cavity between the first portion and the second portion.

The first portion of the polymeric material may be a first polymeric sheet, and the second portion of the polymeric material may be a second polymeric sheet. The method may further include thermally bonding the first polymeric sheet to the second polymeric sheet to enclose the interior cavity, thermally bonding the lower surface of the second polymer sheet to the upper surface of the first outsole component, and removing the thermally bonded upper and lower polymer sheets and first outsole component from the thermoforming mold as a unit after a predetermined cooling period.

A second outsole component may be positioned on the second portion of the bottom surface of the first outsole component, and adhered to the first outsole component. For example, positioning the second outsole component may be by nesting the second outsole component in a recess in the outer surface of the wall of the first outsole component. Nesting the second outsole component in the recess may include placing an upper edge of the second outsole component along a lip of the first outsole component at an upper extent of the recess.

The method may include securing a footwear upper to an upper surface of the first polymer sheet. The first and the second polymer sheets, the first outsole component, and the second outsole component may be configured as a forefoot sole structure and secured to a forefoot region of the footwear upper, and the method may include securing a heel sole structure to a heel region of the footwear upper with a forward edge of the heel sole structure adjacent a rearward edge of the forefoot sole structure.

The second mold surface may have a positioning marker, and placing the first outsole component into the thermoforming mold may include placing a predetermined portion of the first outsole component at the positioning marker, thereby orienting the first outsole component in a predetermined position in the thermoforming mold.

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.

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.

In an embodiment, the shaped article may be a cushioning layer and an outsole of an article of footwear.FIG. 1illustrates such an embodiment.FIG. 1is a cross-sectional view of an article of footwear including a co-molded article. An article of footwear100includes an upper120and a sole structure130. Upper120provides a comfortable and secure covering for a foot of a wearer. As such, the foot may be located within upper120to effectively secure the foot within article of footwear100or otherwise unite the foot and article of footwear100. Sole structure130is secured to a lower area of upper120and extends between the foot and the ground to attenuate ground reaction forces (i.e., cushion the foot), provide traction, enhance stability, and influence the motions of the foot, for example. In effect, sole structure130is located under the foot and supports the foot.

Upper120is depicted as having a substantially conventional configuration. A majority of upper120incorporates various material elements (e.g., textiles, foam, leather, and synthetic leather) that are stitched or adhesively bonded together to produce an interior void for securely and comfortably receiving a foot. The material elements may be selected and located in upper120to selectively impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort, for example. The void in upper120is shaped to accommodate the foot. When the foot is located within the void, therefore, upper120extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. A lace122extends over a tongue123. Lace122and the adjustability provided by tongue123may be utilized in a conventional manner to modify the dimensions of the interior void, thereby securing the foot within the interior void and facilitating entry and removal of the foot from the interior void. Sockliner125may enhance the comfort of article of footwear100.

Further configurations of upper120may also include one or more of (a) a toe guard positioned in forefoot region and formed of a wear-resistant material, (b) a heel counter located in heel region for enhancing stability, and (c) logos, trademarks, and placards with care instructions and material information. Given that various aspects of the present discussion primarily relate to sole structure130, upper120may exhibit the general configuration discussed above or the general configuration of practically any other conventional or non-conventional upper. Accordingly, the structure of upper120may vary significantly.

FIG. 3andFIG. 4illustrate a way of producing a sole structure such as but not limited to sole structure130ofFIG. 1.FIG. 3andFIG. 4depict a cross-section of a mold for co-molding fluid-filled chamber140with outsole160with protuberances135thereon. Outsole160may be produced by a number of pre-formed objects or elements assembled in the mold. In some embodiments, outsole160wraps at least a portion of edge143on fluid-filled chamber140. Molded article131is an embodiment of an article having outsole160wrapping a significant portion of the edge of fluid-filled chamber140. As the components are produced of thermoplastic materials, they may be softened to aid in producing the shapes in the mold.

Stated generally, the co-molded article may be produced in a two-piece mold with an upper and a lower mold portion by placing outsole elements into the lower mold portion, then placing the layers that will form the fluid-filled chamber140on top of the outsole elements. The mold is then closed so that the upper and lower mold portions abut one another. The mold is shaped so that the closing the mold results in the formation of the chamber. Fluid under pressure is then introduced into the chamber so that the inflation of the chamber forces the upper surface of the chamber into conforming relationship with the underside of the upper mold portion, and also forces the lower portion of the chamber into conforming relationship with the outside elements underneath. Energy may be applied to the mold as heat, radio frequency, or the like to co-mold the first and second elements together with the chamber inflated and pushing the article against the mold surfaces and the outsole elements. The second element portions such as layers of polymer may be provided in the mold as a precursor for the completed product. Such precursor may be formed in the mold as part of the co-molding process as described herein, or may be provided as completely pre-formed chamber that is ready for inflation.

A variety of manufacturing processes may be utilized to produce sole structure131. In some embodiments, mold300that may be utilized in the manufacturing process is depicted as including a first mold portion310and a second mold portion320. Mold300is utilized to produce fluid-filled chamber140from a first polymer layer410and a second polymer layer420, which are the polymer layers producing fluid-filled chamber upper surface141and fluid-filled chamber lower surface142, respectively. More particularly, mold300facilitates the manufacturing process by (a) shaping first polymer layer410and second polymer layer420in areas corresponding with edges143of the fluid-filled chambers140, flange146, and conduits between chambers, and (b) joining first polymer layer410and second polymer layer420in areas corresponding with flange146and web area147.

Various surfaces or other areas of mold300will now be defined for use in discussion of the manufacturing process. First mold portion310includes a first mold portion surface350, which shapes the top surface of the co-molded article. Various parts of a first element, such as outsole160, and a second element, such as a fluid-filled chamber140, are illustrated inFIG. 3. Second mold portion320is shaped so as to receive protuberances135in close engagement with slots325in second mold portion320. Outsole160then is placed in the mold. Outsole160fits within undercut335. Then, second element precursor or first polymer layer410is put into place to become the top surface of the article and second element precursor or second polymer layer420produces the bottom or lower surface142of the second element, herein the fluid-filled chamber, when the article is molded.

As first mold portion310and second mold portion320are moved toward each other, various techniques may be utilized to draw first polymer layer410and second polymer layer420against surfaces of first mold portion310and second mold portion320, thereby beginning the process of shaping first polymer layer410and second polymer layer420. For example, air may be partially evacuated from the areas between (a) first mold portion310and first polymer layer410and (b) second mold portion320and second polymer layer420. More particularly, air may be withdrawn through various vacuum ports in first mold portion310and second mold portion320. By removing air, first polymer layer410is drawn into contact with the surfaces of first mold portion310and second polymer layer420is drawn into contact with the surfaces of second mold portion320. As another example, fluid may be injected into the area between first polymer layer410and second polymer layer420, thereby elevating the pressure between first polymer layer410and second polymer layer420. During a preparatory stage of this process, an injection needle may be located between first polymer layer410and second polymer layer420, and a fluid, such as a gas, a liquid, or a gel, for example, or a blend thereof, then may be ejected from the injection needle such that first polymer layer410and second polymer layer420engage the surfaces of mold300. Each of these techniques may be used together or independently.

As first mold portion310and second mold portion320continue to move toward each other, first polymer layer410and second polymer layer420are pinched between first mold portion310and second mold portion320. More particularly, first polymer layer410and second polymer layer420are compressed between pinch surface330and pinch edge360. In addition to beginning the process of separating excess portions of first polymer layer410and second polymer layer420from portions that form fluid-filled chamber140, the pinching of first polymer layer410and second polymer layer420begins the process of bonding or joining first polymer layer410and second polymer layer420in the area of flange146.

Following the pinching of first polymer layer410and second polymer layer420, first mold portion310and second mold portion320proceed with moving toward each other and into a closed configuration, as depicted inFIG. 4. As the mold closes, pinch surface330contacts and slides against a portion of second seam-forming surface370. The contact between pinch surface330and second seam-forming surface370effectively severs excess portions of first polymer layer410and second polymer layer420from portions that form fluid-filled chamber140. The material forming first polymer layer410and second polymer layer420compacts or otherwise collects to form flange146. In addition to forming flange146, first polymer layer410and second polymer layer420are (a) shaped to produce fluid-filled chamber140and (b) compressed and joined to produce web area147.

When producing of fluid-filled chamber140is complete, mold300is opened. Fluid then may be injected into fluid-filled chamber140to pressurize forefoot component fluid-filled chambers145, thereby completing the manufacture of structure131. As a final step in the process, structure131may be incorporated into a sole structure of an article of footwear100.

Co-molded articles may have many uses.FIG. 5illustrates a tank or other container.FIG. 5depicts molding of a tank or other container. Mold600includes first mold portion610having mold surface650. Second mold portion620includes slots625to securely engage protuberances535on first element560. Second polymer layer520and first polymer layer510are in position in the open mold. After first element560is inserted into the mold, second polymer layer520will form the layer of the tank in contact with first element560. First polymer layer510will form the upper surface of the tank.

FIG. 6illustrates mold600closed to form tank or article570within the mold. Surface650of first mold portion610shapes upper surface512of top layer506of the article. A sealed tank may be produced by fusing or adhering the polymer layers at flange546, which may extend around the periphery of the tank. Protuberances535on first element560fit closely in slots625in the second portion620of the mold.

Whereas the method and the molds described previously shape parts satisfactorily, the skilled practitioner recognizes that it may be difficult to extract the co-molded article from the mold. So long as the co-molded article is sufficiently flexible and resilient, the article may be deformed slightly to remove it from the undercut mold. However, protuberances formed on the outer surface of a co-molded article in slots and other features that extend the article into the mold may make it very difficult to remove the article from the mold.

Therefore, this disclosure is directed to co-molding articles in a mold that minimizes contact between protuberances on the article and surfaces of the mold. The co-molded article may include a pre-formed article. In some embodiments, the pre-formed article is capable of essentially retaining its shape. In such embodiments, a first element may be a pre-formed element placed in a mold wherein the interior surface is essentially uninterrupted by slots and other features in which protuberances may be formed. Rather, in such embodiments, the first element is placed in the mold with minimal interference or contact between the protuberances and the mold. The element essentially retains its shape when placed in the mold. In some embodiments, a base or end surface of a protuberance may contact the surface of the mold, but the sides of the protuberances are essentially free of contact with the mold. In this way, the co-molded article may be easily removed from the mold.

In some embodiments, a sole structure for an article of footwear may be made in accordance with a method for co-molding a first element and a second element to produce a co-molded article.FIG. 7,FIG. 8, andFIG. 9depict stages of this method for co-molding a sole structure of an article of footwear. Mold700may have a first mold portion710and a second mold portion720. Shape750on first mold portion710may form the top surface741of the co-molded article.

The first element760may have top surface761, edge surface762, and protuberance735having base737opposite top surface761. Edge surface762may extend any distance away from top surface761. First element760also may have bottom surface794. The second element765may have edge743, upper surface741, and lower surface764.

Any suitable polymeric material may be used to produce the first element, which would be an outsole as depicted inFIG. 7. Although each feature is illustrated in the figures as a single layer, each such feature may comprise a single layer of material or multiple layers, and may be thermoformed or otherwise shaped. Examples of polymeric materials that may be utilized for such a sole structure include any of polyurethane, urethane, polyester, polyester polyurethane, polyether, polyether polyurethane, latex, polycaprolactone, polyoxypropylene, polycarbonate macroglycol, and blends thereof. These and other polymeric materials, an exemplary embodiment, and a method for manufacturing them, may be found in U.S. Pat. No. 9,420,848 to Campos II et al., the entirety of which is hereby incorporated by reference.

An outsole typically may be produced from any durable material. Typically, outsole material is tough, durable, resistant to abrasion and wear, flexible, and skid-resistant. In some embodiments, polyurethane materials sufficiently durable for ground contact. Suitable thermoplastic polyurethane elastomer materials include Bayer Texin®285, available from Bayer. Elastollan® SP9339, Elastollan® SP9324, and Elastollan® C705, available from BASF, also are suitable. Polyurethane and other polymers that may not be sufficiently durable for direct ground contact may be used to produce part of an outsole in some embodiments. In such embodiments, a rubber outsole may be adhered or cemented onto the outsole. In embodiments, the outsole material is transparent or translucent. In embodiments, ground-engaging lugs may be integrally produced as part of an outsole, or may be separately produced and adhered to the outsole. The outsole may have a textured ground-engaging surface to improve traction.

As depicted inFIG. 7,FIG. 8, andFIG. 9, first element760may be an outsole. For such an embodiment, in accordance with the method, outsole760is located in second mold portion720with base737of protuberance735in contact with surface780of second mold portion720. Surface780of second mold portion720is shaped so as to not contact a significant fraction of protuberance735other than base737. Protuberance735may be considered to be a ground-engaging portion, with an end thereof being a base737that engages the ground. As depicted with particularity inFIG. 7andFIG. 8, outsole760may have a slight arc or curve that cause edge762to not contact edge862of second mold portion720. Not all bases737may touch surface780simultaneously before molding with a second element.

Precursor for a second element, a fluid-filled chamber, is placed in the mold and the mold is closed. First polymer layer810may form top surface741of second element765. Second polymer layer820may form edge743of second element765and lower surface or bottom764of second element or fluid-filled chamber765.

Each of first polymer layer810and second polymer layer820are initially located between first mold portion710and second mold portion720, which are in a spaced or open configuration, as depicted inFIG. 7. In this position, first polymer layer810is positioned adjacent or closer to first mold portion710, and second polymer layer820is positioned adjacent or closer to second mold portion720. A shuttle frame or other device may be utilized to properly position first polymer layer810and second polymer layer820. As part of the manufacturing process, one or both of first polymer layer810and second polymer layer820are heated to a temperature that facilitates shaping and bonding. As an example, various radiant heaters or other devices may be utilized to heat first polymer layer810and second polymer layer820, possibly prior to being located between first mold portion710and second mold portion720. As another example, mold700may be heated such that contact between mold700and first polymer layer810and second polymer layer820at a later potion of the manufacturing process raises the temperature to a level that facilitates shaping and bonding.

Once first polymer layer810and second polymer layer820are properly positioned, first mold portion710and second mold portion720translate or otherwise move toward each other and begin to close on first polymer layer810and second polymer layer820. Fluid under pressure may be introduced into fluid-filled chamber765to conform upper surface741of fluid-filled chamber765to the shape750of the first mold portion710, to conform lower surface764of fluid-filled chamber or second element765to the shape of top surface761of first element760, and to conform edge743of fluid-filled chamber765to edge surface762of first element760or edge862of second mold portion720.

Upon injection of fluid into fluid-filled chamber765, second polymer layer820may be urged toward top surface761of outsole760, edge762of outsole760, and edge862of second mold portion720. As the pressure in fluid-filled chamber765increases, pressure on outsole top surface761may urge bases737on protuberances735toward surface780of second mold portion720. Similarly, pressure in fluid-filled chamber765may urge edge743of fluid-filled chamber765toward edge762of outsole760, and may urge both toward edge862of second mold portion. Edge743also may be urged into contact with edge862of second mold portion720where edge762of outsole760does not preclude contact therewith.

As can be seen with particularity inFIG. 8andFIG. 9, bottom surface794of outsole760typically may not contact bottom surface780of second mold portion720even after the fluid-filled chamber is fully molded. Although outsole760is held in position, demolding is carried out with less force than demolding from a mold that exerts forces on such protuberances, such as inFIG. 3andFIG. 4. Fluid pressure in fluid-filled chamber765may be adjusted after the sole structure is demolded.

FIG. 10andFIG. 11illustrate another embodiment of a co-molded article in the produce of a sole structure for an article of footwear that may be made in accordance with a method for co-molding a first element and a second element to produce a co-molded article. Mold1100may have a first mold portion1110and a second mold portion1120. Shape1150on first mold portion1110may produce the top surface1041of the co-molded article.

Outsole1060may have top surface1061, edge surface1062, and protuberance1035having base1037opposite top surface1061. The second element1065may have edge1043, upper surface1041, and lower surface1064. Any suitable polymeric material may be used to produce the sole structure, as described with regard toFIG. 7,FIG. 8, andFIG. 9.

In some embodiments, such as in the embodiments depicted inFIG. 10andFIG. 11, first element1060may be an outsole. For such an embodiment, in accordance with the method, outsole1060is located in second mold portion1120with base1037of protuberance1035in contact with surface1180of second mold portion1120. Surface1180of second mold portion1120is shaped so as to not contact a significant fraction of protuberance1035other than base1037. Protuberance1035may be a ground-engaging portion, with the end thereof being a base1037that engages the ground. As depicted with particularity inFIG. 10, outsole1060may have a slight arc or curve that cause edge1062to not contact edge1162of second mold portion1120. Outsole1060may include flange1063, which may provide additional support to the sole structure.

Precursor for a second element, a fluid-filled chamber, is placed in the mold and the mold is closed. First polymer layer1010may produce top surface1041of second element1065. Second polymer layer1020may form edge1043and lower surface or bottom1064of second element or fluid-filled chamber1065.

Each of first polymer layer1010and second polymer layer1020are initially located between each of first mold portion1010and second mold portion1020, which are in a spaced or open configuration, as depicted inFIG. 10andFIG. 11. The polymer layers are placed and heated as described in relationship toFIG. 7,FIG. 8, andFIG. 9.

Fluid under pressure may be introduced into fluid-filled chamber1065as it forms to conform upper surface1041of fluid-filled chamber1065to the shape1150of the first mold portion, to conform lower surface1064of fluid-filled chamber or second element1065to the shape of top surface1041of first element or outsole1060, and to conform edge1043of fluid-filled chamber1065to edge surface1062of outsole1060or edge1162of second mold portion1120.

Upon injection of fluid into fluid-filled chamber1065, second polymer layer1020may be urged toward top surface1061of outsole1060, edge1062of outsole1060, and edge1162of second mold portion1120. As the pressure in fluid-filled chamber1165increases, pressure on outsole top surface1061may urge bases1037on protuberances1035toward surface1080of second mold portion1120. Similarly, pressure in fluid-filled chamber1065may urge edge1043of fluid-filled chamber1065toward edge1062of outsole1060, and may urge both toward edge1162of second mold portion. Edge1043also may be urged into contact with edge1162of second mold portion1120where edge1162of outsole1060does not preclude contact therewith.

As can be seen with particularity inFIG. 11, bottom surface1094of outsole1060typically may not contact bottom surface1180of second mold portion1120even after the fluid-filled chamber is fully molded. Although outsole1060is held in position during molding, demolding is carried out with less force than demolding from a mold that exerts forces on such protuberances. Fluid pressure in fluid-filled chamber1065may be adjusted after the sole structure is demolded. Fluid pressure in fluid-filled chamber1065may be adjusted after the sole structure is demolded.

Embodiments of the disclosure may be molded from any moldable sheet material, such as thermoplastic polymer. Embodiments also may have any function, and may have any shape that can be molded. Embodiments accommodate pressurization of the mold after the bottom layer of the object is inserted into the mold so that the pressure will urge the layer to contact the fixed object, the edges of the fixed object or of the mold, and urge the fixed object toward the mold.

In some embodiments, the shape of the co-molded article may produce a container.FIG. 12andFIG. 13depict a container having feet. The container may be first element1260, which may be characterized as case1260. As depicted inFIG. 12, first element or case1260has been placed in second mold portion1320. Case1260may have a foot or protuberance1235, with the foot having a bottom1237. Second mold portion1320may include bottom surface1280. In some embodiments, bottom surface1280may not contact each bottom1237of feet1235. Case1260may have a shape that includes a slight arc. Thus, whether each bottom1237of feet1235touches bottom surface1280depends upon the arrangement of feet1235and whether case1260may have an arc when placed in second mold portion1320. In such embodiments, an arc may be exhibited in object edge1262. As depicted inFIG. 12, object edge1262illustrates such an arc, as object edge1262is not in contact with mold edge1362.

Placement of first and second polymer webs between first mold portion1310and second mold portion1320in mold1300before closing the mold, as depicted inFIG. 13, is carried out in essentially the same manner as is the method described with regard toFIG. 7,FIG. 8, andFIG. 9.

In some embodiments, box top1206, produced from a first polymer layer, may be adhered or otherwise affixed to a second polymer layer1208that forms the remainder of the box at flange1246. The top surface of box top1206is shaped by surface1350to form box surface1212.

Fluid may be injected into the volume formed by second polymer layer1208and box top1206. The fluid may be a gas, a liquid, or a gel. Injection of fluid into box1265may urge second polymer layer1208toward top surface1264of case1260, edge1262of case1260, and edge1362of second mold portion1320. As the pressure in box1265increases, pressure on first element bottom surface1264may urge bases1237on protuberances1235toward surface1280of second mold portion1320. Similarly, pressure in case1260may urge edge1243of second polymer layer toward edge1262of object1260, and may urge both toward edge1362of second mold portion1320. Edge1243also may be urged into contact with edge1362of second mold portion1320where edge1262of case1260does not preclude contact therewith.

As can be seen with particularity inFIG. 13, bottom surface1294of case1260typically may not contact bottom surface1390of second mold portion1320even after the case is fully molded. Although case1260is held in position, demolding is carried out with less force than demolding from a mold that exerts forces on such protuberances1235. Fluid pressure in box1265may be adjusted after the co-molded article is demolded.

Embodiments include articles made in accordance with the method disclosed herein. Embodiments of these articles may be a sole structure for an article of footwear, as described herein. Such a sole structure may be attached to an upper for an article of footwear to produce an article of footwear. The upper for an article of footwear may be any suitable composition of material element. Such material elements may include textiles, foams, leathers, and synthetic leathers, for example. More than one material may be present in an upper. The sole structure may be affixed to the upper by adhesion, sewing, or stitching, or by any method known to the skilled practitioner.

FIG. 14illustrates an article of footwear3100having a sole structure3130, which is secured to the outer periphery of an upper3120, also shown inFIG. 15, or upper120ofFIG. 1. The sole structure3130may be secured to a bottom surface of the upper3120, or a strobel, lasting board, or foam layer may be secured to the upper3120and the sole structure3130may secure to the bottom surface of the strobel, lasting board, or foam layer. Sole structure3130is located under the foot and supports the foot. The primary elements of sole structure3130are a forefoot sole structure3131and a heel sole structure3132. The sole structure3130has a forefoot region3134, a midfoot region3133, and a heel region3136and extends from a medial side3137to a lateral side3138.

The forefoot sole structure3131includes a forefoot midsole, which, in the embodiment shown, is a polymeric bladder element3140, and is also referred to as a forefoot component, forefoot bladder element, or a fluid-filled chamber. The polymeric bladder element3140is best shown inFIG. 16. The polymeric bladder element3150is best shown inFIG. 20. The bladder element3140encloses a fluid-filled interior cavity3142indicated inFIGS. 15 and 16. Similarly, the heel sole structure3132includes a heel midsole, which, in the embodiment shown, is a polymeric bladder element3150, and is also referred to as a heel component, heel bladder element, or a fluid-filled chamber. The bladder element3150encloses a fluid-filled interior cavity3152indicated inFIGS. 15 and 20. The bladder elements3140,3150are between the outsole components of the bottom view ofFIG. 14and the upper3120, as best shown inFIG. 15.

The bladder elements3140and3150are separate from one another and are not in fluid communication with one another. The bladder element3140has multiple tubular portions with arcuate shapes (e.g., generally U shaped) so that the fluid-filled interior cavity3142has corresponding tubular portions3142A,3142B,3142C,3142D, and3142E interconnected and in fluid communication with one another by channels3143as best shown inFIG. 16. The bladder element3150has multiple interconnected portions arranged in a U-shape so that the fluid-filled interior cavity3152has multiple portions3152A,3152B,3152C,3152D and3152E interconnected and in fluid communication with one another by channels3153, as best shown inFIG. 20. The polymeric bladder element3140is configured so that arcuate portions of the fluid-filled interior cavity3142are at an outer periphery in the forefoot region3134of the sole structure3131as shown inFIG. 15. The bladder element3140has arcuate tubular portions3149in the forefoot region of the sole structure, as best shown inFIG. 16. The arcuate tubular portions3149have inner curved walls3151with tighter curvature than the outer walls of the arcuate tubular portions3149. Stated differently, the inner curved walls3151are at the inside of the U-shaped arcuate tubular portions3149. The side surface3079of the bladder element3140to which the first wall of the first outsole component is secured is at the inner curved wall3151. The inner wall3099can thus support and reinforce both the second wall3087and the inner curved wall3151of the bladder element3140at the arcuate tubular portion during flexing of the forefoot region. This support and reinforcement should reduce stresses on the second wall3087to prevent cracking of the second wall3087.

The bladder elements3140and3150are separate from one another and are not in fluid communication with one another. The bladder element3140has multiple tubular portions with arcuate shapes (e.g., generally U shaped) so that the fluid-filled interior cavity3142has corresponding tubular portions3142A,3142B,3142C,3142D, and3142E interconnected and in fluid communication with one another by channels3143as best shown inFIG. 16. The bladder element3150has multiple interconnected portions arranged in a U-shape so that the fluid-filled interior cavity3152has multiple portions3152A,3152B,3152C,3152D and3152E interconnected and in fluid communication with one another by channels3153, as best shown inFIG. 20. The polymeric bladder element3140is configured so that arcuate portions of the fluid-filled interior cavity3142are at an outer periphery in the forefoot region3134of the sole structure3131as shown inFIG. 15. The bladder element3140has arcuate tubular portions3149in the forefoot region of the sole structure, as best shown inFIG. 16. The arcuate tubular portions3149have inner curved walls3151with tighter curvature than the outer walls of the arcuate tubular portions3149. Stated differently, the inner curved walls3151are at the inside of the U-shaped arcuate tubular portions3149. The side surface3079of the bladder element3140to which the first wall of the first outsole component is secured is at the inner curved wall3151. The inner wall3099can thus support and reinforce both the second wall3087and the inner curved wall3151of the bladder element3140at the arcuate tubular portion during flexing of the forefoot region. This support and reinforcement should reduce stresses on the second wall3087to prevent cracking of the second wall3087.

The bladder elements3140,3150may each be thermoformed from upper and lower sheets3144,3146as shown inFIGS. 24 and 27and described herein (also referred to as first and second sheets, first and second layers, or upper and lower layers), or, in the alternative, may be blow-molded. The sheets may have alternating layers of TPU and a gas barrier material. In any embodiment, each bladder element3140,3150is configured to retain fluid within the fluid-filled interior cavities3142,3152. As used herein, a “fluid” includes a gas, including air, an inert gas such as nitrogen, or another gas. Accordingly, “fluid-filled” includes “gas-filled”. The various materials used for the bladder elements3140,3150may be substantially transparent or may have a tinted color. For example, the bladder elements3140,3150can be formed from any of various polymeric materials that can retain a fluid at a predetermined pressure, including a fluid that is a gas, such as air, nitrogen, or another gas. For example, the bladder elements3140,3150can be a thermoplastic urethane (TPU) material, a urethane, polyurethane, polyester, polyester polyurethane, and/or polyether polyurethane.

Moreover, in one embodiment, the bladder elements3140,3150can be formed of one or more sheets having layers of different materials. The sheets may be laminate membranes formed from thin films having one or more first layers that comprise thermoplastic polyurethane layers and that alternate with one or more second layers, also referred to herein as barrier layers, gas barrier polymers, or gas barrier layers. The second layers may comprise 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 to Bonk et al., which is incorporated by reference in its entirety. The first layer may be arranged to form an outer surface of the polymeric sheet. That is, the outermost first layer may be the outer surface of the bladder element3140or3150. The bladder elements3140,3150may 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. Each sheet may also be a flexible microlayer membrane that includes alternating layers of a gas barrier polymer material such as second layers and an elastomeric material such as first layers, 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 bladder elements3140,3150are 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 bladder elements3140,3150include 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 bladder elements3140,3150, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. When the bladder element3140or3150is formed from sheets, the thicknesses of the sheets used to form the bladder element3140or3150can be selected to provide these characteristics.

Forefoot bladder element3140and heel bladder element3150are formed from a polymer material that encloses a fluid, which may be a gas, liquid, or gel. During walking and running, for example, forefoot bladder element3140and heel bladder element3150may compress between the foot and the ground, thereby attenuating ground reaction forces. That is, after thermoforming, forefoot bladder element3140and heel bladder element3150are inflated and generally pressurized with the fluid to cushion the foot.FIG. 14shows sealed inflation ports3155through which fluid is introduced into the interior cavities3142,3152prior to sealing.

In some configurations, sole structure3130may include a foam layer, for example, that extends between upper3120and one or both of forefoot bladder element3140and heel bladder element3150, or a foam element may be located within indentations in the lower areas of forefoot bladder element3140and heel bladder element3150. In other configurations, forefoot sole structure3131may incorporate plates, moderators, lasting elements, or motion control members that further attenuate forces, enhance stability, or influence the motions of the foot. Heel sole structure3132also may include such members to further attenuate forces, enhance stability, or influence the motions of the foot.

The forefoot sole structure3131also includes a first outsole component3060secured to the bladder element3140, and multiple second outsole components3062secured to the first outsole component3060as described herein. The first outsole component3060is shown in isolation inFIGS. 17 and 18. The second outsole component3062is secured to the first outsole component inFIG. 14. The heel sole structure3132includes a first outsole component3070, and a second outsole component3072secured to the first outsole component3070as described herein. The first outsole component3070is shown inFIGS. 21 and 22. The second outsole component3072is secured to the first outsole component3070as shown inFIG. 14.FIG. 15shows the first outsole components3060,3070secured to the bladder elements3140and3150, with the second outsole components3062,3072removed.

In addition to providing a wear surface (i.e., a ground-engaging surface) of an article of footwear, forefoot outsole component3060and heel outsole component3070may enhance various properties and characteristics of sole structure3130. Properties and characteristics of the outsoles, such as the thickness, flexibility, the properties and characteristics of the material used to make the outsole, and stretch, may be varied or selected to modify or otherwise tune the cushioning response, compressibility, flexibility, and other properties and characteristics of sole structure3130. In the embodiment shown, the first outsole components are a first material and the second outsole components are a second material different than the first material. The first outsole components3060and3070are injection molded thermoplastic polyurethane (TPU) components that are preformed with their desired shape and configuration by the injection molding process prior to being thermally bonded to the respective bladder element3140,3150by the method described herein. The second outsole components3062,3072are rubber and are preformed in their desired shape and then secured to the first outsole component3060or3070as described herein. First outsole component3060is a single, unitary, one-piece component, and first outsole component3070is a single, unitary, one-piece component. Each of the second outsole components3062and3072are also single, unitary, one-piece components.

Forefoot outsole component3060is secured to a lower surface of forefoot bladder element3140. In some embodiments, forefoot sole structure3131may extend into a midfoot region. The forefoot outsole component3060also may be secured to lower areas of forefoot bladder element3140in a midfoot region. Heel outsole component3070is secured to lower areas of heel bladder element3150. Both heel bladder elements3150and heel outsole component3070may extend into a midfoot region. Forefoot outsole component3060and heel outsole component3070may be formed from a wear-resistant material. The wear-resistant material may be transparent or translucent to provide a visually appealing effect. The wear-resistant material may be textured on the ground-engaging surface to impart traction, such as by including integral tread elements3135,3191as described herein. Any or all of the components of forefoot sole structure3131and heel sole structure3132may be translucent or transparent, and may be colored or patterned for aesthetic appeal.

FIGS. 14, 17 and 18also illustrate gas escape openings2069in the first outsole component3060of the forefoot sole structure3131, andFIGS. 14, 21, and 22illustrate gas escape openings2079in the first outsole component3070of the heel sole structure3132only some of which are indicated with reference numbers. These gas escape openings allow air or other gases trapped between a bladder element and the corresponding outsole component during manufacturing to escape. The inside surface of an outsole component may be shaped in a manner that may accumulate trapped gas and direct the entrapped gas to a gas escape opening. For example, small interconnected grooves2071may be formed on the inside surface of the outsole component3060during injection molding, or may be provided in the surface by removal of material after molding. The gas escape openings2069are in the bottom of the grooves2071, as shown inFIG. 19. The second outsole component3070also has grooves2071on the inner surface, as shown inFIG. 22, that direct entrapped gas to the gas escape openings2079. The gas escape openings2079are in fluid communication with the grooves3071.

Reinforcement of the outsole (for example, inclusion of structural elements, such as ribs), apertures, the height of the walls of the outsole, the number and location of the walls of outsole and walls of the bladder elements (also referred to as edges of the bladder elements) that overlap, or other features of an outsole all may be used to tune the responses of the sole structure. In particular, overlap of a wall of an outsole component with the side walls of a forefoot bladder element or a heel bladder element, or with the sidewalls of an underlying outsole component, such as described and illustrated at least inFIGS. 14-28, may be used to tune the elastic response and cushioning response of the resultant sole structure. With the guidance provided herein, these and other properties and characteristics of the outsole in combination with the properties and characteristics of the fluid-filled bladder elements can be selected and configured to provide a desired cushioning response.

In the embodiment shown inFIGS. 14-28and manufactured as described with respect toFIGS. 25-28, the configuration of the first outsole components3060and3070supports the respective bladder elements3140and3150and allows a second outsole component3062or3072to be received and nested partially within a recess4050in the first outsole component3060, or within a recess4150in the first outsole component3070. The recesses4050and4150provide positioning guidance during assembly and, as discussed herein, protect the second outsole components3062and3072from delamination during wear. Moreover, both the first outsole components3060,3070and the second outsole components3062,3072have tread elements3135,3191, respectively, that establish a ground-engaging surface of the sole structure (contacting the ground G inFIG. 24), enabling different tractive properties to be provided at the locations of the tread elements3135,3191, by using different shapes, sizes of the tread elements3135,3191, and/or by using different materials for the first and second outsole components3060and3062. The tread elements3135,3191may be protrusions, ridges, or ground-engaging lugs or sections that impart traction. As shown inFIG. 14, the tread elements3135have different sizes and shapes including rectangular and trapezoidal. The tread elements3191are generally larger than the tread elements3135. Depending on the materials used for the outsole components3060,3062,3070,3072, the second outsole components3062,3072may provide increased traction relative to the first outsole components3060,3070, or decreased traction.

The tread elements3135of the first outsole component3060,3070are an integral portion of the first outsole component (i.e., formed together with the base and walls by injection molding of the first outsole component) as best shown inFIGS. 17 and 20, and the tread elements3191of the second outsole component3062or3072are likewise an integral portion of the one-piece, unitary second outsole component3062or3072. Configuration of the outsole components in this manner simplifies manufacturing and lessens the possibility of separation of the tread elements from the base of the outsole component during wear.

FIGS. 17 and 18show the first outsole component3060prior to attachment of the second outsole component3062.FIGS. 21 and 22show the first outsole component3070prior to attachment of the second outsole component3072.FIGS. 23 and 24show the first outsole component3060attached to a bottom surface3080of the bladder element3140and to side surfaces3078,3079of the bladder element3140. More specifically, the first outsole component3060has a first base3083attached to the bottom surface3080of the bladder element3140, a first wall3085integral with the first base3083secured to a side surface3078of the bladder element3140, and a second wall3087integral with the first base3083and secured to a side surface3079of the bladder element3140. As indicated by the location of the cross-sections ofFIGS. 23 and 24inFIG. 14, and as shown inFIG. 18, the first wall3085and the second wall3087are at the arcuate portion of the fluid-filled interior cavity3142. The second wall3092of the second outsole component3062is at the arcuate portion.

The first outsole component3060has integral tread elements3135at predetermined portions of the bottom surface3081of the first outsole component, while other portions are free from tread elements.FIG. 24shows a base3083of the first outsole component3060attached to the first bladder element3140and having integral tread elements3135at first portion3082of a bottom surface3081of base3083. Second portion3084of the bottom surface3081of base3083is free from any tread elements3135. The other portion of the first outsole component3060shown attached to the bladder element3140also has a base3083and walls3085,3087integral with the base3083, with a first portion3082of the base3083with integral tread elements3135and a second portion3084free from any tread elements. At least some of the tread-free portions are free from tread elements3135specifically because a second outsole component3062with its own integral tread element(s) is to be attached at the second portion3084, as shown inFIG. 14. As such, no tread elements of the first outsole component3060will interfere with attachment of the second outsole component3062.

The second outsole component3062has a second base3090and optionally includes one or more integral tread elements3191. The second base3090is secured to the second portion3084of the bottom surface3081of the first base3083. The second outsole component3062has a second wall3092integral with the second base3090. The second wall3092is secured to the outer surface3094of the first wall3085of the first outsole component3060. The outer surface3094is adjacent the second portion3084of the bottom surface3081. With this configuration, a ground-engaging surface3098of the sole structure3131includes integral tread elements3135of the first outsole component3060, and integral tread elements3191of the second outsole component3062.

Similarly, as best shown inFIGS. 21 and 22, the first outsole component3070of the heel sole structure3132has integral tread elements3135at predetermined portions of the bottom surface4002of the first outsole component3070, such as at first area4004, and has a second area4006free from any tread elements. The first outsole component3070has a first base4008and an integral first wall4010extending from the first base adjacent the second area4006. The first wall4010is an outer wall. The first outsole component3070also has a second wall, referred to as an inner wall4011, which is integral with the first base4008.

The second outsole component3072has a second base4012secured to the first base4008. The second outsole component3072has a second wall4014(i.e., outer wall) integral with the second base4012and secured to the outer surface4016of the first wall4010. The second outsole component3072has an inner wall4015integral with the second base4012and secured to the outer surface4017of the second wall4011as is evident inFIGS. 14, 15, and 21.

As best shown inFIG. 23, the first outsole component3060has an arcuate shape corresponding to the arcuate shape of the fluid-filled interior cavity3142with the first wall3085at the outer periphery of the arcuate portion of the fluid-filled interior cavity3142. The second wall3092of the second outsole component3062is also at the arcuate portion. The first wall3085and second wall3092are thus outer walls. The second wall3087of the first outsole component3060is an inner wall located at the inner curve of the arcuate portion. The inner wall3099of the second outsole component3072is also at the inner curve of the arcuate portion. Supporting the tubular arcuate portions of the bladder elements with the outer and inner walls of the outsole components3060,3070provides support, acting as a geometric constraint on the bladder element3140, and provides stiffness, tuning the cushioning response of the bladder element3140.

Reinforcement of the outsole components3060,3062,3070,3072(for example, inclusion of structural elements, such as ribs), apertures, the height of the walls3085,3087,3092,3099of the outsole components3060,3062,3070,3072, the number and location of overlapping walls of outsole components3060,3062,3070,3072and of the bladder elements3140,3150(also referred to as edges of the bladder elements), or other features of outsole components3060,3062,3070,3072all may be used to tune the responses of the sole structures3131and3132. In particular, overlap of a wall4010,4011,4014,4015of a first outsole component3060,3070away from the respective base portion4008and up the side surface3078,3079of a forefoot bladder element3140, or the side surface of a heel bladder element3150, and overlap of a wall3092,3099,4014of a second outsole component3062,3072away from the respective base portion and up the wall3085,3087,4010,4011of the respective first outsole component3060,3070such as described and illustrated at least inFIGS. 15-24, may be used to tune the elastic response and cushioning response of the resultant sole structure3131,3132. With the guidance provided herein, these and other properties and characteristics of the outsole components3060,3062,3070,3072in combination with the properties and characteristics of the fluid-filled bladder elements3140,3150can be selected and configured to provide a desired cushioning response.

The first outsole component3060and the second outsole component3062are cooperatively configured to fit together to assist with locating the second outsole component3062on the first outsole component3060and to reduce the possibility of the second outsole component3062separating from the first outsole component3060during wear. More specifically, and as best shown inFIG. 24, the outer surface of3094the first wall3085of the first outsole component3060has a recess4050. When the forefoot sole structure3131is thermoformed, the recess4050is adjacent the second portion3084of the bottom surface3081of the first outsole component3060as shown inFIG. 24. With reference toFIGS. 25 and 26, the recess4050is provided due to the shape of the injection mold5010in which the first outsole component3060is injection molded. In an embodiment, the injection mold5010may have upper and lower molds5012,5014with mold surfaces5016,5018, respectively. TPU material is injected through ports5020in molding the first outsole component3060to the contours of the mold surfaces5016,5018. A protrusion5022in the lower mold5014causes the recess4050in the first wall3085of the medial side of the first outsole component3060. A similar protrusion5022causes the recess4050in the first wall3085of the lateral side of the first outsole component3060. The mold surface5018also has recesses5026that create the tread elements3135. Additionally, the mold surfaces5016,5018are shaped so that the second walls3087(i.e., the inner walls) of the first outsole component3060have a greater height than the first walls3085(i.e., the outer walls) of the first outsole component3060and so that an upper end4070,4072of the walls3085,3087are tapered.

The second wall3092of the second outsole component3070is configured so that it can fit in and be secured to the outer surface of the first wall3085of the first outsole component3060in the recess4050. The first outsole component3070and the second outsole component3072of the heel sole structure3172are cooperatively configured in the same manner.

Moreover, as shown inFIG. 24, the second wall3092has a first thickness T1and the recess4050has a first depth D1. The first thickness T1is greater than the first depth D1so that second outsole component3070protrudes outward of the first outsole component3060at the first wall3085. The upper edge4060of the second outsole component3062is abutted against or just below a lip4062of the first outsole component3060in the recess4050. The lip4062protects the upper edge4060from direct applied forces during use, reducing the possibility of delamination or other dislocation of the second outsole component3062.

As best shown inFIG. 23, the inner wall3099of the second outsole component3062extends upward from the second base3090of the second outsole component further than the second wall3092(i.e. the outer wall) of the second outsole component. Support for the bladder element3040at the inner wall3099is desirable to limit inward movement of the bladder element3040during compression and deformation. The second outsole component3072of the bladder element3050may be similarly configured, with inner walls that extend upward along inner walls of the first outsole component3070further than outer walls.

In the embodiment shown, the recess4050extends across the bottom surface and up the outer surface of the inner wall3087of the first outsole component3060. Accordingly, only a portion of the thickness T2of the inner wall3099of the second outsole component3062protrudes from the outer surface of the inner wall3087of the first outsole component3060as shown inFIG. 23. Alternatively, the recess4050may end at the bottom surface so that the inner wall3087may be configured without a recess. Both the outer wall3085and the inner wall3087of the first outsole component3060have a tapered upper end4070,4072, shown inFIG. 18, helping to prevent delamination of the first outsole component3060from the bladder element3140. The first outsole component3070is similarly configured with a tapered upper end4073at the first wall4010. The upper end4074of the first outsole component3070continues up the inner wall of the tubular portion of the lower polymer sheet3146of the bladder element3050to the lower surface of the lower polymer sheet3146adjacent the tubular portion as indicated inFIGS. 14 and 22, providing maximum support against the inner wall of the bladder element3150.

A method of manufacturing an article of footwear that includes the sole structure3131and/or the sole structure3132as described above includes placing a preformed first outsole component3160into a thermoforming mold6012,6014. InFIG. 27, the thermoforming mold is schematically depicted as including an upper mold6012and a lower mold6014. As described with respect toFIGS. 25 and 26and shown inFIGS. 17 and 18, the first outsole component3060is preformed with a base3083having integral tread elements3135protruding from a first portion3082of a bottom surface3081of the base, with a second portion3084of the bottom surface3081free of any tread elements, and with a wall3085integral with the base3083and adjacent the second portion3084of the bottom surface. As used herein, “preformed” means that the first outsole component3060has the features prior to the thermoforming process (i.e., prior to placement in the thermoforming mold6012,6014).

In an embodiment, the lower mold6014may have one or more positioning markers to orient the first outsole component3060. As shown inFIG. 27, the second mold surface6018has a positioning marker6024, and placing the first outsole component3060into the lower mold6014includes placing a predetermined portion of the first outsole component3060at the positioning marker6024, thereby orienting the first outsole component3060in a predetermined position in the thermoforming mold6014. The positioning marker6024is a cavity in the second mold surface6018, and the predetermined portion of the first outsole component3060is one of the tread elements3135. Other alternative positioning markers may be used instead of or in addition to positioning marker6024.

The method further includes placing polymeric material in the thermoforming mold6012,60014with the first outsole component3060. The polymeric material may be a first polymeric sheet3144and a second polymeric sheet3146also referred to as an upper polymeric sheet and a lower polymeric sheet due to their relative positions in the completed article of footwear. Alternatively, the polymeric material may be a preform (e.g., polymeric material not in sheet form).

The thermoforming mold6012,6014is then closed by placing the upper and lower molds6012,6014together as shown inFIG. 28to enclose the polymeric material (i.e., an enclosed portion of the sheets3144,3146and the first outsole component3060in a mold cavity6028defined between the mold surface6026of the upper mold6012and the mold surface6018of the lower mold6014. The method then includes forming the sheets3144,3146by a combined thermoforming and vacuuforming process, which includes applying a vacuum to conform a first portion of the polymeric material (i.e., the enclosed portion of the first sheet3144) to the first mold surface (i.e., the surface6026) of the thermoforming mold and conform a second portion of the polymeric material (i.e., the bottom surface3080of the enclosed portion of the second sheet3146) to an upper surface3088of the first outsole component3060and to the second mold surface6018with the interior cavity3142between the first sheet3144and the second sheet3146. InFIG. 28, the lip4062of the first outsole component3060is not apparent as it is compressed against the mold surface6018. The interior cavity3142may be inflated after the thermoforming process is complete (i.e., after removal of the bladder element3140and first outsole component3060from the thermoforming mold6012,6014). Gaps may exist between the bottom surface of the first outsole component3060and the mold surface6018to ease removal of the sole surface after thermoforming.

In an embodiment in which the polymeric material is the first and second polymer sheets3144,3146, the method then includes thermally bonding the first polymeric sheet3144to the second polymeric sheet3146to enclose the interior cavity3142, and thermally bonding the lower surface3080of the second polymer sheet3146to the upper surface3088of the first outsole component.

The first and second polymer sheets3144,3146are thermally bonded to one another around the peripheral flange3148formed between the pinch surface6030and the seam-forming surface6070and at web areas3147between the portions of the fluid-filled interior cavity3142. As the mold6012,6014closes, pinch surface6030contacts and slides against a portion of second seam-forming surface6070. The contact between pinch surface6030and second seam-forming surface6070effectively severs excess portions6810,6820of first and second polymer sheets3144,3146from portions that form bladder element3140. The material forming first polymer sheet3144and second polymer sheet3146compacts or otherwise collects to form flange3148. In addition to forming flange3148, first polymer sheet3144and second polymer sheet3146are (a) shaped to produce bladder element3140and (b) compressed and joined to produce web area3147.

The thermoformed sheets3144,3146are allowed to cool, and then the mold6012,6014is opened by separating the upper and lower molds6012,6014, and the thermally bonded upper and lower polymer sheets3144,3146and first outsole component3060are removed from the mold6012,6014as a unit after a predetermined cooling period. If the mold6012,6014is configured to mold multiple sole structures3131,3132simultaneously, additional trimming may be necessary around the flange3148or between the adjacent sole structures. The bladder element3140with the attached first outsole component3060may be inflated after thermoforming and prior to attachment of the second outsole component3062, or may be inflated after attachment of the second outsole component3062.

After the first outsole component3060is attached to the bladder element3140, the second outsole component3062is positioned on the second portion3084of the bottom surface3080of the first outsole component3060. Positioning the second outsole component3062is by nesting the second outsole component3062in the recess4050. Nesting includes abutting the upper edge4060of the second outsole component3062against the lip4062of the first outsole component3060at an upper extent of the recess4050, as indicated with respect to one of the outsole components3062inFIG. 15. The upper edge4060of the second outsole component3062is abutted against a lip4062of the first outsole component3060in the recess4050, as shown inFIGS. 15, 23, and 24. The second outsole component3062is adhered to the first outsole component3060. As shown inFIG. 15, the footwear upper3120is then secured to the upper surface4041of the first polymer sheet3144. InFIG. 15, the flange3148is shown at the lateral side of the sole structure3130and is adhered to the lower lateral side of the upper3120.

The method has been described with respect to the forefoot sole structure3131. The method may also include injection molding the first outsole component3070, vacuum/thermoforming the bladder element3150and thermally bonding the first outsole component3070to the bladder element3150in a thermoforming mold, attaching the second outsole component to the3072as described, and then securing the heel sole structure3132to the heel region of the upper3120with a forward edge3110of the heel sole structure adjacent a rearward edge3112of the forefoot sole structure as shown inFIGS. 14 and 15.

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 only and not as limiting.