Patent Publication Number: US-2022219405-A1

Title: Fluid-filled cushioning article with seamless side walls and method of manufacturing

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. application Ser. No. 16/426,111, filed May 30, 2019, which claims the benefit of priority to U.S. Provisional Application No. 62/678,504, filed May 31, 2018, and both of which are incorporated by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     The present teachings generally relate to a cushioning article and a method of manufacturing a cushioning article. 
     BACKGROUND 
     Fluid-filled bladders used for cushioning in footwear or other articles provide the advantage of lightweight cushioning and resiliency. Those skilled in the footwear arts strive to simplify manufacturing methods while providing repeatability, reliability, and aesthetically pleasing cushioning articles. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic perspective view of a polymeric sheet and a knurling tool. 
         FIG. 2  is a schematic perspective view of the polymeric sheet of  FIG. 1  and a support. 
         FIG. 3  is a schematic perspective view of the polymeric sheet of  FIG. 2  wrapped around the support of  FIG. 2 . 
         FIG. 4  is a schematic perspective view of the polymeric sheet and support of  FIG. 2  and a first welding tool. 
         FIG. 5  is a schematic perspective view of the polymeric sheet removed from the tool after welding with the first welding tool of  FIG. 4 . 
         FIG. 6  is a schematic perspective view of the polymeric sheet of  FIG. 5  and a second welding tool. 
         FIG. 7  is a schematic top view of the polymeric sheet of  FIG. 6  after welding with the second welding tool. 
         FIG. 8  is a schematic fragmentary cross-sectional view of the welded polymeric sheet of  FIG. 7  taken a lines  8 - 8  in  FIG. 7 . 
         FIG. 9  is a schematic top view of the welded polymeric sheet of  FIG. 7  after trimming. 
         FIG. 10  is a schematic perspective view of the welded polymeric sheet of  FIG. 9  after inflating to form a cushioning article and shows the first side wall. 
         FIG. 11  is a schematic perspective view of the welded polymeric sheet of  FIG. 9  after inflating to form the cushioning article and shows the second side wall. 
         FIG. 12  is an article of footwear with the cushioning article of  FIG. 11  disposed in a sole structure. 
         FIG. 13  is a schematic fragmentary cross-sectional view of the sole structure of  FIG. 12  taken a lines  13 - 13  in  FIG. 12 . 
         FIG. 14  is a schematic top perspective view of a single sheet welded to form multiple cushioning articles. 
         FIG. 15  is a schematic top perspective view of the welded sheet of  FIG. 14  after trimming. 
         FIG. 16  is a schematic top perspective view of one of the cushioning articles of  FIG. 15 . 
         FIG. 17  is a flow diagram of a method of manufacturing a cushioning article. 
     
    
    
     DESCRIPTION 
     Cushioning articles that includes sealed, fluid-filled bladders made from sheets of multi-layer polymeric films are typically welded or thermoformed. The multiple layers may include one or more gas barrier layers that retain the fluid in the bladder. Because the multiple layers are welded or thermoformed to provide the desired shape of the bladder, weld seams typically are disposed at the periphery of the bladder. If the bladder is exposed for viewing when assembled in the article, it may be more aesthetically pleasing to view a portion of the bladder without weld seams, but it can be difficult to locate the weld seams so that they will not show. 
     A method of manufacturing disclosed herein provides a cushioning article that has side walls that are free from any weld seams. The method of manufacturing a cushioning article comprises wrapping a polymeric sheet around a support so that the polymeric sheet surrounds a perimeter of the support. A first portion of the polymeric sheet adjacent a first side edge of the polymeric sheet overlaps and is stacked on a second portion of the polymeric sheet adjacent a second side edge of the polymeric sheet. The method includes welding the first portion to the second portion at a first weld disposed between the first side edge and the second side edge while the polymeric sheet is wrapped around the support so that the polymeric sheet forms an open-ended sheath with a top wall, a bottom wall, a first side wall and a second side wall with the first weld disposed at only one of the top wall and the bottom wall. The polymeric sheet is then removed from the support, and, after removing the polymeric sheet from the support, the top wall is welded to the bottom wall at a first transverse weld and a second transverse weld. Both the first transverse weld and the second transverse weld cross the first weld and extend from the first side wall to the second side wall so that the polymeric sheet defines and encloses an interior cavity capable of retaining a fluid, and the first side wall and the second side wall are weld-free. 
     The method may include, prior to removing the polymeric sheet from the support, welding the first portion to the second portion at a second weld that is disposed between the first side edge and the second side edge and is spaced apart from the first weld. Welding the first weld may be contemporaneous with welding the second weld. 
     The method may include, prior to welding the first weld, knurling at least one of the first portion of the polymeric sheet and the second portion of the polymeric sheet. Knurling one or both portions helps roughen the surface of the polymeric sheet, which may enable a stronger weld seam. 
     The first side edge and the second side edge may both extend from a first edge of the polymeric sheet to a second edge of the polymeric sheet. The method may further comprise, contemporaneously with welding the first transverse weld, welding a first outer weld between the first transverse weld and the first edge. The first outer weld may extend from the first side wall to the second side wall, and the polymeric sheet may form a flange extending outward from the first transverse weld to the first outer weld, with the flange having a recess between the first transverse weld and the first outer weld. 
     Similarly, the method may further comprise, contemporaneously with welding the second transverse weld, welding a second outer weld between the second transverse weld and the second edge. The second outer weld may extend from the first side wall to the second side wall. The polymeric sheet may form a flange extending outward from the second transverse weld to the second outer weld, with the flange having a recess between the second transverse weld and the second outer weld. 
     The method may further comprise, after welding the polymeric sheet at the first transverse weld and the second transverse weld, trimming the polymeric sheet at the first edge, at the second edge, or at both the first edge and the second edge. Additionally, the method may include inflating the interior cavity with the fluid and sealing the interior cavity such that the interior cavity retains the fluid. 
     In one or more embodiments, the method may further comprise welding the top wall to the bottom wall at an intermediate weld that extends across the first weld and terminates inward of each of the first side wall, the second side wall, the first transverse weld, and the second transverse weld. Welding the top wall to the bottom wall at the intermediate weld may be contemporaneous with welding the polymeric sheet at the first transverse weld and the second transverse weld. By securing the top wall to the bottom wall between the side walls, the intermediate welds control the maximum height of the bladder when the bladder is inflated, helping it to stay flatter than it would otherwise. 
     In one or more embodiments, the method may further comprise disposing the cushioning article in a footwear sole structure, wherein the footwear sole structure is configured with an opening, and at least one of the first side wall and the second side wall is positioned at the opening. Because the welds are located at the top wall or the bottom wall and not at either of the side walls, no welds will extend across the opening, and the weld-free surface of one of the side walls may be viewable at the opening. 
     Within the scope of the disclosure a cushioning article comprises a polymeric sheet having a first portion overlapped with a second portion and welded to the second portion at a first weld, the first portion adjacent a first side edge of the polymeric sheet and the second portion adjacent a second side edge of the polymeric sheet. The polymeric sheet forms a top wall, a bottom wall, a first side wall, and a second side wall. The first side wall and the second side wall extend between the top wall and the bottom wall, and the first weld is disposed at only one of the top wall or the bottom wall. The polymeric sheet has a first transverse weld at which the top wall is welded to the bottom wall and a second transverse weld at which the top wall is welded to the bottom wall. Both the first transverse weld and the second transverse weld cross the first weld and extending from the first side wall to the second side wall so that the polymeric sheet defines and encloses an interior cavity capable of retaining a fluid, and the first side wall and the second side wall are weld-free. 
     In one or more embodiments, the cushioning article may include a second weld at which the first portion is welded to the second portion, the second weld disposed between the first side edge and the second side edge and spaced apart from the first weld. 
     In one or more embodiments of the cushioning article, the first side edge and the second side edge both extend from a first edge of the polymeric sheet to a second edge of the polymeric sheet, and a first outer weld is between the first transverse weld and the first edge and extends from the first side wall to the second side wall. The polymeric sheet forms a flange extending outward from the first transverse weld to the first outer weld. The flange has a recess between the first transverse weld and the first outer weld. 
     In one or more embodiments, the cushioning article further comprises a second outer weld between the second transverse weld and the second edge and extending from the first side wall to the second side wall. The polymeric sheet forms a flange extending outward from the second transverse weld to the second outer weld. The flange has a recess between the second transverse weld and the second outer weld. 
     In one or more embodiments, the cushioning article further comprises an intermediate weld securing the top wall to the bottom wall and that extends across the first weld and terminates inward of each of the first side wall, the second side wall, the first transverse weld, and the second transverse weld. 
     In one or more embodiments of the cushioning article, the polymeric sheet comprises a multi-layer polymeric sheet. The multi-layer polymeric sheet may be a laminate membrane having at least a first layer comprising a thermoplastic polyurethane, and at least a second layer comprising a gas barrier polymer. The gas barrier polymer may be an ethylene-vinyl alcohol copolymer. 
     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. 
     Cushioning articles that includes sealed, fluid-filled bladders made from sheets of multi-layer polymeric films are typically welded or thermoformed. The multiple layers may include one or more gas barrier layers that retain the fluid in the bladder. Because the multiple layers are welded or thermoformed to provide the desired shape of the bladder, weld seams typically are disposed at the periphery of the bladder. If the bladder is exposed for viewing when assembled in the article, it may be more aesthetically pleasing to view a portion of the bladder without weld seams, but it can be difficult to locate the weld seams so that they will not show. 
     A method of manufacturing  100  disclosed herein provides a cushioning article that has side walls that are free from any weld seams. Referring to the drawings, wherein like reference numbers refer to like components,  FIG. 1  shows a polymeric sheet  10  that is subjected to the method of manufacturing  100  shown in the flowchart of  FIG. 17  to form a cushioning article  12  shown in  FIGS. 10-11 . The cushioning article  12  has no welds or seams on its side walls. This is difficult to achieve for a cushioning article that is not injection molded. The polymeric sheet  10  is a multi-layer sheet and, as such, is not conducive to injection molding. For example, the polymeric sheet  10  may be a multi-layer polymeric sheet that is a laminate membrane having at least a first layer  14  comprising a thermoplastic polyurethane, and at least a second layer  16  comprising a gas barrier polymer. In the embodiment shown, the sheet includes alternating first layers  14  and second layers  16 . The sheet  10  can include 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 sheet  10  can include thermoplastic polymeric material, such as a urethane, polyurethane, polyester, polyester polyurethane, and/or polyether polyurethane. 
       FIG. 13 , which is a close-up fragmentary cross-sectional portion of the cushioning article  12  formed from the sheet  10  in an article of footwear  18  taken at lines  13 - 13  in  FIG. 12 , shows that the polymeric sheet  10  is a laminate membrane formed from thin films having one or more first layers  14  that comprise thermoplastic polyurethane layers  14  and that alternate with one or more second layers  16 , also referred to herein as barrier layers, gas barrier polymers, or gas barrier layers, that 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. One of the first layers  14  may be arranged to form an outer surface of the polymeric sheet  10 . That is, the outermost first layer  14  shown in  FIG. 13  may be a portion of the outer surface of the cushioning article  12 . The polymeric sheet  10  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 polymeric sheet  10  may also be a flexible microlayer membrane that includes alternating layers of a gas barrier polymer material such as second layers  16  and an elastomeric material such as first layers  14 , 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 polymeric sheet  10  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 polymeric sheet  10  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 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 polymeric sheet  10  used to form the cushioning article  12  can be selected to provide these characteristics. 
     Referring again to  FIG. 1 , the polymeric sheet  10  begins in a flat, planar configuration, and has a first edge  20 , a second edge  22 , a first side edge  24 , and a second side edge  26 . In  FIG. 1 , the side of the sheet  10  facing upward is the inner side of the surface of the cushioning article  12  when manufactured according to the method  100 , and so the surface facing upward in  FIG. 1  is referred to as the inner surface  28 . The surface  30  on the opposite side is the outer surface when the cushioning article  12  is manufactured according to the method  100  and is therefore referred to as the outer surface  30 . 
     The method  100  begins with step  102 , in which portions of the polymeric sheet  10  are knurled in preparation for subsequent welding. More specifically, the polymeric sheet  10  has a first portion  32  adjacent the first side edge  24  and a second portion  34  adjacent the second side edge  26 . The portions  32 ,  34  are shown extending from the respective side edges  24 ,  26  to phantom lines parallel with the side edge. A knurling tool  38  is used to knurl the portions  32 ,  34 . At least the inner surface  28  at the first portion  32  and the outer surface  30  at the second portion  34  are knurled, although the portions  32 ,  34  may each be knurled at both surfaces  28 ,  30 . 
     The method  100  then proceeds to step  104 , wrapping the polymeric sheet  10  around a support  40  so that the polymeric sheet  10  surrounds a perimeter  41  of the support  40 , and so that the first portion  32  of the polymeric sheet  10  overlaps and is stacked on the second portion  34  of the polymeric sheet  10 . Wrapping the polymeric sheet  10  around the support  40  is depicted in  FIGS. 2 and 3 . In  FIG. 2 , the polymeric sheet  10  is generally centered under the support  40 , and the side edges  24 ,  26  are moved upward and around the support  40 , as indicated by arrows A in  FIG. 2 , until the second portion  34  rests on the support  40 , and the first portion  32  overlaps and rests on the second portion  34  as shown in  FIG. 3 . In this arrangement, the knurled inner surface  28  at the first portion  32  lays against the knurled outer surface  30  at the second portion  34 . 
     With the polymeric sheet wrapped on the support  40  as shown in  FIG. 3 , the method  100  proceeds to step  106 , in which a first longitudinal weld W 1  (also referred to herein as a first weld or a first weld seam) welds the first portion  32  to the second portion  34 . Because one or both of the portions  32 ,  34  are knurled, the material of the sheet  10  may bond together at the weld W 1  more strongly than if the surfaces were smoother. 
     The method  100  may include step  108 , in which, prior to removing the polymeric sheet  10  from the support  40 , the first portion  32  is also welded to the second portion  34  at a second weld W 2  that is disposed between the first side edge  24  and the second side edge  26  and is spaced apart from the first weld W 1 . Welding the first weld W 1  may be contemporaneous with welding the second weld W 2 , as each may be welded using the same welding tool  42 . The first and second welds W 1 , W 2  are parallel with one another and with the first and second side edges  24 ,  26 . The first and second welds W 1 , W 2  extend from the first edge  20  to the second edge  22 . 
       FIG. 4  shows a welding tool  42  used to create the first weld W 1  and the second weld W 2 . Two parallel protrusions  44  of the welding tool  42  create the welds W 1 , W 2  when the welding tool  42  is powered by a power source  46  to provide power for radio frequency welding (also referred to as high frequency or dielectric welding) of the first portion  32  to the second portion  34 . The power source  46  supplies energy creating an alternating electric field that heats the polymeric sheet  10  at the overlapping portions  32 ,  34  where the protrusions  44  are applied to the polymeric sheet  10 . Alternatively, the portions  32 ,  34  may be secured to one another by another manner of thermal or adhesive bonding. 
     After step  108 , the method  100  proceeds to step  110  in which the polymeric sheet  10  is removed from the support  40 . Due to the first and second welds W 1 , W 2 , the polymeric sheet  10  forms an open-ended sheath, best shown in  FIG. 5 , with a top wall  50 , a bottom wall  52 , a first side wall  54 , and a second side wall  56 . The first side wall  54  and the second side wall  56  extend between the top wall  50  and the bottom wall  52 . The flexible polymeric sheet  10  may almost flatten at the side walls  54 ,  56  in the state following step  108 . The polymeric sheet  10  may be referred to as being folded at the side walls  54 ,  56 . However, there are no creases at the side walls  54 ,  56 , but the flexible nature of the polymeric sheet  10  allows it to change direction from the bottom wall to the top wall along the side walls  54 ,  56  without creasing. 
     Because the polymeric sheet  10  is wrapped around the support  40  during welding, the opposite side of the polymeric sheet  10  is protected from the welding tool  42  by the support  40  and is unaffected by the welding of the first weld W 1  and the second weld W 2 . The first weld W 1  and the second weld W 2  are disposed at only the top wall  50 . If the polymeric sheet  10  is instead wrapped around the support  40  from above and welded at a lower side of the support  40 , then the first weld W 1  and the second weld W 2  would be disposed only at the bottom wall  52 . 
     With the polymeric sheet  10  now removed from the support  40 , the method proceeds to step  112 , in which the top wall  50  is welded to the bottom wall  52  at a first transverse weld TW 1  and a second transverse weld TW 2 , shown in  FIG. 7 . Both the first transverse weld TW 1  and the second transverse weld TW 2  cross the first weld W 1  and the second weld W 2  and extend from the first side wall  54  to the second side wall  56 . This causes the polymeric sheet  10  to define and encloses an interior cavity  60  capable of retaining a fluid, while leaving the first side wall  54  and the second side wall  56  weld-free, as best shown in  FIGS. 10 and 11 . 
       FIG. 6  shows a welding tool  62  used to create the first transverse weld TW 1  and the second transverse weld TW 2 . The polymeric sheet  10  is placed on a welding table  64  and the welding tool  62  is powered by the power source  46  to provide power for radio frequency welding or are secured by another manner of thermal or adhesive bonding. The power source  46  supplies energy creating an alternating electric field that heats the polymeric sheet  10  at the stacked top and bottom walls  50 ,  52  where two parallel protrusions  68  of the welding tool  62  are applied to the top wall  50  to create the welds TW 1 , TW 2 . The entire cushioning article  12  is formed from the single polymeric sheet  10 . 
     Because the welding tool  62  has additional protrusions, the method  100  may further comprise step  114  which may occur contemporaneously with welding the first transverse weld TW 1  and the second transverse weld TW 2 , and includes welding a first outer weld OW 1  between the first transverse weld TW 1  and the first edge  20 , and welding a second outer weld OW 2  between the second transverse weld TW 2  and the second edge  22 . More specifically, the parallel protrusions  70  are spaced from one another and from the protrusions  68 , further toward the first and second edges  20 ,  22 . Like the transverse welds TW 1 , TW 2 , the first outer welds OW 1  and OW 2  cross the first and second longitudinal welds W 1  and W 2 , and extend from the first side wall  54  to the second side wall  56 . The polymeric sheet  10  forms a flange  70 A extending outward from the first transverse weld TW 1  to the first outer weld OW 1  and outward to the first edge  20 . The polymeric sheet  10  also forms a flange  70 B extending outward from the first transverse weld TW 2  to the first outer weld OW 2  and outward to the second edge  22 . As best shown in  FIG. 8 , the flange  70 A has a recess  72 A between the first transverse weld TW 1  and the first outer weld OW 1 . Flange  70 B has a similar recess  72 B between the second transverse weld TW 2  and the second outer weld OW 2 . The first transverse weld TW 1  and the first outer weld OW 1  serve as a double seal of the interior cavity  60  near the first edge  20 , and the second transverse weld TW 2  and the second outer weld OW 2  serve as a double seal of the interior cavity  60  near the second edge  22 . Stated differently, the outer welds OW 1  and OW 2  provide redundant sealing of the interior cavity  60 . The recesses  72 A and  72 B may serve as guides at which the cushioning article  12  may be secured to other components with which it is subsequently assembled, such as a midsole, and upper, etc. 
     In addition to the transverse welds TW 1  and TW 2  and the outer welds OW 1  and OW 2 , the method  100  may further comprise step  116 , welding the top wall  50  to the bottom wall  52  at one or more intermediate welds IW that extends across the first weld W 1  and the second weld W 1  and terminate inward of each of the first side wall  54 , the second side wall  56 , the first transverse weld TW 1 , and the second transverse weld TW 2 . The intermediate welds IW thus do not create sub-chambers within the interior cavity  60 . Step  116 , welding the top wall  50  to the bottom wall  52  at the one or more intermediate welds IW may be contemporaneous with step  112 , welding the polymeric sheet at the first transverse weld TW 1  and the second transverse weld TW 2 , and contemporaneous with step  114 , welding the first outer weld OW 1  and the second outer weld OW 2 . As shown in  FIG. 6 , the welding tool  62  includes protrusions  74  that are parallel with and spaced from one another, and are also parallel with and spaced from the protrusions  68 ,  70  and are generally thicker and shorter than the protrusions  68  and  70 . The protrusions  74  do not extend to the side walls  54 ,  56 , but extend across the longitudinal welds W 1  and W 2 . The protrusions  74  result in intermediate welds IW shown in  FIG. 7  that secure the top wall  50  to the bottom wall  52  and the ability of the top control the maximum height H 1  of the cushioning article  12  when the cushioning article  12  is inflated, as shown in  FIG. 11 , helping it to stay flatter than it would otherwise. 
     The method  100  may further comprise, step  118 , which occurs after welding the polymeric sheet at the first transverse weld and the second transverse weld, and includes trimming the polymeric sheet  10  at the first edge  20 , at the second edge  22 , or at both the first edge and the second edge. The trimming occurs between the outward weld OW 1  and the first edge  20 , and between the outward weld OW 2  and the second edge  22  and OW 2 . The trimming step is best illustrated in  FIG. 9 , where the polymeric sheet  10  has been trimmed to the outward welds OW 1  and OW 2 . Apertures  76  have also been punched or otherwise provided at ends of each of the intermediate welds IW, as shown in  FIG. 9 . After trimming in step  118 , the method  100  proceeds to step  120  in which the interior cavity is inflated by filling it with a gas or air to a predetermined pressure. Inflation may occur through an inflation port (not shown) at either flange  70 A or  70 B provided by a short fill tube laid between the top wall and the bottom wall where the welding tool  62  forms the transverse weld TW 1  or TW 2  and the corresponding outward weld OW 1  or OW 2 . Alternatively, step  120  can be omitted if the interior cavity  60  is to be at ambient pressure. The inflated interior cavity  60  is subsequently sealed in step  122 , such as by sealing the plug. 
     If the cushioning article  12  is for an article of footwear, the method  100  may move from step  122  to step  124 , in which the cushioning article is disposed in a sole structure  80  of the article of footwear  18  of  FIG. 12 . The sole structure  80  is secured to a footwear upper  19 . The sole structure  80  has a midsole  82  that is configured with an opening  84 , as best illustrated in the cross-section of  FIG. 13 . Either the first side wall  54  or the second side wall  56  is positioned at the opening  84 , depending on the configuration. In the embodiment shown, the first side wall  54  is positioned at the opening  84  so that it is visible through the opening from the exterior of the article of footwear  18 . As is evident in  FIG. 12 , because the welds (including longitudinal welds W 1 , W 2 , transverse welds TW 1 , TW 2 , and outer welds OW 1 , OW 2 ), are located at the top wall  50  or the bottom wall  52  and not at either of the side walls  54 ,  56 , no welds will extend across the opening  84 , and the weld-free surface of the side wall  54  is viewable at the opening  84 . 
       FIGS. 14-16  illustrate that multiple cushioning articles  12  may be manufactured from the same single polymeric sheet  10 , according to the same method  100 . Two identical cushioning articles referred to as cushioning articles  12 A and  12 B are formed according to the same steps described with respect to method  100 . The first and second longitudinal welds W 1  and W 2  extend through both of the cushioning articles  12 A and  12 B. The welding tool used has a different pattern of protrusions, and the transverse welds that result near the first edge  20  and the second edge  22  are nonlinear. The polymeric sheet  10  is turned 90 degrees relative to  FIG. 1  in  FIG. 14 . Excess polymeric material between the first edge  20  and the first transverse weld W 1 , between the second edge  22  and the second transverse weld W 2 , and between some of the interior welds IW is trimmed, as shown in  FIG. 15 . The two cushioning articles  12 A,  12 B may be doubled over at a welded joint  86  at which they are connected or may be separated by cutting at the joint to provide two disjoined cushioning articles, one of which (cushioning article  12 B) is shown in  FIG. 16 . Neither of the cushioning articles  12 A,  12 B have any welds along the side walls  54 ,  56 . 
     The following Clauses provide example configurations of a cushioning article and a method of manufacturing a cushioning article as disclosed herein. 
     Clause 1: A method of manufacturing a cushioning article, the method comprising: wrapping a polymeric sheet around a support so that the polymeric sheet surrounds a perimeter of the support and a first portion of the polymeric sheet adjacent a first side edge of the polymeric sheet overlaps and is stacked on a second portion of the polymeric sheet adjacent a second side edge of the polymeric sheet; welding the first portion to the second portion at a first weld disposed between the first side edge and the second side edge while the polymeric sheet is wrapped around the support so that the polymeric sheet forms an open-ended sheath with a top wall, a bottom wall, a first side wall and a second side wall and with the first weld disposed at only one of the top wall and the bottom wall; removing the polymeric sheet from the support; and after removing the polymeric sheet from the support, welding the top wall to the bottom wall at a first transverse weld and a second transverse weld, both the first transverse weld and the second transverse weld crossing the first weld and extending from the first side wall to the second side wall so that the polymeric sheet defines and encloses an interior cavity capable of retaining a fluid, and the first side wall and the second side wall are weld-free. 
     Clause 2: The method of clause 1, further comprising: before removing the polymeric sheet from the support, welding the first portion to the second portion at a second weld; wherein the second weld is disposed between the first side edge and the second side edge and is spaced apart from the first weld. 
     Clause 3: The method of clause 2, wherein welding the first weld is contemporaneous with welding the second weld. 
     Clause 4: The method of any of clauses 1-3, further comprising: prior to welding the first weld, knurling at least one of the first portion of the polymeric sheet and the second portion of the polymeric sheet. 
     Clause 5: The method of any of clauses 1-4, wherein the first side edge and the second side edge both extend from a first edge of the polymeric sheet to a second edge of the polymeric sheet, and the method further comprising; contemporaneously with welding the first transverse weld, welding a first outer weld between the first transverse weld and the first edge, the first outer weld extending from the first side wall to the second side wall, the polymeric sheet forming a flange extending outward from the first transverse weld to the first outer weld, and the flange having a recess between the first transverse weld and the first outer weld. 
     Clause 6: The method of any of clauses 1-5, wherein the first side edge and the second side edge both extend from a first edge of the polymeric sheet to a second edge of the polymeric sheet, and the method further comprising: contemporaneously with welding the second transverse weld, welding a second outer weld between the second transverse weld and the second edge, the second outer weld extending from the first side wall to the second side wall, the polymeric sheet forming a flange extending outward from the second transverse weld to the second outer weld, and the flange having a recess between the second transverse weld and the second outer weld. 
     Clause 7: The method of any of clauses 1-6, wherein the first side edge and the second side edge both extend from a first edge of the polymeric sheet to a second edge of the polymeric sheet, and the method further comprising: after welding the polymeric sheet at the first transverse weld and the second transverse weld, trimming the polymeric sheet at the first edge, at the second edge, or at both the first edge and the second edge. 
     Clause 8: The method of any of clauses 1-7, further comprising: inflating the interior cavity with the fluid. 
     Clause 9: The method of any of clauses 1-8, further comprising: sealing the interior cavity such that the interior cavity retains the fluid. 
     Clause 10: The method of any of clauses 1-9, further comprising: welding the top wall to the bottom wall at an intermediate weld that extends across the first weld and terminates inward of each of the first side wall, the second side wall, the first transverse weld, and the second transverse weld. 
     Clause 11: The method of clause 10, wherein welding the top wall to the bottom wall at the intermediate weld is contemporaneous with welding the polymeric sheet at the first transverse weld and the second transverse weld. 
     Clause 12: The method of any of clauses 1-11, further comprising: disposing the cushioning article in a footwear sole structure; wherein the footwear sole structure is configured with an opening, and at least one of the first side wall and the second side wall is positioned at the opening. 
     Clause 13: A cushioning article comprising: a polymeric sheet having a first portion overlapped with a second portion and welded to the second portion at a first weld, the first portion adjacent a first side edge of the polymeric sheet and the second portion adjacent a second side edge of the polymeric sheet; the polymeric sheet forming a top wall, a bottom wall, a first side wall, and a second side wall, the first side wall and the second side wall extending between the top wall and the bottom wall, the first weld disposed at only one of the top wall or the bottom wall; and the polymeric sheet having a first transverse weld at which the top wall is welded to the bottom wall and a second transverse weld at which the top wall is welded to the bottom wall, both the first transverse weld and the second transverse weld crossing the first weld and extending from the first side wall to the second side wall so that the polymeric sheet defines and encloses an interior cavity capable of retaining a fluid, and the first side wall and the second side wall are weld-free. 
     Clause 14: The cushioning article of clause 13, further comprising: a second weld at which the first portion is welded to the second portion, the second weld disposed between the first side edge and the second side edge and spaced apart from the first weld. 
     Clause 15: The cushioning article of any of clauses 13-14, wherein the first side edge and the second side edge both extend from a first edge of the polymeric sheet to a second edge of the polymeric sheet, and the cushioning article further comprising: a first outer weld between the first transverse weld and the first edge and extending from the first side wall to the second side wall, the polymeric sheet forming a flange extending outward from the first transverse weld to the first outer weld, and the flange having a recess between the first transverse weld and the first outer weld. 
     Clause 16: The cushioning article of clause 15, further comprising: a second outer weld between the second transverse weld and the second edge and extending from the first side wall to the second side wall, the polymeric sheet forming a flange extending outward from the second transverse weld to the second outer weld, and the flange having a recess between the second transverse weld and the second outer weld. 
     Clause 17: The cushioning article of any of clauses 13-16, further comprising: an intermediate weld securing the top wall to the bottom wall, extending across the first weld, and terminating inward of each of the first side wall, the second side wall, the first transverse weld, and the second transverse weld. 
     Clause 18: The cushioning article of any of clauses 13-17, wherein the polymeric sheet comprises a multi-layer polymeric sheet. 
     Clause 19: The cushioning article of clause 18, wherein the multi-layer polymeric sheet is a laminate membrane having: at least a first layer comprising a thermoplastic polyurethane; and at least a second layer comprising a gas barrier polymer. 
     Clause 20: The cushioning article of clause 19, wherein the gas barrier polymer is an ethylene-vinyl alcohol copolymer. 
     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” or “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” refers to a direction extending a length of a component. For example, a longitudinal direction of an article of footwear extends between a forefoot region and a heel region of the article of footwear. The term “forward” or “anterior” is used to refer to the general direction from a heel region toward a forefoot region, and the term “rearward” or “posterior” is used to 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” refers to a direction extending a width of a component. For example, a transverse direction of an article of footwear extends between a lateral side and a medial side of the article of footwear. 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” refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole structure 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 structure. The term “upward” or “upwards” 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” 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, refers to portions at the space that is occupied by a wearer&#39;s foot when the article of footwear is worn. The “inner side” of a component 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 refers to the side or surface of the component that is (or will be) oriented away from the interior of the article of footwear in an assembled article of footwear. 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” refer to the direction toward the interior of the component or article of footwear, such as a shoe, and the terms “outward” and “outwardly” refer to the direction toward the exterior of the component or article of footwear, such as the shoe. In addition, the term “proximal” 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” 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.