Patent Publication Number: US-2023147255-A1

Title: Articulated cushioning article with tensile component and method of manufacturing a cushioning article

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 17/095,088 filed Nov. 11, 2020, which is a continuation of U.S. application Ser. No. 15/982,731 filed May 17, 2018, now U.S. Pat. No. 10,863,792, issued Dec. 15, 2020, which claims the benefit of priority to U.S. Provisional Application No. 62/508,035 filed May 18, 2017, and each of which is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     The present teachings generally include a cushioning article having an articulated tensile component, and a method of manufacturing the cushioning article with an inwardly-protruding bond. 
     BACKGROUND 
     A cushioning article, such as a sole component of an article of footwear, is typically configured to provide cushioning, motion control, and/or resilience. Some cushioning articles utilize a sealed interior cavity filled with a gas that resiliently reacts a compressive load. A tensile component may be disposed in the interior cavity, and may limit the outward expansion of the cushioning article. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic illustration in plan view of a cushioning article in accordance with the present teachings. 
         FIG.  2    is a schematic illustration in bottom view of the cushioning article of  FIG.  1   . 
         FIG.  3    is a schematic illustration in cross-sectional view of the cushioning article of  FIG.  1   , taken at lines  3 - 3  in  FIG.  1   . 
         FIG.  4    is a schematic illustration in cross-sectional view of the cushioning article of  FIG.  1   , taken at lines  4 - 4  in  FIG.  1   . 
         FIG.  5    is a schematic illustration in cross-sectional view of the cushioning article of  FIG.  1   , taken at lines  5 - 5  in  FIG.  1   . 
         FIG.  6    is a schematic illustration in medial side view of the cushioning article of  FIG.  1   . 
         FIG.  7    is a schematic illustration in medial side view of an article of footwear with a sole structure that includes the cushioning article of  FIG.  1   , indicated in hidden lines. 
         FIG.  8    is a schematic illustration in exploded view of components of the cushioning article of  FIG.  1    prior to manufacturing the cushioning article. 
         FIG.  9    is a schematic illustration in slightly perspective bottom view of a first mold insert used in a method of manufacturing the cushioning article of  FIG.  1   . 
         FIG.  10    is a schematic illustration in exploded cross-sectional view of components of the cushioning article of  FIG.  1    and a mold used in manufacturing the cushioning article. 
         FIG.  11    is a schematic illustration of the components of the cushioning article of  FIG.  1    in the mold of  FIG.  10   , with the mold in a closed position. 
         FIG.  12    is a schematic perspective illustration of a mold portion for manufacturing an alternative cushioning component in accordance with an alternative aspect of the present teachings. 
         FIG.  13    is a schematic perspective illustration of the mold portion of  FIG.  12    with a first mold insert secured to the mold portion. 
         FIG.  14    is a schematic perspective illustration of a second mold insert for use with the mold portion of  FIG.  12   . 
         FIG.  15    is a schematic illustration in plan view of a cushioning article in accordance with the present teachings. 
         FIG.  16    is a schematic illustration in bottom view of the cushioning article of  FIG.  15   . 
         FIG.  17    is a schematic illustration in cross-sectional view of the cushioning article of  FIG.  15   , taken at lines  17 - 17  in  FIG.  15   . 
         FIG.  18 A  is a schematic illustration in plan view of a sole structure configured for a left foot. 
         FIG.  18 B  is a schematic illustration in plan view of a sole structure configured for a right foot. 
         FIG.  19    is a flow chart of a method of manufacturing a cushioning article. 
     
    
    
     DESCRIPTION 
     A cushioning article comprises a bladder enclosing an interior cavity and retaining a gas in the interior cavity. The cushioning article further comprises a tensile component disposed in the interior cavity. The tensile component includes tensile layers and a plurality of tethers connecting the tensile layers. The tensile layers are connected to an inner surface of the bladder such that the tethers span across the interior cavity. The bladder has an inwardly-protruding bond that joins an inner surface of the bladder to the tensile component, protrudes inward into the interior cavity, and partially traverses the plurality of tethers such that the bladder is narrowed at the inwardly protruding bond and the gas in the interior cavity fluidly communicates across the inwardly-protruding bond. Stated differently, the inwardly-protruding bond is directly outward of some of the tethers. The inwardly-protruding bond is spaced apart from the second polymeric sheet such that the interior cavity is narrowed at the inwardly-protruding bond and the gas in the interior cavity is able to fluidly communicate across the inwardly-protruding bond. 
     In one or more embodiments, a portion of the interior cavity at a first side of the inwardly-protruding bond is in fluid communication with a portion of the interior cavity at a second side of the inwardly-protruding bond, the second side opposite of the first side. The gas in the interior cavity can thus be displaced across the inwardly-protruding bond, such as during a foot strike or foot roll of an article of footwear when the cushioning article is included in a sole structure. 
     In one or more embodiments, an inflation pressure of the gas in the interior cavity is sufficient to tension the plurality of tethers, and the inwardly-protruding bond defines a groove at an outer surface of the bladder such that the cushioning article is divided into a first article portion on one side of the groove and a second article portion on the other side of the groove. The groove may function as a flex groove at which the cushioning article articulates. Accordingly, the consistency and responsiveness of tethers in returning the interior cavity to its original shape following a dynamic compressive load is combined with the flexibility of an articulated cushioning component, with articulation occurring in alignment with the tethers traversed by the inwardly-protruding bond. 
     In one or more embodiments, the tensile layers include a first tensile layer spaced apart from a second tensile layer by a first distance at a location adjacent to the inwardly-protruding bond, and with the inwardly-protruding bond spaced apart from the second tensile layer by a second distance. The second distance may be between 50 percent and 80 percent of the first distance. Narrowing of the interior cavity by this ratio may provide an optimal range of articulation that contributes to flexibility of the cushioning article. 
     Because the inwardly-protruding bond at least partially traverses the plurality of tethers, in one or more embodiments, the plurality of tethers includes tethers aligned with the inwardly-protruding bond and tethers displaced from the inwardly-protruding bond. The tethers aligned with the inwardly-protruding bond are shorter, thicker, or both shorter and thicker than the tethers displaced from the inwardly-protruding bond. The tethers are originally all of the same length and width prior to manufacturing the cushioning article and establishing the inwardly-protruding bond. The deformation of the tethers that occurs during manufacturing at the inwardly-protruding bond contributes to the articulation and flexibility of the cushioning article. 
     In one or more embodiments, the bladder comprises a first polymeric sheet and a second polymeric sheet bonded to one another at a peripheral flange and enclosing the interior cavity. The tensile layers include a first tensile layer connected to the first polymeric sheet and a second tensile layer connected to the second polymeric sheet. The inwardly-protruding bond is spaced apart from the second polymeric sheet. The second polymeric sheet may be recessed inward toward the inwardly-protruding bond, across from the groove, when the interior cavity is inflated due to the tension of the tethers. Due to the groove, the first article portion is articulated relative to the second article portion along the groove. Accordingly, the outer surface of the first polymeric sheet at a first side of the inwardly-protruding bond may be non-planar with the outer surface of the first polymeric sheet at a second side of the inwardly-protruding bond, with the second side opposite of the first side. 
     In one or more embodiments, the inwardly-protruding bond is a first inwardly-protruding bond, and the cushioning article further includes a second inwardly-protruding bond that joins the first polymeric sheet to the first tensile layer and protrudes inward from the first polymeric sheet toward the second polymeric sheet and partially traverses the tensile component. The second inwardly-protruding bond intersects the first inwardly-protruding bond and is spaced apart from the second polymeric sheet such that the interior cavity is narrowed at the second inwardly-protruding bond and the gas in the interior cavity fluidly communicates across the second inwardly-protruding bond. 
     A first surface bond may join an inner surface of the first polymeric sheet to the first tensile layer, and a second surface bond may join an inner surface of the second polymeric sheet to the second tensile layer opposite the first tensile layer. The inwardly-protruding bond protrudes inward from the first polymeric sheet toward the second polymeric sheet farther than the first surface bond. 
     In one or more embodiments, the cushioning article is a sole component for an article of footwear, and the inwardly-protruding bond establishes a flexion axis of the sole component. Accordingly, the cushioning component may be articulated at the inwardly-protruding bond, and the flexion axes may be aligned with desired flexion regions of a foot, for example, such as the metatarsal-phalangeal joints. 
     The cushioning article may include multiple inwardly-protruding bonds arranged in a symmetrical manner, which is beneficial for enabling the use of identically-configured cushioning articles in both right foot and left foot articles of footwear with the bonds (and, therefore, the flex grooves) at a proximal side of the bladder in both instances. For example, the inwardly-protruding bond may be one of a plurality of inwardly-protruding bonds protruding inward from a proximal side of the bladder that are arranged in a symmetrical pattern about an axis of symmetry of the bladder. The plurality of inwardly-protruding bonds may include a first set of bonds and a second set of bonds spaced apart from one another and having parallel segments. The first set and the second set establish articulation axes when the cushioning article bends along an axis that is disposed at a first angle counterclockwise from the axis of symmetry. The plurality of inwardly-protruding bonds may further include a third set of bonds and a fourth set of bonds spaced apart from one another and having parallel segments. The third set and the fourth set establish articulation when the cushioning article bends along an axis that is disposed at the first angle clockwise from the axis of symmetry. 
     In one or more embodiments, the plurality of inwardly-protruding bonds may include a first central bond extending across the axis of symmetry, a pair of symmetrical forward-angled bonds extending from a first end and a second end of the first central bond, and a pair of symmetrical rearward-angled bonds extending from the first end and the second end of the first central bond. The plurality of inwardly-protruding bonds may further include a second central bond extending across the axis of symmetry and spaced from the first central bond, a pair of symmetrical forward-angled bonds extending from a first end and a second end of the second central bond, and a pair of symmetrical rearward-angled bonds extending from the first end and the second end of the second central bond. 
     The cushioning article may articulate at first and second flexion axes when the cushioning article bends along an axis disposed at the first angle counterclockwise from the axis of symmetry, and may articulate at third and fourth flexion axes when the cushioning article bends along an axis disposed at the first angle clockwise from the axis of symmetry. The first and second flexion axes extend along the first central bond and the second central bond, respectively, the forward-angled bonds extend from the first ends of the first and second central bonds, and the rearward-angled bonds extend from the second ends of the first and second central bonds. The third and fourth flexion axes extend along the first central bond and the second central bond, respectively, the forward-angled bonds extending from the second ends of the first and second central bonds, and the rearward-angled bonds extending from the first ends of the first and second central bonds. 
     A method of manufacturing a cushioning article comprises conforming a first polymeric sheet and a second polymeric sheet to components of a mold. For example, conforming the first polymeric sheet and the second polymeric sheet to components of the mold may be by vacuum, compression, or both. Conforming the first and second polymeric sheets in this manner depresses the first polymeric sheet toward the second polymeric sheet at one or more protrusions of one of the components of the mold. A tensile component is disposed between the first polymeric sheet and the second polymeric sheet. The tensile component includes a first tensile layer positioned adjacent the first polymeric sheet, a second tensile layer positioned adjacent the second polymeric sheet, and a plurality of tethers connecting the first tensile layer to the second tensile layer. The protrusion may be directly outward of the plurality of tethers. Conforming the first and second polymeric sheets according to the method produces an inwardly-protruding bond at the protrusion that joins the first polymeric sheet and the first tensile layer and partially traverses the plurality of tethers. The inwardly-protruding bond protrudes toward the second polymeric sheet but is spaced apart from the second tensile layer and the second polymeric sheet. 
     In one or more embodiments, the method comprises thermally bonding the first tensile layer to the first polymeric sheet and the second tensile layer to the second polymeric sheet opposite the first tensile layer. The thermal bonding may include at least one of heating the first polymeric sheet and the second polymeric sheet prior to disposing the first polymeric sheet and the second polymeric sheet in the mold cavity, radio frequency welding, or heating the mold. 
     In one or more embodiments, the method may further comprise bonding the first polymeric sheet to the second polymeric sheet at a peripheral bond such that the first polymeric sheet and the second polymeric sheet define a bladder at least partially enclosing an interior cavity containing the tensile component. The plurality of tethers span across the interior cavity from the first tensile layer to the second tensile layer, the inwardly-protruding bond protrudes inward, and the interior cavity is narrowed at the inwardly-protruding bond. 
     In one or more embodiments, the method may further comprise inflating and sealing the interior cavity. Inflating the interior cavity tensions the plurality of tethers and creates a groove in an outer surface of the first polymeric sheet at the inwardly-protruding bond at which the cushioning article articulates. In one or more embodiments, the cushioning article is a sole component for an article of footwear and the groove establishes a flexion axis of the sole component. 
     In one or more embodiments, the inwardly-protruding bond is one of a plurality of inwardly-protruding bonds on a proximal side of the cushioning article arranged in a symmetrical pattern about an axis of symmetry of the bladder. The method further includes securing the cushioning article (referred to as a first cushioning article) to a first sole structure configured for a right foot with the axis of symmetry of the first cushioning article rotated at a first angle in a direction that is either clockwise or counterclockwise relative to a longitudinal axis of the first sole structure, and securing an identically-configured second cushioning article to a second sole structure configured for a left foot with the axis of symmetry of the second cushioning article rotated at the first angle in a direction that is an opposite one of clockwise or counterclockwise than the first cushioning article relative to a longitudinal axis of the second sole structure. The first and second sole structures are mirror images of one another. In this arrangement, one set of the flexion axes will be correctly aligned with the joints of the right foot, and another set of the flexion axes will be correctly aligned with the joints of the left foot. Accordingly, the symmetrical pattern of the plurality of inwardly-protruding bonds is specifically designed to allow identical cushioning components to be used in both sole structures having right foot configurations and sole structures having left foot configurations. 
     In one or more embodiments, the components of the mold include a first mold portion and a second mold portion, at least one of the first mold portion and the second mold portion is translatable relative to the other of the first mold portion and the second mold portion between an open position and a closed position. Bonding the first polymeric sheet and the second polymeric sheet at the peripheral bond includes compressing the first polymeric sheet and the second polymeric sheet between the first mold portion and the second mold portion in the closed position. 
     In one or more embodiments of the method, prior to conforming the first polymeric sheet and the second polymeric sheet to components of the mold, the method may comprise securing a mold insert to a first mold portion of the mold. The mold component having the protrusion may be the mold insert. This enables the bond pattern of the cushioning articles manufactured according to the method to be easily changed by changing the mold insert to a different mold insert that has a different pattern of protrusions. For example, in one or more embodiments, the mold insert is a first mold insert, the cushioning article is a first cushioning article, and the method further comprises manufacturing a second cushioning article by removing the first mold insert from the first mold portion, and securing a second mold insert having a second protrusion to the first mold portion, wherein the second protrusion is shaped or dimensioned differently than the first protrusion. A subsequent first polymeric sheet and a subsequent second polymeric sheet are then conformed to the second mold insert and to another one of the mold components, respectively, with a subsequent tensile component between the subsequent first polymeric sheet and the subsequent second polymeric sheet. This conforming of the subsequent first polymeric sheet and the subsequent second polymeric sheet depresses the subsequent first polymeric sheet toward the subsequent second polymeric sheet at the second protrusion, with the second protrusion directly outward of the subsequent tensile component. A second inwardly-protruding bond is thereby produced at the second protrusion, and partially traverses the subsequent tensile component. The mold thus provides the second cushioning article with a different bond pattern than the first cushioning article due to the second mold insert. 
     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. 
     Referring to the drawings, wherein like reference numbers refer to like components throughout the views,  FIG.  1    shows a cushioning article  10  that may be manufactured according to a method  210  of  FIG.  19    and has features that provide a desirable combination of cushioning and flexibility. The cushioning article  10  is shown and described as a cushioning article used in a sole structure  12  of an article of footwear  14 , shown in  FIG.  7   . For example, the cushioning article  10  is shown at least partially encased in a foam sole layer  11 , and together the cushioning article  10  and sole layer  11  serve as a midsole of the sole structure  12 . An outsole, an insole, and other sole components may also be included in the sole structure  12 . The cushioning article  10  is thus a sole component. However, the cushioning article  10 , the cushioning article  110  discussed herein, or other cushioning articles manufactured according to the method  210  may be used in other articles, such as athletic apparel, sports equipment, furniture, and floor mats. For example, the cushioning article  10  or  110  may be for a backpack strap, a helmet cushion, a shin guard, a baseball glove, a seat cushion, or a floor mat. 
     The cushioning article  10  includes a bladder  13  formed from a first polymeric sheet  16  and a second polymeric sheet  18  bonded to one another at a peripheral bond  20  located along a peripheral flange  21  to enclose an interior cavity  22 . When the sheets  16 ,  18  are bonded together at the peripheral bond  20  and any inflation port is sealed, the bladder  13  retains a fluid in the interior cavity  22 . As used herein, a “fluid” filling the interior cavity  22  may be a gas, such as air, nitrogen, another gas, or a combination thereof. The first and second polymeric sheets  16 ,  18  can be a variety of polymeric materials that can resiliently retain a fluid such as nitrogen, air, or another gas. Examples of polymeric materials for the first and second polymeric sheets  16 ,  18  include thermoplastic urethane, polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Moreover, the first and second polymeric sheets  16 ,  18  can each be formed of layers of different materials including polymeric materials. In one embodiment, each of the first and second polymeric sheets  16 ,  18  is formed from thin films having one or more thermoplastic polyurethane layers with one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein such as a flexible microlayer membrane that includes alternating layers of a gas barrier material and an elastomeric material, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk et al. which are incorporated by reference in their entireties. Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. Additional suitable materials for the first and second polymeric sheets  16 ,  18  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 first and second polymeric sheets  16 ,  18  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 cushioning article  10 , engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. For example, the thicknesses of the first and second polymeric sheets  16 ,  18  used to form the cushioning article  10  can be selected to provide these characteristics. 
     As best shown in  FIG.  3   , the cushioning article  10  includes a tensile component  30  disposed in the interior cavity  22 . The tensile component  30  includes a first tensile layer  32 , a second tensile layer  34 , and a plurality of tethers  36  spanning the interior cavity  22  from the first tensile layer  32  to the second tensile layer  34 . The tethers  36  connect the first tensile layer  32  to the second tensile layer  34 . Only some of the tethers  36  are indicated with reference numbers in  FIG.  3   . The tethers may also be referred to as fabric tensile members or threads, and may be in the form of drop threads that connect the first tensile layer  32  and the second tensile layer  34 . The tensile component  30  may be formed as a unitary, one-piece textile element having a spacer-knit textile. 
     The first tensile layer  32  is bonded to an inner surface  42  of the first polymeric sheet  16 , and the second tensile layer  34  is bonded to an inner surface  46  of the second polymeric sheet  18 . More specifically, a first surface bond  40  joins the inner surface  42  of the first polymeric sheet  16  to the outer surface of the first tensile layer  32 . A second surface bond  44  joins the inner surface  46  of the second polymeric sheet  18  to the outer surface of the second tensile layer  34 , opposite the first tensile layer  32 . In one or more embodiments, no anti-weld material is used on the inner surface  42  of the first polymeric sheet  16  or the outer surface of the first tensile layer  32 , or on the inner surface  46  of the second polymeric sheet  18  or the outer surface of the second tensile layer  34 , as entire interfacing portions of theses surfaces are bonded to one another. 
     The tethers  36  restrain separation of the first and second polymeric sheets  16 ,  18  to the maximum separated positions shown in  FIG.  3    under a given inflation pressure of gas in the interior cavity  22 . The outward force of pressurized gas in the interior cavity  22  places the tethers  36  in tension, and the tethers  36  prevent the tensile layers  32 ,  34  and polymeric sheets  16 ,  18  from further outward movement away from one another. However, the tethers  36  do not present resistance to compression when under a compressive load. When pressure is exerted on the cushioning article  10  such as due to a force of a dynamic impact of a wearer during running or other movements, the cushioning article  10  is compressed, and the polymeric sheets  16 ,  18  move closer together with the tethers  36  collapsing (i.e., going slack) in proportion to the pressure exerted on the first and second polymeric sheets  16 ,  18  adjacent the particular tethers  36 . 
     Prior to bonding to the first and second polymeric sheets  16 ,  18  according to the method  210  disclosed herein, the tethers  36  of the tensile component  30  may all be initial lengths, and possibly all substantially the same length, and the first and second tensile layers  32 ,  34  connected by the tethers  36  may have generally flat outer surfaces  45 ,  47 , respectively, directly above the tethers  36  as shown in  FIG.  10   . In  FIG.  8   , the tethers  36  are represented in a slackened state as the tensile component  30  is not within a sealed interior cavity and is not subjected to tension in  FIG.  8   . In  FIG.  10   , the tethers  36  are also represented in a slackened state as  FIG.  10    represents the tensile component  30  prior to securement within a sealed, pressurized interior cavity  22 . 
     Under the method  210  provided herein, although the tethers  36  are originally of the same length and the outer surfaces  45 ,  47  of the first and second tensile layers  32 ,  34  and the outer surfaces  49 ,  57  of the first and second polymeric sheets  16 ,  18 , respectively, are generally flat directly above the tethers (i.e., not contoured) prior to manufacture of the cushioning article  10 , the method of manufacturing  210  produces an inwardly-protruding bond  50  that joins the first polymeric sheet  16  to the first tensile layer  32  and protrudes from the first polymeric sheet  16  toward the second polymeric sheet  18  directly into a region of the cavity occupied by some of the tethers  36 . In fact, in  FIG.  3   , there are multiple inwardly-protruding bonds  50 . Each bond  50  protrudes farther toward the second polymeric sheet  18  than the first surface bond  40 . 
     Each bond  50  results from a respective protrusion  51  of a mold component  53  that contacts the first polymeric sheet  16  during the method of manufacturing  210  disclosed herein.  FIG.  9    shows a representative mold component  53  having the protrusions  51  in a first pattern that result in the bond pattern  55 A of inwardly-protruding bonds  50  of the cushioning article  10  shown in  FIG.  1   . The mold component  53  is a mold insert, and may also be referred to as such, or may be referred to as a shim. The bonds  50  are indicated with hidden lines in the top view of  FIG.  1    as they protrude inward from the outer surface  49  shown. 
     The bonds  50  result in depressed grooves  52  at the outer surface  49  of the first polymeric sheet  16 . Only some of the bonds  50  and some of the grooves  52  are indicated in  FIG.  1    for clarity. In the embodiment shown, the inwardly-protruding bonds  50  are only at the first polymeric sheet  16 . In other embodiments, the method of manufacturing  210  may provide inwardly-protruding bonds at the second polymeric sheet  18  as an alternative to or in addition to the inwardly-protruding bonds  50  at the first polymeric sheet  16 . The outer surface  49  of the first polymeric sheet  16  may be the proximal side of the bladder  13  (i.e., the side closest to the foot) when assembled in a sole structure  12 , and the outer surface  57  of the second polymeric sheet  18  may be the distal side of the cushioning article  10  (i.e., the ground-facing side of the bladder  13 ) as indicated in  FIG.  7   . As shown in  FIG.  1   , the bladder  13  is not symmetrical and is for use in a sole structure configured for a left foot. Stated differently, the shape of the bladder  13  generally follows the shape of a forefoot portion of a left foot. Additionally, the articulation due to the bonds  50  and grooves  52  as shown in  FIGS.  6  and  7    is best achieved with the first polymeric sheet  16  on the proximal side. Nevertheless, if flipped so that the second sheet  18  is the proximal side, the cushioning article  10  could be used in a sole structure configured for a right foot. 
     Each inwardly-protruding bond  50  partially traverses the plurality of tethers  36  as shown in  FIG.  3   . Stated differently, the bonds  50  are directly outward of different ones of the tethers  36  and protrude inward on those tethers  36 . The tethers  36  may be arranged in rows, with each row extending transversely between the tensile layers  32 ,  34 , or in any other pattern in which the tethers  36  extend between the tensile layers  32 ,  34 . Various different ones of the tethers  36  are aligned with the bonds  50 . An inwardly-protruding bond  50  may traverse different rows of the tethers  36  such that different tethers from different rows are aligned with an inwardly-protruding bond  50 , or an inwardly-protruding bond  50  may be directly aligned with a single row. Some of the inwardly-protruding bonds  50  could be between rows of tethers. 
     With reference to  FIG.  3   , the plurality of tethers  36  includes tethers  36 A aligned with the inwardly-protruding bond  50  and tethers  36 B displaced from the inwardly-protruding bond  50 . Tethers  36 A that are aligned with an inwardly-protruding bond  50  are deformed by heat, by compression of the overlaying of material of the first tensile layer  32 , and/or by the overlaying material of the first tensile layer  32  coating the tethers  36 A such that the tethers  36 A are shorter, thicker, or both shorter and thicker at the inwardly-protruding bonds  50  than elsewhere. Such tethers are indicated with reference numeral  36 A in  FIG.  3    and may be referred to as modified tethers  36 A. However, references to tethers  36  herein include tethers  36 A and tethers  36 B unless otherwise specified. 
     When the interior cavity  22  is inflated, the modified tethers  36 A result in depressed grooves  52  in the outer surface  49  of the first polymeric sheet  16  as indicated in  FIGS.  1  and  3   . When an inflation pressure of the gas in the interior cavity  22  is sufficient to tension the plurality of tethers  36 , the inwardly-protruding bonds  50  define grooves  52  at the outer surface  49  of the first polymeric sheet  16 . At each groove  52 , the cushioning article  10  is divided into what may be referred to as a first article portion  61  on one side of the groove  52  and a second article portion  62  on the other side of the groove  52 , as indicated in  FIG.  4   . The first article portion  61  is articulated relative to the second article portion  62  along the groove  52 . Stated differently, the outer surface  49  of the first polymeric sheet  16  at a first side of the inwardly-protruding bond  50  (the first side indicated in  FIG.  4    as portion  49 A of outer surface  49 ) is non-planar with the outer surface  49  of the first polymeric sheet at a second side of the inwardly-protruding bond  50  (the second side indicated in  FIG.  4    as portion  49 B of outer surface  49 ), the second side opposite of the first side. 
     The tension of the modified tethers  36 A also causes recesses  56  in the outer surface  57  of the second polymeric sheet  18 . The second polymeric sheet  18  is recessed inward toward a corresponding groove  52  and inwardly-protruding bond  50  at each recess  56  when the interior cavity  22  is inflated. 
     The physical deformation of the first polymeric sheet  16  and the first tensile layer  32  combined with the tension of the modified tethers  36 A will cause the grooves  52  to be deeper than the recesses  56 , which result only from the tension of the shortened modified tethers  36 A. Accordingly, the cushioning article  10  may have an articulated shape, such as when not under loading at the grooves  52 , as shown in  FIG.  6   . Additionally, the grooves  52  and recesses  56  together encourage articulation (i.e., flexion) of the cushioning article  10  to occur at the grooves  52 , as the overall thickness of the cushioning article  10  is reduced at the grooves  52 , decreasing bending stiffness of the cushioning article at the grooves  52 . 
     The grooves  52  thus act as flexion axes of the cushioning article  10 . For example, where the cushioning article  10  is included in the sole structure  12  of the article of footwear  14  in  FIG.  7   , the inwardly-protruding bonds  50  and resulting grooves  52  may establish flexion axes F 1 , F 2 , F 3 , F 4  of the sole structure  12 , with the flexion axes aligned with joints of the foot, such as the metatarsal phalangeal joints, thereby increasing flexibility of the sole structure  12 . The flexion axes F 1 , F 2 , F 3 , F 4  are indicated in  FIGS.  1  and  6   . Additional flexion axes F 5  and F 6  are created by the bonds  50  and grooves  52  that run generally longitudinally. Flexion axes F 5  and F 6  increase transverse (i.e. lateral) flexibility of the cushioning article  10 . 
     Referring to  FIGS.  3  and  4   , each inwardly-protruding bond  50  is spaced apart from the second polymeric sheet  18  such that the interior cavity  22  is narrowed but not closed at the inwardly-protruding bond  50 , and the gas in the interior cavity  22  can still fluidly communicate across the inwardly-protruding bond  50 . The first tensile layer  32  is spaced apart from the second tensile layer  34  by a first distance D 1  at a location adjacent to the inwardly-protruding bond  50 , and the inwardly-protruding bond  50  is spaced apart from the second tensile layer  34  by a second distance D 2 . The first distance D 1  may be the distance between the tensile layers  32 ,  34  at the tethers  36  that are not the modified tethers  36 A. The second distance D 2  may be the minimum distance between the inwardly-protruding bond  50  and the second tensile layer  34  (i.e., the distance at the most narrowed portion of the interior cavity  22  under the bond  50 ). In an embodiment, the method of manufacturing  210  may be controlled so that the second distance D 2  is between  50  percent and  80  percent of the first distance D 1 . Bonds in this range of depth may create the most desirable amount of articulation for flexion, while maintaining fluid communication within the bladder  13  (i.e., not creating closed sub-chambers in the bladder). For example, factors that may influence the bond  50  and the extent of its protrusion toward the second polymeric sheet  18  can be controlled to provide this desired ratio of the second distance D 2  to the first distance D 1 . Such factors may include the depth of the protrusion  51  that creates the bond  50 , the temperature of the mold insert  53  or other mold components, the temperature of the components of the cushioning article  10 , vacuum and/or inflation pressures in the mold cavity during manufacturing, the power of weld frequency if radio frequency welding is used, and other factors. 
     Accordingly, a portion  22 A of the interior cavity  22  at a first side of the inwardly-protruding bond  50  is in fluid communication with a portion  22 B of the interior cavity  22  at a second side of the inwardly-protruding bond  50 , the second side opposite of the first side, as indicated in  FIG.  4   . The modified tethers  36 A shown extending under the bond  50  between the two portions  22 A,  22 B are narrow in diameter and allow gas to flow around and between the tethers  36 A from the portion  22 A to the portion  22 B and vice versa. This allows the gas to be displaced from the portion  22 A to the portion  22 B and from portion  22 B to portion  22 A when compressive forces are applied to the cushioning article  10 , such as during impact of the article of footwear  14  with the ground G in  FIG.  7   . For example, as a foot rolls forward from heel to toe during a foot strike, the gas may be displaced from rearward in the cushioning article  10  to a portion more forward in the cushioning article  10 . Supportive cushioning provided by the interior cavity  22  can thus be provided in areas most needed during use of the cushioning article  10 . 
     In  FIG.  3   , the bond  50  labelled  50 A may be referred to as a first inwardly-protruding bond, and the bond  50  labelled  50 B may be referred to as a second inwardly-protruding bond. Like bond  50 A, the bond  50 B joins the first polymeric sheet  16  to the first tensile layer  32 , protrudes inward from the first polymeric sheet  16  toward the second polymeric sheet  18 , and at least partially traverses the tethers  36 A of the tensile component  30 . As is evident from  FIGS.  1 ,  3 , and  4    taken together, the second inwardly-protruding bond  50 B intersects the first inwardly-protruding bond  50 A at the cross-section of  FIG.  5   , and is spaced apart from the second polymeric sheet  18  such that the interior cavity  22  is narrowed but not closed at the second inwardly-protruding bond  50 B. Accordingly, the gas in the interior cavity  22  fluidly communicates across the second inwardly-protruding bond  50 B. 
       FIG.  10    shows the components of the cushioning article  10  in an exploded view and positioned between components of a mold  66 . More specifically, the mold components of mold  66  include a first mold portion  66 A, a second mold portion  66 B, and the mold insert  53 .  FIG.  11    shows the components of the cushioning article  10  in a mold cavity  68  of the mold  66  defined by the mold components with the mold  66  in a closed position. 
       FIGS.  15  and  16    show an alternative embodiment of a cushioning article  110  that has many of the same features as the cushioning article  10  which are indicated with like reference numerals. For example, first and second polymeric sheets  16 ,  18  are bonded to one another at a peripheral bond  20  to form a bladder  113  enclosing an interior cavity  22  and retaining a gas in the interior cavity. The tensile component  30  is disposed in the interior cavity  22  and is as secured to the inner surfaces of the polymeric sheets  16 ,  18  as shown in  FIG.  17    and as described with respect to the cushioning article  10 . As shown in  FIG.  15   , the outer surface  49  of the first polymeric sheet  16  is the proximal side of the bladder  113  when used in a sole structure such as sole structure  12  of  FIG.  7   , and the outer surface  57  of the second polymeric sheet  18  is the distal side. This enables the deeper grooves  52  of the cushioning article  110  (i.e., deeper than the recesses  56 ) and the tendency to flex at the grooves  52  in the manner shown in  FIG.  7    to be matched to the movement of a foot in dorsiflexion. 
     In contrast to the cushioning article  10  and the bladder  13 , the cushioning article  110  and the bladder  113  are symmetrical in overall shape at the outer perimeter (i.e., at the peripheral bond  20 ), and the plurality of inwardly-protruding bonds  50  are arranged on the proximal side of the bladder  113  in a symmetrical pattern  155 A about an axis of symmetry  115  of the bladder  113 . Corresponding recesses  56  at the distal side shown in  FIG.  16    are also arranged in a symmetrical pattern about the axis of symmetry  115 . Only some of the recesses  56  are labeled in  FIG.  16   . As discussed with respect to  FIGS.  18 A and  18 B , the symmetrical pattern  155 A of the bonds  50  enables the cushioning article  110  to be used in a sole structure configured for a right foot or a sole structure configured for a left foot without any difference in underfoot feel to the wearer. 
     The plurality of inwardly-protruding bonds  50  of the bladder  113  are labelled with alphanumeric identifiers (e.g.,  50 C 1 , etc.) in order to differentiate the bonds  50  for purposes of discussion. The bonds  50  includes a first central bond  50 H extending across the axis of symmetry  115 , and a second central bond  50 L also extending across the axis of symmetry  115  and disposed generally parallel to and spaced from the first central bond  50 H. Each of the central bonds  50 H and  50 L is symmetrical relative to the axis of symmetry  115 . The bonds  50  also include symmetrical pairs of bonds, such as: bonds  50 C 1  and  50 C 2 ; bonds  50 D 1  and  50 D 2 ; bonds  50 E 1  and  50 E 2 ; bonds  50 F 1  and  50 F 2 ; bonds  50 G 1  and  50 G 2 ; bonds  50 I 1  and  50 I 2 , bonds  50 J 1  and  50 J 2 ; bond  50 K 1  and  50 K 2 ; bonds  50 M 1  and  50 M 2 ; and bonds  50 N 1  and  50 N 1 . 
     The bonds  50  include a first set of bonds  50 G 1 ,  50 H,  50 F 2 , and a second set of bonds  50 K 1 ,  50 L,  50 J 2  spaced apart from one another and having parallel segments. For example, bonds  50 G 1  and  50 K 1  are segments that are parallel with one another, and bonds  50 F 2 ,  50 J 2  are also segments that are parallel with one another. The first set of bonds  50 G 1 ,  50 H,  50 F 2  establishes a first articulation axis A 1 , and the second set of bonds  50 K 1 ,  50 L,  50 J 2  establish a second articulation axis A 2 . Both axes A 1  and A 2  act as flexion axes for example when the cushioning article  110  bends in dorsiflexion along an axis at angle  117 B (i.e., counterclockwise) relative to the first axis of symmetry  115 . In the bladder  113  is rotated to this orientation, the axes A 1 , A 2  would be generally perpendicular to the original position of the axis of symmetry  115  shown in  FIG.  15   . 
     The bonds  50  also include a third set of bonds  50 F 1 ,  50 H,  50 G 2  and a fourth set of bonds  50 J 1 ,  50 L,  50 K 2  spaced apart from the third set of bonds and having parallel segments. For example, bonds  50 G 2  and  50 K 2  are parallel segments, and bonds  50 F 1 ,  50 J 1  are also parallel segments. The third set of bonds  50 F 1 ,  50 H,  50 G 2  establishes a third articulation axis A 3  and the fourth set of bonds  50 J 1 ,  50 L,  50 K 2  establishes a fourth articulation axis A 4 . Both axes A 3  and A 4  act as flexion axes, for example, when the cushioning article  110  bends in dorsiflexion along an axis at angle  117 A relative to the axis of symmetry  115  having the same numerical value as angle  117 B but a different direction (i.e. clockwise) relative to the axis of symmetry  115 ). If the bladder  113  is rotated to this orientation, the axes A 3 , A 4  would be generally perpendicular to the original position of the axis of symmetry  115  shown in  FIG.  15   . 
     As shown in  FIG.  15   , the bonds  50  include the first central bond  50 H extending across the axis of symmetry  115 , and a pair of symmetrical forward-angled bonds  50 F 1 ,  50 F 2  extending from a first end  118  and a second end  119 , respectively of the first central bond  50 H. The bonds  50  also include a pair of symmetrical rearward-angled bonds  50 G 1 ,  50 G 2  extending from the first end  118  and the second end  119 , respectively, of the first central bond  50 H. 
     The bonds  50  further include the second central bond  50 L extending across the axis of symmetry  115  and spaced from the first central bond  50 H, and a pair of symmetrical forward-angled bonds  50 J 1 ,  50 J 2  extending from a first end  120  and a second end  121 , respectively, of the second central bond  50 L. The bonds  50  also include a pair of symmetrical rearward-angled bonds  50 K 1 ,  50 K 2  extending from the first end  120  and the second end  121 , respectively, of the second central bond  50 L. 
     The cushioning article  110  articulates at first and second flexion axes A 1 , A 2  when the cushioning article  110  bends along an axis disposed at the first angle  117 B counterclockwise from the axis of symmetry  115 , and articulates at third and fourth flexion axes A 3 , A 4  when the cushioning article  110  bends along an axis disposed at the first angle  117 A clockwise from the axis of symmetry  115 . Accordingly, with reference to FIGA.  18 A and  18 B, cushioning articles  110 A and  110 B are identical to cushioning article  110  and to each other except for their orientation relative to the respective sole structures  12 R,  12 L. By securing the cushioning article  110 A in a sole structure  12 R configured for a right foot in a position in which the cushioning article  110 A is rotated clockwise by the first angle  117 B relative to a longitudinal bending axis LA of a sole structure  12 R, the cushioning article  110 A will articulate (i.e., flex) along the first axis A 1  and the second axis A 2  when the right foot dorsiflexes. By securing the cushioning article  110 B in a sole structure  12 L configured for a left foot in a position in which the cushioning article  110 B is rotated counterclockwise by the first angle  117 A relative to a longitudinal bending axis LA of a sole structure  12 L, the cushioning article  110 B will articulate along the third axis A 3  and the fourth axis A 4  when the left foot dorsiflexes. Alternatively, the cushioning article  110 A can be rotated counterclockwise when secured to the right foot sole structure  12 R and the cushioning article  110 B can be rotated clockwise when secured to the left foot sole structure  12 L in which case the cushioning article  110 A of the right foot sole structure  12 R will articulate along flexion axes A 3  and A 4 , and the cushioning article  110 B of the left foot sole structure  12 L will articulate along the flexion axes A 1  and A 2  during dorsiflexion of the respective right foot and left foot. In this manner, economies of scale can be achieved in manufacturing by using identically configured cushioning articles  110  in both right foot articles of footwear and left foot articles of footwear. 
     A method  210  of manufacturing a cushioning article, such as cushioning article  10 , is shown in the flow chart of  FIG.  19   , and is described with reference to  FIGS.  10  and  11   . The method  210  may begin with block  212 , securing a first mold insert  53  with a first protrusion pattern to the first mold portion  66 A. For example, the first mold insert  53  has openings  70  that receive fasteners  72 . The fasteners  72  extend into openings  74  in the first mold portion  66 A to secure the first mold insert  53  to the first mold portion  66 A. The openings  74  are in a recess  75  of the first mold portion  66 A, and the insert  53  fits within the recess  75  so that the surface  76  is flush with adjacent surfaces  78  of the first mold portion  66 A. The openings  70 ,  74  and the fasteners  72  may be threaded, for example. When disposed as set forth in block  212 , the mold insert  53  is therefore in and partially defines the mold cavity  68 . 
     Next, in block  214 , prior to disposing the components of the cushioning article  10  into the open mold cavity  68 , the components of the cushioning article  10 , the mold components, or both, may be pre-heated to help expedite the subsequent thermoforming that occurs via the combined blocks  218 ,  220 . In embodiments of the method  210  in which the mold component having the protrusion that creates the inwardly-protruding bond is one of the mold portions  66 A or  66 B rather than a mold insert  53 , the method  210  may instead begin with block  214 . 
     In block  216 , the first and second polymeric sheets  16 ,  18  and the tensile component  30  are then disposed in the mold cavity  68 , with the first tensile layer  32  positioned adjacent the first polymeric sheet  16 , the second tensile layer  34  positioned adjacent the second polymeric sheet  18 , and the plurality of tethers  36  connecting the first tensile layer to the second tensile layer. Block  216  may comprise placing first and second polymeric sheets  16 ,  18  and the tensile component  30  between the open mold portions  66 A,  66 B. This may be accomplished by the use of shuttle frames (not shown) that separately hold the various components of the cushioning article  10  in alignment with one another and with the mold components  66 A,  66 B,  53 , as shown in  FIG.  10   . In an embodiment, one or both of the first and second polymeric sheets  16 ,  18  may already by bonded to the respective tensile layers  32 ,  34  of the tensile component  30  when placed in the mold cavity  68 , such as by lamination or by the use of adhesive. In such an embodiment, block  220  is not necessary. If only one of the first and second polymeric sheets  16 ,  18  is laminated to the respective tensile layer  32 ,  34  prior to placement of the components in the mold cavity  68  and thermoforming, the completed cushioning article  10  will tend to curl along its longitudinal axis toward the side that is not pre-laminated. Alternatively, as shown in  FIG.  10   , the first and second polymeric sheets  16 ,  18  may not yet be bonded to the tensile component  30  when disposed in the mold cavity  68 . Once the components of the cushioning article  10  are positioned, one or both of the mold components  66 A,  66 B is translated toward the other mold component to close the mold cavity  68 . 
     Next, in block  218 , the first polymeric sheet  16  and the second polymeric sheet  18  are conformed to components of the mold  66 , as shown in  FIG.  11   . For example, the outer surface  49  of the first polymeric sheet  16  is conformed to the surface  76  of the mold insert  53 . The surface  76  includes the protrusions  51 . Portions of the outer surface  49  of the first polymeric sheet  16  are conformed directly to the mold surface  78  of the first mold portion  66 A adjacent to the mold insert  53 . Conforming of the first polymeric sheet  16  to the surface  76 , including the protrusions  51 , in this manner depresses the first polymeric sheet  16  toward the second polymeric sheet  18  at the protrusions  51 , with the protrusions  51  directly outward of some of the plurality of tethers  36 . In block  218 , the outer surface  57  of the second polymeric sheet  18  is also conformed to the mold surface  80  of the second mold component  66 B, as indicated in  FIG.  11   . Conforming the polymeric sheets  16 ,  18  to the surfaces  76 ,  78 ,  80  may include applying a vacuum to the mold cavity  68  to pull the sheets  16 ,  18  against the surfaces  76 ,  78 ,  80 . Alternatively or in addition, conforming the polymeric sheets  16 ,  18  to the surfaces  76 ,  78 ,  80  may include pressurizing the mold cavity  68 , thereby compressing the polymeric sheets  16 ,  18  against the surfaces  76 ,  78 ,  80 . 
     After or contemporaneously with the first and second polymeric sheets  16 ,  18  conforming to the surfaces  76 ,  78 ,  80  in block  218 , the first tensile layer  32  may be thermally bonded to the first polymeric sheet  16  and the second tensile layer  34  may be thermally bonded to the second polymeric sheet  18  opposite the first tensile layer  32  in block  220 . The heating of the polymeric sheets  16 ,  18 , the tensile layers  32 ,  34 , and/or the mold components  53 ,  66 A,  66 B in addition to the vacuum and/or pressurization of the mold cavity  68  enables the thermal bonding at the surface bonds  40 ,  44  and the inwardly-protruding bonds  50 . When the components are cooled, the bonds  40 ,  44 ,  50  remain. Conforming in block  218  and thermally bonding in block  220  may be referred to as thermoforming, and produces the inwardly-protruding bonds  50  at the protrusions  51  that join the first polymeric sheet  16  and the first tensile layer  32  and partially traverse the plurality of tethers  36 , with the inwardly-protruding bonds  50  protruding toward the second polymeric sheet  18  but remaining spaced apart from the second tensile layer  34  and the second polymeric sheet  18  as described with respect to  FIG.  3   . 
     The thermal bonding of block  220  may include heating the first polymeric sheet  16  and the second polymeric sheet  18  prior to disposing the first polymeric sheet  16  and the second polymeric sheet  18  in the mold cavity  68 . Alternatively or in addition, the thermal bonding may include heating one or more of the mold components  53 ,  66 A,  66 B, or radio frequency welding via the mold  66 . 
     Following block  220  or contemporaneously with block  220 , the method  210  may include block  222 , bonding the first polymeric sheet  16  to the second polymeric sheet  18  at the peripheral bond  20  such that the first polymeric sheet  16  and the second polymeric sheet  18  at least partially enclose the interior cavity  22  containing the tensile component  30 . For example, bonding the first polymeric sheet  16  and the second polymeric sheet  18  at the peripheral bond  20  in block  222  may include compressing the first polymeric sheet  16  and the second polymeric sheet  18  between the first mold portion  66 A and the second mold portion  66 B in the closed position, as shown in  FIG.  11   . A small portion of the periphery of the first and second polymeric sheets  16 ,  18  can be left unbonded, such as at an inflation port  82  molded into the sheets in blocks  218  and  220 . 
     After block  222 , the mold cavity  68  may be opened in block  224  by translating one or both of the mold portions  66 A,  66 B away from one another. The cushioning article  10  can then be removed from the mold cavity  68  in block  226 . 
     In block  228 , the interior cavity  22  can be inflated to a desired inflation pressure, such as through the inflation port  82  of  FIG.  1   . For example, a fill tube may fit into the inflation port  82  or may be integrally formed by the sheets  16 ,  18  at the inflation port  82 . Prior to or after inflating the interior cavity  22  in block  228 , excess material of the sheets  16 ,  18  around the peripheral bond  20  can be trimmed. Gas, such as air, can be dispensed from a pressurized source or pumped into the interior cavity  22  through the inflation port  82  from a pressurized source. In some embodiments, the interior cavity  22  is not inflated, but instead simply retains gas at atmospheric pressure. 
     The interior cavity  22  is sealed in block  230 . In the embodiment shown, this may be accomplished by sealing the inflation port  82 , such as by thermally bonding the sheets  16 ,  18  to one another at the inflation port  82 , adhering the sheets  16 ,  18  to one another at the inflation port  82 , or plugging the inflation port  82 . In  FIG.  1   , the sheets  16 ,  18  and any fill tube is already trimmed, and the inflation port  82  is sealed. The cushioning article  10  is completely manufactured once block  230  is completed, and is ready to be assembled in the article of footwear  14 . If the interior cavity  22  is inflated to a sufficient pressure, the plurality of tethers  36  are tensioned, creating the grooves  52  in the outer surface  49  of the first polymeric sheet  16  at the inwardly-protruding bonds  50 , thereby articulating the cushioning article  10  as discussed with respect to  FIG.  6   , with the grooves  52  establishing flexion axes. 
     The method  210  may be used to manufacture the cushioning article  110  having bonds with a symmetrical configuration. In such an embodiment, the method  200  may include block  232 , securing the cushioning article  110  (denoted as cushioning article  110 A in  FIG.  18 B ) to a first sole structure  12 R configured for a right foot with the axis of symmetry  115  of the cushioning article  110 A rotated at a first angle  117 B clockwise (or counterclockwise) relative to a longitudinal axis LA of the first sole structure. The method  210  may also include block  234 , securing a second cushioning article  110 B configured identically to the cushioning article  110 A (and as described herein with respect to cushioning article  110 ) to a second sole structure  12 L configured for a left foot with the axis of symmetry  115  of the second cushioning article  110 B rotated at the first angle  117 A counterclockwise (or clockwise if the cushioning article  110 A of the first sole structure  12 R is rotated counterclockwise) relative to a longitudinal axis LA of the second sole structure  12 L as shown in  FIG.  18 A . With the configuration shown in  FIGS.  18 A and  18 B , the cushioning article  110 A will articulate along axes A 1  and A 2 , and the cushioning article  110 B will articulate along axes A 3  and A 4 , both cushioning articles  110 A,  110 B therefore generally aligning in the same manner with the joints of the right foot as with the joints of the left foot when the sole structures  12 R,  12 L are assembled in articles of footwear worn by a wearer on a right foot and a left foot, respectively. 
     It should be appreciated that, although in  FIGS.  10 - 11    the mold component having the protrusions  51  that create the inwardly-protruding bonds  50  is a mold insert  53 , either or both of the mold portions  66 A,  66 B could have one or more protrusions, and no mold insert need be used. However, the use of mold inserts may allow the production of cushioning articles having different bond patterns with lower tooling expense. For example, the same mold portions  66 A,  66 B may be used with a different tooling insert to produce cushioning articles with different bond patterns.  FIG.  12    shows a mold portion  66 AA for a cushioning article for a full length sole structure. The mold portion  66 AA may be used in a mold similar to mold  66  in the same position as mold portion  66 A. The mold portion  66 AA has a recess  75 A similar to recess  75  at which a mold insert may be secured with fasteners extending into openings  74  similar to mold insert  53 .  FIG.  13    shows a first mold insert  53 A that has a first pattern of protrusions  51 . The first mold insert  53 A is secured to the mold portion  66 AA within the recess  75 A. When the mold portion  66 AA and first mold insert  53 A are used in a mold according to blocks  212  to  230  of the method of manufacturing  210 , a cushioning article that is a full length sole component with a first bond pattern (i.e., a bond pattern produced by the pattern of protrusions  51  of the mold insert  53 A) will be manufactured according to the method  210 . 
       FIG.  14    shows a second mold insert  53 B with a second pattern of protrusions  51 . The protrusions  51  of the second mold insert  53 B are shaped or dimensioned differently than the protrusions  51  of the first mold insert  53 A such that the second pattern of protrusions  51  is different than the first pattern of protrusions. After manufacturing the cushioning article having a first bond pattern (i.e., a first pattern of inwardly-protruding bonds corresponding to the first pattern of protrusions of the first mold insert  53 A), the method  210  may include block  236 , removing the first mold insert  53 A from the mold cavity  68 . Then, in block  238 , the second mold insert  53 B may be secured to the mold portion  66 AA, using fasteners  72  extending through openings  70 ,  74  as described with respect to the mold insert  53 A. With the second mold insert  53 B now disposed in the mold cavity  68 , blocks  212  to  230  of the method  210  can now be repeated to manufacture a second cushioning article that is a full length sole component having a different bond pattern than the first full length sole component produced using mold insert  53 A, the different bond pattern being a pattern of inwardly-protruding bonds  50  as described herein, but corresponding to the different pattern of protrusions of the second mold insert  53 B. For example, in repeating blocks  212  to  230 , block  216  is repeated by disposing a subsequent first polymeric sheet, a subsequent second polymeric sheet, and a subsequent tensile component in the mold cavity  68  with the subsequent tensile component between the subsequent first polymeric sheet and the subsequent second polymeric sheet. Block  218  is repeated by conforming the subsequent first polymeric sheet and the subsequent second polymeric sheet to the second mold insert  53 B and to another one of the mold components (e.g., a mold component similar to mold component  66 B), respectively, the conforming depressing the subsequent first polymeric sheet toward the subsequent second polymeric sheet at the second protrusion  51  (i.e., at one of the protrusions  51  of the second mold portion  53 B), with the second protrusion directly outward of the subsequent tensile component. For example, block  220  is repeated, thermally bonding the first tensile layer of the subsequent tensile component to the subsequent first polymeric sheet and the second tensile layer of the subsequent tensile component to the subsequent second polymeric sheet to produce a second inwardly-protruding bond at the second protrusion partially traversing the subsequent tensile component, the same mold portions and mold cavity thus providing a second cushioning article with a different bond pattern than the first cushioning article due to the second mold insert  53 B, and simply by removing the first mold insert  53 A and replacing it with the second mold insert  53 B. 
     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. As used in the description and the accompanying claims, unless stated otherwise, a value is considered to be “approximately” equal to a stated value if it is neither more than 5 percent greater than nor more than 5 percent less than the stated value. 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.