Patent Publication Number: US-2023147851-A1

Title: 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. Nonprovisional application Ser. No. 16/883,093 filed on May 26, 2020, which is a divisional of U.S. Nonprovisional application Ser. No. 15/982,749 filed on May 17, 2018, now U.S. Pat. No. 10,694,814, issued Jun. 30, 2020, which claims the benefit of priority to U.S. Provisional Application No. 62/508,044 filed on 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 a 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 close-up cross-sectional view of a portion of the cushioning article of  FIG.  3   . 
         FIG.  5    is a schematic illustration in close-up cross-sectional view of the cushioning article of  FIG.  4    under loading in a first stage of compression. 
         FIG.  6    is a schematic illustration in close-up cross-sectional view of the cushioning article of  FIG.  4    under loading in a second stage of compression. 
         FIG.  7    is a schematic illustration in close-up cross-sectional view of the cushioning article of  FIG.  4    under loading in a third stage of compression. 
         FIG.  8    is a schematic illustration in cross-sectional view of the cushioning article of  FIG.  1   , taken at lines  8 - 8  in  FIG.  1   . 
         FIG.  9    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.  10    is a schematic illustration in plan view of a cushioning article in accordance with an alternative aspect of the present teachings. 
         FIG.  11    is a schematic illustration in bottom view of the cushioning article of  FIG.  10   . 
         FIG.  12    is a schematic illustration in fragmentary cross-sectional view of the cushioning article of  FIG.  10   , taken at lines  12 - 12  in  FIG.  10   . 
         FIG.  13    is a schematic illustration in medial side view of the cushioning article of  FIG.  1   . 
         FIG.  14    is a schematic illustration in medial side view of the cushioning article of  FIG.  10   . 
         FIG.  15    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.  16    is a schematic illustration of the components of the cushioning article of  FIG.  1    in the mold of  FIG.  16   , with the mold in a closed position. 
         FIG.  17    is a schematic perspective illustration of a mold portion for manufacturing cushioning components. 
         FIG.  18    is a schematic perspective illustration of the mold portion of  FIG.  17    with a first mold insert secured to the mold portion. 
         FIG.  19    is a schematic perspective illustration of a second mold insert for use with the mold portion of  FIG.  17   . 
         FIG.  20    is a flow chart of a method of manufacturing a cushioning article. 
         FIG.  21    is a schematic illustration in plan view of a cushioning article in accordance with an alternative aspect of the present teachings. 
         FIG.  22    is a schematic illustration in bottom view of the cushioning article of  FIG.  21   . 
         FIG.  23    is a schematic illustration in cross-sectional view of the cushioning article of  FIG.  21   , taken at lines  23 - 23  in  FIG.  21   . 
         FIG.  24    is a schematic illustration in medial side view of the cushioning article of  FIG.  21   . 
     
    
    
     DESCRIPTION 
     A cushioning article comprises a bladder enclosing an interior cavity and retaining a gas in the interior cavity. A tensile component is disposed in the interior cavity and 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 a plurality of bonds arranged in closed shapes surrounding domed portions of the bladder. The plurality of bonds bond the inner surface of the bladder to the tensile component. The domed portions of the bladder are unbonded to the tensile component and are therefore displaced from the tensile component by the gas. 
     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. At least one of the first polymeric sheet and the second polymeric sheet includes the domed portions. 
     The plurality of bonds may protrude inward into the interior cavity and partially traverse the plurality of tethers such that the bladder is narrowed at the plurality of bonds. When an inflation pressure of the gas in the interior cavity is sufficient to tension the plurality of tethers, the plurality of bonds defines grooves at an outer surface of the bladder such that the cushioning article is articulated along the grooves. 
     The plurality of bonds may be a first plurality of bonds in a first region of the bladder, and the bladder may have a second plurality of bonds arranged in closed shapes in a second region of the bladder. Portions of the bladder surrounded by the closed shapes in the second region may be bonded to the tensile component. 
     The cushioning article may be for a variety of applications, such as but not limited to a sole component of an article of footwear. In such an embodiment, the first region may be on a distal side of the bladder (i.e., a ground contact side), and the second region may be on a proximal side of the bladder (i.e., a foot-facing side). In other embodiments, the first region and the second region are both on a distal side of the bladder or are both on a proximal side of the bladder. In still other embodiments, the plurality of bonds are a first plurality of bonds in a first region of the bladder, and the bladder has a second plurality of bonds arranged in closed shapes in a second region of the bladder. Portions of the bladder surrounded by the closed shapes in the second region are unbonded to the tensile component and form domed portions that are displaced from the tensile component by the gas. For example, both the proximal side and the distal side of the cushioning article may have the domed portions. 
     A cushioning article comprises a first polymeric sheet and a second polymeric sheet bonded to one another and enclosing an interior cavity. The first polymeric sheet and the second polymeric sheet retain a gas in the interior cavity. A tensile component is disposed in the interior cavity. The tensile component includes a first tensile layer, a second tensile layer, and a plurality of tethers spanning the interior cavity from the first tensile layer to the second tensile layer and connecting the first tensile layer to the second tensile layer. An inwardly-protruding bond joins the first polymeric sheet to the first tensile layer, protrudes inward from the first polymeric sheet toward the second polymeric sheet, and partially traverses the plurality of tethers. The first polymeric sheet is displaced from the first tensile layer adjacent to the inwardly-protruding bond by the gas. 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 fluidly communicates across the inwardly-protruding bond. Accordingly, the consistency and responsiveness of tethers in returning the interior cavity to its original shape following a dynamic compressive load is combined with staged cushioning, and 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 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. 
     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, with 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 at the inwardly-protruding bond, and the inwardly-protruding bond defines a groove at an outer surface of the first polymeric sheet such that the cushioning article is divided into a first article portion on one side of the groove and a second article portion on the other side of the groove, and the first article portion is articulated relative to the second article portion along the groove. 
     In one or more embodiments, the first tensile layer is spaced apart from the second tensile layer by a first distance at a location adjacent to the inwardly-protruding bond, and the inwardly-protruding bond is spaced apart from the second tensile layer by a second distance. The second distance is 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 inwardly-protruding bond defines a closed shape surrounding a portion of the first polymeric sheet displaced from the first tensile layer such that the portion of the first polymeric sheet has a domed surface extending away from the first tensile layer. 
     In some embodiments, the second polymeric sheet is recessed inward toward the inwardly-protruding bond of the first polymeric sheet when the interior cavity is inflated. In other embodiments, the second polymeric sheet also has inwardly-protruding bonds. 
     In some embodiments, the inwardly-protruding bond may be a first inwardly-protruding bond, the portion of the first polymeric sheet surrounded by the closed shape is a first portion of the first polymeric sheet in a first region of the first polymeric sheet, an inner surface of a second portion of the first polymeric sheet in a second region of the first polymeric sheet spaced apart from the first region is bonded to an outer surface of the first tensile layer; and the cushioning article may further comprise a second inwardly-protruding bond that joins the first polymeric sheet to the first tensile layer and protrudes from the first polymeric sheet toward the second polymeric sheet in the second region and partially traverses the tensile component. The second inwardly-protruding bond may be 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 method of manufacturing a cushioning article comprises disposing anti-weld material on at least one of an inner surface of a first polymeric sheet and an outer surface of a first tensile layer of a tensile component. The tensile component includes the first tensile layer, a second tensile layer, and a plurality of tethers connecting the first tensile layer to the second tensile layer. The method further comprises conforming the first polymeric sheet and a second polymeric sheet to components of a mold. Conforming the first polymeric sheet in this manner depresses the first polymeric sheet toward the second polymeric sheet at protrusions of the mold arranged in closed shapes and with the protrusion directly outward of the plurality of tethers. The method further 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. Thermally bonding the tensile layers to the polymeric sheets in this manner produces a plurality of bonds at the protrusion that joins the first polymeric sheet to the first tensile layer and partially traverses the plurality of tethers. The plurality of bonds protrude toward the second polymeric sheet and are spaced apart from the second tensile layer and the second polymeric sheet. The first polymeric sheet is separated from the first tensile layer adjacent to the inwardly-protruding bonds due to the anti-weld material such that portions of the first polymeric sheet surrounded by the plurality of bonds forming the closed shapes are displaceable from the first tensile layer. For example, when inflated, a portion of the first polymeric surrounded by bonds forming a closed shape forms a domed surface. 
     In one or more embodiments, the method further comprises 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 at least partially enclose 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 plurality of bonds protrudes inward such that the interior cavity is narrowed at the inwardly-protruding bond. 
     In one or more embodiments, the method further comprises inflating and sealing the interior cavity. Inflating the interior cavity in this manner lifts the portions of the first polymeric sheet surrounded by the closed shapes away from the tensile component to form the domed portions, and tensions the plurality of tethers at the plurality of bonds to creates a plurality of grooves in an outer surface of the first polymeric sheet at the plurality of bonds, thereby articulating the cushioning article. For example, the cushioning article may be a sole component for an article of footwear, and the groove may establish a flexion axis of the sole component. 
     In one or more embodiments, the components of the mold include a first mold portion and a second mold portion. At least one of the first mold portion and the second mold portion is translatable relative to the other of the first mold portion and the second mold portion between an open position and a closed position. Bonding the first 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, the mold component having the plurality of protrusions is one of the first mold portion and the second mold portion. Alternatively, in other embodiments, the mold component having the plurality of protrusions is a 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, the method may further comprise, prior to conforming the first polymeric sheet and the second polymeric sheets to components of the mold, securing a mold insert to a mold portion of the mold, and wherein the mold component having the plurality of protrusions is the mold insert. In some embodiments, the mold insert is a first mold insert, the mold portion is a first mold portion, the plurality of bonds is a first plurality of bonds, and the method further comprises securing a second mold insert to a second mold portion of the mold, wherein the second mold insert has a second plurality of protrusions directly opposite the first plurality of protrusions and outward of the plurality of tethers. In such an embodiment, conforming the first and second polymeric sheets and thermally bonding the first tensile layer to the first polymeric sheet and the second tensile layer to the second polymeric sheet produces a second plurality of bonds at the second plurality of protrusions partially traversing the tensile component directly opposite the first plurality of bonds. The second plurality of bonds protrudes toward the first plurality of bonds and the first polymeric sheet, and is spaced apart from the first plurality of bonds, the first tensile layer, and the first polymeric sheet. 
     In one or more embodiments, the cushioning article is a first cushioning article, and the method further comprises manufacturing a second cushioning article by removing the mold insert from the mold portion, and securing a second mold insert having a second plurality of protrusions to the mold portion. The second plurality of protrusions is shaped, dimensioned or positioned differently than the first plurality of protrusions. The method further comprises conforming a subsequent first polymeric sheet and a subsequent second polymeric sheet to the second mold insert and to another one of the components of the mold, respectively, with a subsequent tensile component between the subsequent first polymeric sheet and the subsequent second polymeric sheet. Conforming the subsequent first and second polymeric sheets in this manner depresses the subsequent first polymeric sheet toward the subsequent second polymeric sheet at the second plurality of protrusions, with the second plurality of protrusions directly outward of the subsequent tensile component, thereby producing a second plurality of bonds at the second plurality of protrusions partially traversing 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. 
     In one or more embodiments, conforming the first polymeric sheet and the second polymeric sheet to components of the mold is by vacuum, compression, or both. Additionally, in one or more embodiments, thermal bonding of the first tensile layer to the first polymeric sheet and the second tensile layer to the second polymeric sheet includes at least one of heating the first polymeric sheet and the second polymeric sheet, heating the mold components, or radio frequency welding. 
     The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the 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.  20    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.  9   . The cushioning article  10  is a full length cushioning article for a sole structure  12 , as it has a forefoot region  17 A, a midfoot region  17 B, and a heel region  17 C. The forefoot region  17 A may be generally associated with the toes and joints connecting the metatarsals with the phalanges. The midfoot region  17 B may be generally associated with the arch of a foot. The heel region  17 C may be generally associated with the heel of a foot, including the calcaneus bone. The cushioning article  10  has a lateral side  19  and a medial side  21 . In particular, the lateral side  19  and the medial side  21  may be opposing sides of the cushioning article  10 , and may extend along the forefoot region  17 A, the midfoot region  17 B, and the heel region  17 C. In the embodiment of the cushioning article  10  shown in  FIGS.  1  and  2   , the first polymeric sheet  16  establishes the proximal side of the bladder  23  (i.e., the side closest to the foot when assembled in an article of footwear). The second polymeric sheet  18  establishes the distal side of the bladder  23  (i.e., the ground-facing side of the bladder). 
     In  FIG.  9   , 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  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 may be for a backpack strap, a helmet cushion, a shin guard, a baseball glove, a seat cushion, or a floor mat. 
     Referring to  FIGS.  1 - 3   , the cushioning article  10  includes a bladder  23  having a first polymeric sheet  16  and a second polymeric sheet  18  bonded to one another at a peripheral bond  20  to enclose an interior cavity  22 . When the sheets  16 ,  18  are bonded together at the peripheral bond  20  and any inflation port  82  is sealed, the first polymeric sheet  16  and the second polymeric sheet  18  retain 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  36  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. It should be appreciated that the first tensile layer  32  and the second tensile layer  34  are permeable by the gas in the interior cavity. As such, the interior cavity  22  extends through the first tensile layer  32  and the second tensile layer  34 , in between and around the tethers  36 , from the inner surface of the first polymeric sheet  16  to the inner surface of the second polymeric sheet  18 . The tensile layers  32 ,  34  are not subjected to outward forces by the gas in the interior cavity where the tensile layers are not bonded to the first and second polymeric sheets  16 ,  18 . Accordingly, tethers  36 B that extend between the portions of the tensile layer  32 ,  34  that are not bonded to the polymeric sheets  16 ,  18  (e.g., the portions of the tensile layers  32 ,  34  that are inward of the domed portions) may not be in tension. However, tethers  36 A that extend between the portions of the tensile layers  32 ,  34  bonded to the polymeric sheets  16 ,  18  (e.g., at inwardly-protruding bonds  50 ) are subjected to tension under a sufficiently inflation pressure of the interior cavity  22 . 
     Anti-weld material  48  is applied to selected areas of the outer surfaces  45 ,  47 , respectively, of the first and second tensile layers  32 ,  34  as best shown in  FIG.  15   . For example, anti-weld material may be ink jet printed everywhere except at areas where protrusions of mold components used during thermoforming of the cushioning article  10  cause inwardly-protruding bonds  50  of the first polymeric sheet  16  and the second polymeric sheet  18 , as further explained herein. The inwardly-protruding bonds  50  of the first polymeric sheet  16  are also referred to as a first plurality of bonds. Alternatively, anti-weld material may be applied even where the bonds  50  are desired, if the anti-weld material is not activated. The anti-weld material  48 , if activated, prevents the inner surfaces  42 ,  46  of the first and second polymeric sheets  16 ,  18  from bonding to the outer surfaces  45 ,  47  of the tensile component  30  during the manufacturing method  210  described herein. The first tensile layer  32  is bonded to an inner surface  42  of the first polymeric sheet  16  at the inwardly-protruding bonds  50 . The second tensile layer  34  is bonded to an inner surface  46  of the second polymeric sheet  18  at inwardly-protruding bonds  50  as best shown in  FIG.  3   . The inwardly-protruding bonds  50  of the second polymeric sheet  18  are also referred to as a second plurality of bonds. The first plurality of bonds  50  are in a first region of the bladder  23  (e.g., on the proximal side in each of the forefoot, midfoot, and heel regions), and the second plurality of bonds  50  are in a second region of the bladder  23  (e.g., on the distal side in each of the forefoot, midfoot, and heel regions). 
     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  on the inner surfaces  42 ,  46  of the first and second polymeric sheets  16 ,  18  places the tethers  36 A at the inwardly-protruding bonds  50  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.  15   . In  FIG.  15   , the tethers  36  are represented in a slackened state as  FIG.  15    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 ,  54  of the first and second polymeric sheets  16 ,  18 , respectively, are generally flat directly above the tethers  36  (i.e., not contoured) prior to manufacture of the cushioning article  10 , the method of manufacturing  210  produces inwardly-protruding bonds  50  that join the first polymeric sheet  16  to the first tensile layer  32  that protrude from the first polymeric sheet  16  toward the second polymeric sheet  18  directly into a region of the cavity  22  occupied by some of the tethers  36 . In fact, in  FIG.  3   , there are multiple inwardly-protruding bonds  50 . 
     Each bond  50  in the first polymeric sheet  16  results from a respective protrusion  51  of a mold component  53 A (best shown in  FIGS.  15  and  18    as a plurality of protrusions  51  arranged in closed shapes) that contacts the first polymeric sheet  16  during the method of manufacturing  210  disclosed herein. Each bond  50  in the second polymeric sheet  18  results from a respective protrusion  51  of a mold component  53 B (also shown as a plurality of protrusions  51  arranged in closed shapes) that contacts the second polymeric sheet  18  during the method of manufacturing  210  disclosed herein (see  FIG.  15   ).  FIG.  18    shows a representative mold component  53 A 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 B is identical to mold component  53 A, and results in the same bond pattern  55 A on the second polymeric sheet  18 . The mold component  53 A is a first mold insert, and may also be referred to as a shim. The mold component  53 B is a second mold insert. The bonds  50  are indicated with hidden lines in  FIGS.  1  and  2    as they protrude inward from the outer surfaces  49 ,  54  shown. 
     The bonds  50  result in depressed grooves  52  at the outer surface  49  of the first polymeric sheet  16  and at the outer surface  54  of the second polymeric sheet  18 . Only some of the bonds  50  and some of the grooves  52  are indicated in  FIGS.  1  and  2    for clarity. As best shown in  FIGS.  1  and  2   , the inwardly-protruding bonds  50  on the first polymeric sheet  16  define closed shapes surrounding portions of the first polymeric sheet  16 . The inwardly-protruding bonds  50  on the second polymeric sheet  18  define closed shapes surrounding portions of the second polymeric sheet  18 . In the embodiment shown, the closed shapes are polygons. For example, one closed shape is a pentagon, and is indicated in  FIG.  1    by numbering the bonds  50  that surround and define the closed shape as bonds  50 A,  50 B,  50 C,  50 D, and  50 E. The corresponding grooves  52  are numbered as  52 A,  52 B,  52 C,  52 D, and  52 E. 
     Due to the pressure of the gas in the interior cavity  22 , a portion  16 A of the first polymeric sheet  16  that is not bonded to the first tensile layer  32  (i.e., unbonded) and is surrounded by the bonds  50 A,  50 B,  50 C,  50 D,  50 E defining the closed shape is displaced from the first tensile layer  32  (i.e., lifted away from the first tensile layer) such that the portion  16 A of the first polymeric sheet  16  has a domed surface  49 A extending away from the first tensile layer  32 . The closed shape and domed surface  49 A indicated is only one of many closed shapes and resulting domes surfaces at the outer surface  49  of the first polymeric sheet  16 . Additional portions with domed surfaces  49 B,  49 C,  49 D,  49 E are indicated in  FIG.  3    and may be referred to as domed portions. As is apparent from the plan view of  FIG.  1   , the first polymeric sheet  16  effectively has a multitude of rounded bubble-like shapes extending over each of the forefoot region  17 A, the midfoot region  17 B, and the heel region  17 C of the cushioning article  10 . As used herein, “domed” means rounded, and need not be hemispherical. 
     Similarly, with reference to  FIG.  2   , one closed shape at the second polymeric sheet  18  is a pentagon, indicated in  FIG.  2    by numbering the bonds  50  that surround and define the closed shape as bonds  50 F,  50 G,  50 H,  50 I, and  50 J. The corresponding grooves  52  are numbered as  52 F,  52 G,  52 H,  52 I, and  52 J. Due to the pressure of the gas in the interior cavity  22 , a portion  18 A of the second polymeric sheet  18  surrounded by the bonds  50 F,  50 G,  50 H,  50 I,  50 J defining the closed shape is displaced from the second tensile layer  34  such that the portion  18 A of the second polymeric sheet  18  has a domed surface  54 A extending away from the second tensile layer  34  as best shown in  FIG.  3   . The closed shape and portion of second polymeric sheet  18  with a domed surface  54 A indicated is only one of many closed shapes and resulting portions with domes surfaces at the outer surface  54  of the second polymeric sheet  18 . Additional portions with domed surfaces  54 B,  54 C,  54 D,  54 E are indicated in  FIG.  3   . As is apparent from the bottom view of  FIG.  2   , the second polymeric sheet  18  effectively has a multitude of rounded, bubble-like shapes extending over each of the forefoot region  17 A, the midfoot region  17 B, and the heel region  17 C of the cushioning article  10 . 
     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.  4   , the plurality of tethers  36  includes tethers  36 A aligned with the inwardly-protruding bonds  50  and tethers  36 B displaced from the inwardly-protruding bonds  50 . Tethers  36 A that are aligned with an inwardly-protruding bonds  50  are deformed by heat, by compression of the overlaying materials of the first tensile layer  32  and the second tensile layer  34 , and/or by the overlaying material of the first tensile layer  32  and/or the second tensile layer  34  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.  4    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  FIG.  3   . When an inflation pressure of the gas in the interior cavity  22  against the inner surfaces of the polymeric sheets  16 ,  18  is sufficient to cause the polymeric sheets  16 ,  18  to tension the tethers  36 A, the inwardly-protruding bonds  50  define the grooves  52  at the outer surface  49  of the first polymeric sheet  16  and in the outer surface  54  of the second polymeric sheet  18 . 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    with respect to the left-most groove  52  indicated. 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 D of outer surface  49 ) is non-planar with the outer surface  49  of the first polymeric sheet  16  at a second side of the inwardly-protruding bond  50  (the second side indicated in  FIG.  4    as portion  49 C of outer surface  49 ), with the second side opposite of the first side. The outer surface  54  of the second polymeric sheet  18  at a first side of the inwardly-protruding bond  50  (the first side indicated in  FIG.  4    as portion  54 D of outer surface  54 ) is non-planar with the outer surface  54  of the second polymeric sheet  18  at a second side of the inwardly-protruding bond  50  (the second side indicated in  FIG.  4    as portion  54 C of outer surface  54 ), with the second side opposite of the first side. 
     The grooves  52  may act as flexion axes of the cushioning article  10 . For example, when the cushioning article  10  is included in the sole structure  12  of the article of footwear  14  in  FIG.  9   , the inwardly-protruding bonds  50  and resulting grooves  52  may establish flexion axes of the sole structure  12 . The bonds  50  may be configured so that many of the bonds  50  fall lengthwise near or along a common axis to establish flexion axes that may align with joints of the foot, such as the metatarsal phalangeal joints, thereby increasing flexibility of the sole structure  12 . Various flexion axes F 1 , F 2  are indicated in  FIG.  1   . Flexion axes increase flexibility of the cushioning article  10 . In some embodiments, some of the bonds  50  may be aligned in a straight line from the medial side to the lateral side of the cushioning article, creating a flexion axis that extends transversely across the entire cushioning article. 
     Referring to  FIGS.  3  and  4   , each inwardly-protruding bond  50  at the first polymeric sheet  16  is spaced apart from the second polymeric sheet  18 , and each inwardly-protruding bond  50  at the second polymeric sheet  18  is spaced apart from the first polymeric sheet  16  such that the interior cavity  22  is narrowed but not closed at the inwardly-protruding bonds  50 . Gas in the interior cavity  22  can thus fluidly communicate across any of the inwardly-protruding bonds  50  (i.e., between a bond  50  on the first polymeric sheet  16  and a corresponding bond  50  on the second polymeric sheet  18 ). As shown in  FIG.  4   , 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  at the first polymeric sheet  16  and the first tensile layer  32  is spaced apart from the inwardly-protruding bond  50  at the second polymeric sheet  18  and 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 B that are not the modified tethers  36 A. The second distance D 2  may be the minimum distance between the corresponding inwardly-protruding bonds  50  at the modified tethers  36 A (i.e., the distance at the most narrowed portion of the interior cavity  22  between corresponding bonds  50  of the first and second polymeric sheets  16 ,  18 ). 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  50  in this range of depth may create the most desirable amount of articulation. For example, factors that may influence the bond  50  and the extent of its protrusion toward the opposite first or second polymeric sheet  16 ,  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 corresponding inwardly-protruding bonds  50  is in fluid communication with a portion  22 B of the interior cavity  22  at a second side of the corresponding inwardly-protruding bonds  50 , with the second side opposite of the first side, as indicated in  FIG.  4   . The modified tethers  36 A shown extending under the corresponding bonds  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 Gin  FIG.  9   . 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 . 
       FIGS.  5 - 7    show stages of compression of the cushioning article  10  under compressive force F applied normal to the domed surfaces of the first and second polymeric sheets  16 ,  18 , such as under dynamic compressive loading during a foot strike when the cushioning article is a sole component of the sole structure  12  of  FIG.  9   . During initial loading, the portions with domed surfaces  49 B,  49 C,  49 D and  54 B,  54 C,  54 D begin to flatten, and the gas in the interior cavity  22  becomes more pressurized as the volume of the cavity  22  decreases, as depicted by the changes to the cushioning article  10  from  FIG.  5    to  FIG.  6   . Under continued loading, the domed surfaces may completely flatten, and the first and second polymeric sheets  16 ,  18  contact the first and second tensile components  32 ,  34  between the bonds  50 . With even further loading the shortened tethers  36 A will collapse. When the dynamic compressive forces F are removed, the tethers  36 A will return to a tensioned state, and the portions of the first and second polymeric sheets  16 ,  18  between the closed shapes of the bonds  50  will return to their domed shapes. 
       FIGS.  10 - 11    show another embodiment of a cushioning article  110 . The cushioning article  110  has many of the same features as cushioning article  10 , and these are shown with like reference numbers and are as described with respect to the cushioning article  10 . The sheets  16 ,  18  form a bladder  123 , with the first polymeric sheet establishing the proximal side of the bladder  123  and the second polymeric sheet  18  establishing the distal side of the bladder  123 . In the cushioning article  110 , anti-weld material is applied only forward of a representative dividing line  113  on the first and second polymeric sheets  16 ,  18  and/or on the tensile layers  32 ,  34  where bonding is not desired. Accordingly, as indicated in  FIGS.  12  and  14   , the first and second polymeric sheets  16 ,  18  have portions with inner surfaces  42 ,  46  that are surrounded by a first plurality of bonds  50  arranged in closed shapes, and are displaced from the outer surfaces  45 ,  47  of the adjacent first and second tensile layers  32 ,  34 , respectively, forming the domed surfaces  49 F,  49 G,  54 F,  54 G, etc., only in a first region of the first polymeric sheet  16 , which is the region forward of the dividing line  113 . 
     In a second region of the first polymeric sheet  16 , which is a region rearward of the dividing line  113  in  FIGS.  10 ,  11 ,  12 , and  14   , the inner surface  42  of the first polymeric sheet  16  is bonded to an outer surface  45  of the first tensile layer  32  at surface bonds  40 , and the inner surface  46  of the second polymeric sheet  18  is bonded to the outer surface  47  of the second tensile layer  34  at surface bonds  44 . A mold is used so that protrusions  51  contact the only first polymeric sheet  16  in the second region. A second plurality of inwardly-protruding bonds  50  arranged in closed shapes are formed at the first polymeric sheet  16  in the second region, but not in the second polymeric sheet  18  in the second region. 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  and in the outer surface  54  of the second polymeric sheet  18  at the inwardly-protruding bonds  50 . When an inflation pressure of the gas in the interior cavity  22  is sufficient to tension the plurality of tethers  36 A at the inwardly-protruding bonds  50 , the inwardly-protruding bonds  50  define grooves  52  at the outer surface  49  of the first polymeric sheet  16  and at the outer surface  54  of the second polymeric sheet  18 . Although the first and the second pluralities of bonds  50  are shown on the first polymeric sheet  16  on the proximal side, the cushioning article  110  could be used in an article of footwear with the first polymeric sheet on the distal side. 
     The tension of the modified tethers  36 A also causes recesses  56  in the outer surface  54  of the second polymeric sheet  18  opposite each of the inwardly-protruding bonds  50  of the first polymeric sheet  16 . 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 grooves  52  are generally deeper than the recesses  56 , which may cause the cushioning article  10  to be articulated in the second region even when not under a compressive load, as the cushioning article  10  curves slightly upward at each groove  52 . Stated differently, 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 second region of the cushioning article  10  may have an articulated shape, such as when not under loading at the grooves  52 , as shown in  FIG.  14   , where the second region is slightly curved upward from the horizontal line H. Additionally, the grooves  52  and recesses  56  together encourage articulation 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 . In contrast, the cushioning article  10  that has grooves  52  on both sides due to inwardly-protruding bonds  50  at both the first and second polymeric sheets  16 ,  18  remains more level and less articulated than the cushioning article  110  when not under loading, but, like cushioning article  110 , encourages articulation at the grooves  52 . 
     Due to the surface bonds  40 , any rounding or doming of the polymeric sheet  16  at the closed shapes surrounded by inwardly-protruding bonds  50  is lessened, and does not include any displacement of the first polymeric sheet  16  from the first tensile layer  32 . In  FIG.  14   , the first and second tensile layers  32 ,  34  are indicated with hidden lines following the contours of the first and second polymeric sheets  16 ,  18  in the second region, and are intended to indicate that the inner surfaces  42 ,  46  are bonded to the outer surfaces  45 ,  47  in the entirety of the second region. As shown in  FIG.  12   , at a first inwardly-protruding bond  50 K, the interior cavity  22  is narrowed but not closed, so gas can communicate across the bond  50 K and the corresponding bond  50  of the second polymeric sheet  18 . At a second inwardly-protruding bond  50 L in the second region, the interior cavity  22  is narrowed but not closed, so gas can communicate across the bond  50 L and a corresponding bond  50  of the second polymeric sheet  18 . 
       FIG.  15    shows the components of the cushioning article  10  in an exploded view and positioned between components of a mold  66 . More specifically, the components of mold  66  (also referred to herein as mold components) include a first mold portion  66 A, a second mold portion  66 B, a first mold insert  53 A, and a second mold insert  53 B. The components of the mold necessary to manufacture the cushioning article  110  are the same except that the second mold insert  53 B would not have protrusions  51  as no inwardly-protruding bonds are created at the second polymeric sheet  18  in the cushioning article  110 . Alternatively, the second mold portion  66 B could be modified so that no mold insert is necessary, and the mold surface contacting the outer surface  54  of the second polymeric sheet  18  has no protrusions  51 .  FIG.  16    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. Although the polymeric sheets  16 ,  18  are in contact with the tensile components  32 ,  34  in the mold  66 , anti-weld material prevents bonding of the polymeric sheets  16 ,  18  to the tensile components  32 ,  34  where the anti-weld material is disposed. 
       FIGS.  21 - 24    show another embodiment of a cushioning article  310 . The cushioning article  310  has many of the same features as cushioning articles  10  and  110 , and these are shown with like reference numbers and are as described with respect to the cushioning article  310 . In the cushioning article  310 , anti-weld material is applied to the inner surfaces of only the second polymeric sheet  18  and/or on the tensile layer  34 . Accordingly, as indicated in  FIG.  23   , the first polymeric sheet  16  is at a proximal side of the cushioning article  310  and has a plurality of bonds  50  (referred to as a second plurality of bonds) in a second region of the bladder  323  which is the entire forefoot region  17 A, midfoot region  17 B, and heel region  17 C on a distal side of the bladder  323  (defining closed shapes, and portions surrounded by the closed shapes having surface bonds  40  to the first tensile layer  32 . The second polymeric sheet  18  has portions with a first plurality of bonds  50  arranged in closed shapes surrounding portions with inner surfaces  46  that are displaced from the outer surface  47  of the adjacent second tensile layer  34 , forming the domed surfaces  54 F,  54 G,  54 H,  54 I,  54 J, etc., in a first region of the second polymeric sheet  18 , which is the entire forefoot region  17 A, midfoot region  17 B, and heel region  17 C on a distal side of the bladder  23 . 
     In a second region of the first polymeric sheet  16 , which is a region rearward of the dividing line  113  in  FIGS.  10 ,  11 ,  12 , and  14   , the inner surface  42  of the first polymeric sheet  16  is bonded to an outer surface  45  of the first tensile layer  32  at surface bonds  40 , and the inner surface  46  of the second polymeric sheet  18  is bonded to the outer surface  47  of the second tensile layer  34  at surface bonds  44 . A mold is used so that protrusions  51  contact the only first polymeric sheet  16  in the second region. Inwardly-protruding bonds  50  are formed at the first polymeric sheet  16  in the second region, but not in the second polymeric sheet  18  in the second region. 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  and in the outer surface  54  of the second polymeric sheet  18  at the inwardly-protruding bonds  50 . When an inflation pressure of the gas in the interior cavity  22  is sufficient to tension the plurality of tethers  36 A at the inwardly-protruding bonds  50 , the inwardly-protruding bonds  50  define grooves  52  at the outer surface  49  of the first polymeric sheet  16  and at the outer surface  54  of the second polymeric sheet  18 . 
     A method  210  of manufacturing a cushioning article, such as cushioning article  10 ,  110 , or  310  is shown in the flow chart of  FIG.  20   , and is described with reference to  FIGS.  15  and  16   . The method  210  may begin with block  211 , disposing anti-weld material on the inner surface of the first polymeric sheet  16 , or on the outer surface of the first tensile layer  32 . In manufacturing the cushioning article  110 , the anti-weld material would only be disposed forward of the dividing line  113 , such as in the first region of the first polymeric sheet  16 . In manufacturing the cushioning article  10 , the method also includes block  212 , disposing anti-weld material on the inner surface of the second polymeric sheet  18  or on the outer surface of the second tensile layer  34 . In manufacturing cushioning article  110 , block  212  may be omitted for some regions of the polymeric sheet  18  as discussed herein. In manufacturing cushioning article  310 , block  211  may be omitted. The anti-weld material disposed in blocks  211  and  212  is not disposed in locations where bonds  50  are desired. For example, the anti-weld material may be disposed forward of dividing line  113  as described, but avoiding the areas of the sheets  16 ,  18  and the tensile layers  32 ,  34  where bonds are desired. The correct placement of anti-weld material to achieve this may be by ink-jet printing the correct pattern on the surfaces of the sheets  16 ,  18  and/or tensile layers. Alternatively, the anti-weld material may be disposed at locations where bonds are desired, if it is not activated at those locations. 
     In block  213 , a first mold insert  53 A with a first protrusion pattern  55 A (i.e., the pattern of protrusions  51  arranged in closed shapes) is secured to the first mold portion  66 A, as best shown in  FIG.  18   . For example, as indicated in  FIG.  15   , the first mold insert  53 A 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 A to the first mold portion  66 A. The openings  74  are in a recess  75  of the first mold portion  66 A, and the mold insert  53 A 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 A is therefore in and partially defines the mold cavity  68 . 
     When manufacturing the cushioning article  10  or  310 , a second mold insert  53 B having a plurality of protrusions  51  arranged in closed shapes will be secured to the second mold portion  66 B in block  214  in the same manner as first mold insert  53 A is secured to first mold portion  66 A. For some configurations, the first and second mold portions  66 A,  66 B may be configured with the plurality of protrusions  51  arranged in closed shapes such that no mold inserts  53 A,  53 B need be used. However, the use of mold inserts  53 A,  53 B allows the same mold portions  66 A,  66 B to be used in manufacturing cushioning articles with different bond patterns simply by changing either or both mold inserts  53 A,  53 B for those with an alternative pattern of protrusions. When manufacturing the cushioning article  110 , no protrusions are necessary adjacent the second polymeric sheet  18  rearward of line  113  as no inwardly-protruding bonds  50  are created in the second polymeric sheet  18  in this region. Accordingly, in manufacturing the cushioning article  110 , the second mold portion  66 B configured to align rearward of line  113  may be provided without protrusions and with a surface configured to shape the outer surface of the second polymeric sheet  18 . 
     Next, in block  215 , prior to disposing the components of the cushioning article  10  into the open mold cavity  68 , the components of the cushioning article  10  (or cushioning article  110  or  310 ), the mold components  53 A,  53 B,  66 A,  66 B, or both, may be pre-heated to help expedite the subsequent thermoforming that occurs via the combined blocks  218 ,  220 . 
     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 ,  110 , or  310  in alignment with one another and with the mold components  66 A,  66 B,  53 A,  53 B, as shown in  FIG.  15   . When manufacturing the cushioning article  110 , the first and second polymeric sheets  16 ,  18  may already by bonded to the respective tensile layers  32 ,  34  of the tensile component  30  rearward of the dividing line  113  when placed in the mold cavity  68 , such as by lamination or by the use of adhesive. Alternatively, as shown in  FIG.  15   , the first and second polymeric sheets  16 ,  18  may not yet be bonded to the tensile component  30 . Once the components of the cushioning article  10 ,  110 , or  310  are positioned in the mold cavity  68 , 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.  16   . For example, the outer surface  49  of the first polymeric sheet  16  is conformed to the surface  76  of the mold insert  53 A. The surface  76  includes the plurality of 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 first mold insert  53 A. Conforming of the first polymeric sheet  16  to the surface  76 , including the plurality of protrusions  51 , depresses the first polymeric sheet  16  toward the second polymeric sheet  18  at the plurality of protrusions  51 , with the plurality of protrusions  51  directly outward of some of the plurality of tethers  36 . In block  218 , the outer surface  54  of the second polymeric sheet  18  is also conformed to the surface  77  of the second mold insert  53 B and to the mold surface  79  of the second mold portion  66 B adjacent to the second mold insert  53 B, indicated in  FIG.  16   . Conforming the polymeric sheets  16 ,  18  to the surfaces of the mold inserts  53 A,  53 B and the mold portions  66 A,  66 B may include applying a vacuum to the mold cavity  68  to pull the polymeric sheets  16 ,  18  against the surfaces  76 ,  77 ,  78 ,  79 . Alternatively or in addition, conforming the polymeric sheets  16 ,  18  to the surfaces may include pressurizing the mold cavity  68 , thereby compressing the polymeric sheets  16 ,  18  against the surfaces  76 ,  77 ,  78 ,  79 . 
     After or contemporaneously with the first and second polymeric sheets  16 ,  18  conforming to the surfaces  76 ,  77 ,  78 ,  79  in block  218 , the first tensile layer  32  may be thermally bonded to the first polymeric sheet  16  and the second tensile layer  34  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 A,  53 B,  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 of the cushioning article  10  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 A,  53 B,  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.  16   . 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 ,  110 , or  310  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, portions of the polymeric sheet  16  and/or  18  of the cushioning article  10 ,  110 , or  310  that forms domed portions with domed surfaces  49 A- 49 D,  54 A- 54 J, etc., and the plurality of tethers  36 A at the bonds  50  are tensioned, creating the grooves  52  in the outer surface  49  of the first polymeric sheet  16  and at the outer surface  54  of the second polymeric sheet  18  at the inwardly-protruding bonds  50 , thereby articulating the cushioning article  10 ,  110 , or  310  as discussed with respect to  FIG.  6   , with the grooves  52  establishing flexion axes. 
     It should be appreciated that, although in  FIGS.  15 - 16    the mold component having the protrusions  51  that create the inwardly-protruding bonds  50  is a mold insert  53 A and/or  53 B, 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 having a different pattern of protrusions to produce cushioning articles with different bond patterns. For example,  FIG.  19    shows a different mold insert  53 AA with a different pattern  55 AA of protrusions  51 . The protrusions  51  of the mold insert  53 AA are shaped, dimensioned, or positioned differently than the protrusions  51  of the first mold insert  53 A such that the pattern of protrusions  51  of mold insert  53 AA is different than the first pattern of protrusions of mold insert  53 A. 
     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  232 , removing the first mold insert  53 A from the mold cavity  68 . Then, in block  234 , the different mold insert  53 AA may be secured to the mold portion  66 A, using fasteners  72  extending through openings  70 ,  74  as described with respect to the mold insert  53 A. Mold insert  53 B may also be replaced with a different mold insert with a different pattern of protrusions. With the mold insert  53 AA now disposed in the mold cavity  68 , and potentially a different mold insert secured to mold portion  66 B and disposed in the cavity  68 , blocks  211  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 inserts  53 A,  53 B 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 different mold insert  53 AA, for example. 
     For example, in repeating blocks  211  to  230 , block  216  is repeated by disposing a subsequent first polymeric sheet  16 , a subsequent second polymeric sheet  18 , and a subsequent tensile component  30  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 to the different mold insert  53 AA and the subsequent second polymeric sheet to a different mold insert or 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 different mold insert  53 AA), 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  50  at the second protrusion partially traversing the subsequent tensile component. The same mold portions and mold cavity thus provide a second cushioning article with a different bond pattern than the first cushioning article due to the different mold insert  53 AA, and simply by removing the first mold insert  53 A and replacing it with the different mold insert  53 AA, and, when manufacturing a cushioning article with inwardly-protruding bonds  50  at the second polymeric sheet  18 , such as cushioning article  10 , potentially replacing the second mold insert  53 B with a different mold insert. 
     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.