Patent Description:
Sole structures generally include a layered arrangement extending between an outsole providing abrasion-resistance and traction with a ground surface and a midsole disposed between the outsole and the upper for providing cushioning for the foot.

In conventional articles of footwear, the upper is formed of one or more panels of the materials, which are stitched together to enclose an interior void. Here, different parts of the upper may be formed of different materials to provide desired characteristics. For instance, one or more of the panels may be formed of a breathable material to improve ventilation and comfort, while other panels are formed of more durable materials to provide strength and durability.

Accordingly, provisions must be made within the panels forming the upper to accommodate routing of the fasteners along the upper. For example, the panels of the upper may be provided with one or more eyelets or guides for routing the laces along the upper. Additionally, to improve fit and maximize comfort, the panels must be conformed to the contours of a foot, and are typically provided with one or more features for facilitating ventilation.

<CIT> relates to an upper for a shoe, in which a robber piece is located between an outer part and an inner lining. The rubber piece forms at least one chamber or bubble, preferably several, which can be open or closed in an airtight manner, and which define protuberances, preferably in the form of a spherical cap, which emerge to the outside through holes suitably shaped and positioned on the outer part of the upper.

<CIT> describes that an article of footwear includes sensory elements. The sensory elements are embedded in an upper of an article of foot-wear, the upper having a first layer and a second layer. Sensory elements are proximally disposed toward a foot when contacted by an object. Sensory elements may partially protrude from the first layer and/or the second layer. Sensory elements may also be fully covered between the first layer and the second layer.

<CIT> describes an article of footwear with an insert system. The insert system can include an insert that may be introduced to a side portion of the upper. The insert is configured to adjust properties of a side portion of an up-per.

The claimed invention provides an upper as defined in claim <NUM> and an article of footwear as defined in claim <NUM>.

The upper includes an outer shell attached to the exterior liner of the carcass layer and including a plurality of openings each configured to receive a respective one of the resilient pads therethrough. Here, each of the resilient pads includes a distal end surface defining a first portion of a ball control surface and the outer shell defines a second portion of the ball control surface.

Each of the resilient pads includes a compressible material enclosed between the interior liner and the exterior liner. In some examples, the compressible material includes a compressible fluid. Optionally, each of the resilient pads includes a tensile element disposed therein.

In some configurations, the plurality of resilient pads includes one or more resilient pads in a toe portion of the upper, one or more resilient pads in a ball portion of the upper, and one or more resilient pads in a mid-foot region of the upper.

In some examples, each of the interior liner and the exterior liner includes a polymeric film material. In some configurations, the interior liner includes a first material and the exterior liner includes a second material that is different than the first material.

The upper includes an outer shell attached to the exterior liner of the carcass layer and including a plurality of openings each configured to receive a respective one of the resilient pads therethrough. Here, each of the resilient pads may include a distal end surface defining a first portion of a ball control surface and the outer shell defines a second portion of the ball control surface.

Each of the resilient pads includes a compressible material enclosed between the interior liner and the exterior liner. Optionally, the compressible material includes a compressible fluid. In some configurations, each of the resilient pads includes a tensile element disposed therein.

In some implementations, the plurality of resilient pads includes one or more resilient pads in a toe portion of the upper, one or more resilient pads in a ball portion of the upper, and one or more resilient pads in a mid-foot region of the upper. Optionally, the plurality of resilient pads includes at least one lateral pad disposed on a lateral side of the upper, at least one medial pad disposed on a medial side of the upper, and at least one toe pad disposed on a toe portion of the upper.

Other aspects, features, and advantages will be apparent from the description, the drawings, and the claims.

Referring to <FIG>, an example of an article of footwear <NUM> is provided. In some implementations, the article of footwear <NUM> includes an upper <NUM> and a sole structure <NUM> attached to the upper <NUM>. The article of footwear <NUM>, and components thereof, may be described as including an anterior end <NUM> associated with a forward-most point of the footwear <NUM>, and a posterior end <NUM> corresponding to a rearward-most point of the footwear <NUM>. A longitudinal axis A<NUM> of the footwear <NUM> extends along a length of the footwear <NUM> from the anterior end <NUM> to the posterior end <NUM>, and generally divides the footwear <NUM> into a lateral side <NUM> and a medial side <NUM>. Accordingly, the lateral side <NUM> and the medial side <NUM> respectively correspond with opposite sides of the footwear <NUM> and extend from the anterior end <NUM> to the posterior end <NUM>.

The article of footwear <NUM> may be divided into one or more regions along the longitudinal axis A<NUM>. The regions may include a forefoot region <NUM>, a mid-foot region <NUM>, and a heel region <NUM>. The forefoot region <NUM> may correspond with toes and joints connecting metatarsal bones with phalanx bones of a foot. The mid-foot region <NUM> may correspond with an arch area of the foot, and the heel region <NUM> may correspond with rear regions of the foot, including a calcaneus bone.

The upper <NUM> forms an enclosure having a plurality of components that cooperate to define an interior void <NUM> and an ankle opening <NUM>, which cooperate to receive and secure a foot for support on the sole structure <NUM>. For example, the forefoot region <NUM> of the upper <NUM> includes a toe cap <NUM> disposed at the anterior end <NUM> and configured to cover the toes of the foot. The toe cap <NUM> extends over the forefoot region <NUM> from the lateral side <NUM> to the medial side <NUM>. In the mid-foot region <NUM>, the upper includes <NUM> a pair of quarter panels <NUM> extending from the toe cap <NUM> on opposite sides of the interior void <NUM>. Accordingly, a first quarter panel <NUM> extends along the lateral side <NUM> in the mid-foot region <NUM> and a second quarter panel <NUM> extends along the medial side <NUM> in the mid-foot region <NUM>.

A throat <NUM> extends across the top of the upper <NUM> and defines an instep region extending between the quarter panels <NUM>, from a posterior end of the toe cap <NUM> to an anterior end of the ankle opening <NUM>. In the illustrated example, the throat <NUM> is formed as an independent component (i.e., a tongue) that is moveable relative to the quarter panels <NUM>. However, in other examples, the throat <NUM> may be integrally formed with the quarter panels <NUM>, such that the upper <NUM> extends continuously over the instep of the foot. The throat <NUM> may include a fastening element, such as laces or straps, for adjusting a fit of the upper <NUM> around the foot. As best shown in <FIG>, a longitudinal axis A<NUM> of the throat <NUM> is oriented at an oblique angle relative to the longitudinal axis A<NUM> of the article of footwear. Accordingly, a portion of the throat <NUM> is offset from the center of the upper <NUM>. Additionally or alternatively, a width of the throat <NUM> may taper along the direction of the longitudinal axis A<NUM> from a posterior end to an anterior end of the throat <NUM>. In the illustrated example, an anterior portion of the throat <NUM> is offset towards the medial side <NUM> of the upper <NUM>. The offset and/or tapered arrangement of the throat <NUM> maximizes a ball control area formed on the lateral side <NUM> of the upper <NUM>.

The heel region <NUM> of the upper <NUM> includes a pair of heel side panels <NUM> extending through the heel region <NUM> along the lateral and medial sides <NUM>, <NUM> of the ankle opening <NUM>. Each of the heel side panels <NUM> extends from a posterior end of a respective one of the quarter panels <NUM>. A heel counter <NUM> wraps around the posterior end <NUM> of the footwear <NUM> and connects the heel side panels <NUM> to each other. Uppermost edges of the throat <NUM>, the heel side panels <NUM>, and the heel counter <NUM> cooperate to form a collar, which defines the ankle opening <NUM> of the interior void <NUM>.

The foregoing components and/or portions of the upper <NUM> cooperate to form an interior surface <NUM> defining the interior void <NUM> of the upper <NUM>, and an exterior surface <NUM> formed on an opposite side from the interior surface <NUM>. As described in greater detail below, the upper <NUM> may be formed from one or more materials that are joined together to form the aforementioned components or portions of the upper <NUM>. The example upper <NUM> may be formed from a combination of one or more substantially inelastic or non-stretchable materials and one or more substantially elastic or stretchable materials disposed in different regions of the upper <NUM> to facilitate movement of the article of footwear <NUM> between the tightened state and the loosened state. The one or more elastic materials may include any combination of one or more elastic fabrics such as, without limitation, spandex, elastane, rubber, or neoprene. The one or more inelastic materials may include any combination of one or more of thermoplastic polyurethanes, nylon, leather, vinyl, or another material/fabric that does not impart properties of elasticity.

With reference to <FIG>, the illustrated example of the upper <NUM> includes an inner carcass layer <NUM> and an optional outer shell <NUM>. The inner carcass layer <NUM> forms the interior surface <NUM> of the upper <NUM>, while the carcass layer <NUM> and the outer shell <NUM>, when included, cooperate to define the exterior surface <NUM> of the upper <NUM>. The exterior surface <NUM> of the upper <NUM> is configured as a ball control surface <NUM> and includes a plurality of resilient pads 124a-<NUM> arranged along each of the lateral side <NUM>, the medial side <NUM>, and the throat <NUM>. The resilient pads 124a-<NUM> are separated from each other by a web area <NUM>. As described in greater detail below, the resilient pads 124a-<NUM> are formed by the carcass layer <NUM>, while the web area <NUM> includes the carcass layer <NUM> and the shell <NUM>. The resilient pads 124a-<NUM> of the carcass layer <NUM> are exposed through corresponding openings 128a-<NUM> formed through the shell <NUM> such that when the shell <NUM> is included in the upper <NUM>, the shell <NUM> surrounds each of the resilient pads 124a-<NUM>.

Each of the resilient pads 124a-<NUM> includes a peripheral wall 130a-<NUM> defining a peripheral profile of the resilient pad 124a-<NUM>, and a distal end surface 132a-<NUM> that protrudes from the web area <NUM> of the upper <NUM>. Here, the distal end surfaces 132a-<NUM> of each of the resilient pads 124a-<NUM> cooperate to define a primary ball control surface 118a and the web area <NUM> provides a secondary ball control surface 118b that is recessed from the primary ball control surface 118a. Thus, in use, a ball may initially contact the primary ball control surface 118a collectively defined by one or more of the distal end surfaces 132a-<NUM>. As the one or more resilient pads 124a-<NUM> compress, the ball may engage the secondary ball control surface 118b formed by the web area <NUM>.

The exterior surface <NUM>, collectively defined by the primary ball control surface 118a and the secondary ball control surface 118b, may include one or more gripping features for maximizing engagement with a ball during use. For example, the exterior surface <NUM> may be formed of or include materials having a relatively high coefficient of friction. Additionally or alternatively, the exterior surface <NUM> may include physical gripping features <NUM>. In the illustrated example, the exterior surface <NUM> is embossed to form a plurality of ribs <NUM> arranged in a checkered pattern. For example, the gripping features <NUM> include a first plurality of squares defined by ribs <NUM> extending in a first direction (e.g., vertical) and a second plurality of squares defined by ribs <NUM> extending in a second direction (e.g. horizontal) transverse to the first direction. The embossed pattern of ribs <NUM> is formed continuously over the entire exterior surface <NUM>. Accordingly, as discussed in greater detail below, the web area <NUM> and the resilient pads <NUM> may be embossed with a continuous pattern of the gripping features <NUM>.

With continued reference to <FIG>, one example of the upper <NUM> includes a first plurality of the resilient pads 124a-124c arranged along the lateral side <NUM> of the upper <NUM>, and a second plurality of the resilient pads 124d-124f arranged along the medial side <NUM> of the upper <NUM>. The first plurality of resilient pads 124a-124c includes a lateral toe pad 124a disposed on the lateral side <NUM> of the toe cap <NUM> in the toe portion <NUM>T, a lateral forefoot pad 124b disposed on the lateral quarter panel <NUM> in the ball portion <NUM>B of the forefoot region <NUM>, and a lateral mid-foot pad 124c disposed on the lateral quarter panel <NUM> in the mid-foot region <NUM>. Similarly, the second plurality of resilient pads 124d-124f includes a medial toe pad 124d disposed on the medial side of the toe cap <NUM> in the toe portion <NUM>T, a medial forefoot pad 124e disposed on the medial quarter panel <NUM> in the ball portion <NUM>B of the forefoot region <NUM>, and a medial mid-foot pad 124f disposed on the medial quarter panel <NUM> in the mid-foot region <NUM>. The upper <NUM> includes one or more throat pads <NUM>, <NUM> formed on the tongue or throat <NUM> of the upper <NUM>.

With reference to <FIG>, the example of the upper <NUM> of the article of footwear <NUM> is shown in an exploded state. As shown, the upper <NUM> includes a plurality of components that are configured to be joined together to form the resilient pads 124a-<NUM> and the web area <NUM>. More specifically, the upper <NUM> includes the carcass layer <NUM> defining a plurality of the pads 124a-<NUM> and the web area <NUM>, and the optional shell <NUM> configured to be attached to the web area <NUM>. As shown, the carcass layer <NUM> and the shell <NUM> are configured to form the entire upper <NUM>. Thus, the components <NUM>, <NUM>, <NUM>, <NUM>, <NUM> of the upper <NUM> may be integrally formed of the carcass layer <NUM> and the optional shell <NUM>.

With continued reference to <FIG>, the carcass layer <NUM> of the upper <NUM> is formed as a bladder and includes a pair of liners <NUM>, <NUM> joined together at discrete locations to define the web area <NUM> and the resilient pads 124a-<NUM>. Particularly, the carcass layer <NUM> may include an interior liner <NUM> that defines the interior surface <NUM> of the upper <NUM> and an exterior liner <NUM> that defines the outer, exterior surface <NUM> of the upper <NUM>. In the illustrated example, each of the interior liner <NUM> and the exterior liner <NUM> may be separated into a boot portion 136a, 138a configured to form the toe cap <NUM>, quarter panels <NUM>, heel side panels <NUM>, and the heel counter <NUM>. The liners <NUM>, <NUM> may also include a tongue portion 136b, 138b forming the throat <NUM> of the upper <NUM>. However, as provided above, the throat <NUM> may be integrally formed with the upper <NUM> such that each of the barrier layers <NUM>, <NUM> is provided as a unitary body (i.e., a single piece forms the entire layer).

With continued reference to <FIG>, the carcass layer <NUM> includes a plurality of cushioning elements 140a-<NUM> configured to be disposed within the interior voids of each of the resilient pads 124a-<NUM>. The cushioning elements 140a-<NUM> may include one or more compressible materials, including compressible solids and/or fluids. Thus, while <FIG> and <FIG> show the cushioning elements 140a-<NUM> as physical components having a shape corresponding to each of the resilient pads 124a-<NUM>, it will be understood that the interior voids of the resilient pads 124a-<NUM> may be directly filled with a compressible fluid (<FIG>) sealed within the resilient pad 124a-<NUM> by the web area <NUM>, as discussed in greater detail below. In other aspects, the resilient pads 124a-<NUM> can alternatively include other compressible media, such as pellets, beads, ground recycled material, and the like (e.g., foamed beads and/or rubber beads). Optionally, the interior void of one or more of the resilient pads 124a-<NUM> of the carcass layer <NUM> may directly receive a tensile element <NUM> (<FIG>) therein for restraining the barrier layers <NUM>, <NUM> when the interior voids are pressurized.

Referring to <FIG>, one or more of cushioning elements 140a-<NUM> may be formed as fluid-filled chambers 140a-<NUM> each having a pair of barrier layers <NUM> joined to each other at discrete locations to define a shape of the respective cushioning element 140a-<NUM>. Alternatively, the cushioning elements 140a-<NUM> can be produced from any suitable combination of one or more barrier layers. While <FIG> illustrates the cushioning elements 140a, 140c of the toe pads 124a, 124c, the cushioning elements 140b, 140d-140f of the other pads 124b, 124d-124f of the upper <NUM> may be similarly constructed.

As used herein, the term "barrier layer" (e.g., barrier layers <NUM>) encompasses both monolayer and multilayer films. In some embodiments, one or both of the barrier layers <NUM> are each produced (e.g., thermoformed or blow molded) from a monolayer film (a single layer). In other embodiments, one or both of the barrier layers <NUM> are each produced (e.g., thermoformed or blow molded) from a multilayer film (multiple sublayers). In either aspect, each layer or sublayer can have a film thickness ranging from about <NUM> micrometers to about be about <NUM> millimeter. In further embodiments, the film thickness for each layer or sublayer can range from about <NUM> micrometers to about <NUM> micrometers. In yet further embodiments, the film thickness for each layer or sublayer can range from about <NUM> micrometer to about <NUM> micrometers.

One or both of the barrier layers <NUM> can independently be transparent, translucent, and/or opaque. As used herein, the term "transparent" for a barrier layer and/or a fluid-filled chamber means that light passes through the barrier layer in substantially straight lines and a viewer can see through the barrier layer. In comparison, for an opaque barrier layer, light does not pass through the barrier layer and one cannot see clearly through the barrier layer at all. A translucent barrier layer falls between a transparent barrier layer and an opaque barrier layer, in that light passes through a translucent layer but some of the light is scattered so that a viewer cannot see clearly through the layer.

The barrier layers <NUM> can each be produced from an elastomeric material that includes one or more thermoplastic polymers and/or one or more cross-linkable polymers. In an aspect, the elastomeric material can include one or more thermoplastic elastomeric materials, such as one or more thermoplastic polyurethane (TPU) copolymers, one or more ethylene-vinyl alcohol (EVOH) copolymers, and the like.

Examples of suitable isocyanates for producing the polyurethane copolymer chains include diisocyanates, such as aromatic diisocyanates, aliphatic diisocyanates, and combinations thereof. Examples of suitable aromatic diisocyanates include toluene diisocyanate (TDI), TDI adducts with trimethyloylpropane (TMP), methylene diphenyl diisocyanate (MDI), xylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), hydrogenated xylene diisocyanate (HXDI), naphthalene <NUM>,<NUM>-diisocyanate (NDI), <NUM>,<NUM>-tetrahydronaphthalene diisocyanate, para-phenylene diisocyanate (PPDI), <NUM>,<NUM>' - dimethyldiphenyl-<NUM>, <NUM>' -diisocyanate (DDDI), <NUM>,<NUM> '-dibenzyl diisocyanate (DBDI), <NUM>-chloro-<NUM>,<NUM>-phenylene diisocyanate, and combinations thereof. In some embodiments, the copolymer chains are substantially free of aromatic groups.

In another aspect, the polymeric layer can be formed of one or more of the following: EVOH copolymers, poly(vinyl chloride), polyvinylidene polymers and copolymers (e.g., polyvinylidene chloride), polyamides (e.g., amorphous polyamides), amide-based copolymers, acrylonitrile polymers (e.g., acrylonitrile-methyl acrylate copolymers), polyethylene terephthalate, polyether imides, polyacrylic imides, and other polymeric materials known to have relatively low gas transmission rates. Blends of these materials, as well as with the TPU copolymers described herein and optionally including combinations of polyimides and crystalline polymers, are also suitable.

The barrier layers <NUM> may include two or more sublayers (multilayer film) such as shown in Mitchell et al. , <CIT>, <CIT>, the disclosures of which are incorporated by reference in their entireties. In embodiments where the barrier layers <NUM> include two or more sublayers, examples of suitable multilayer films include microlayer films, such as those disclosed in<CIT>, which is incorporated by reference in its entirety. In further embodiments, the barrier layers <NUM> may each independently include alternating sublayers of one or more TPU copolymer materials and one or more EVOH copolymer materials, where the total number of sublayers in each of the barrier layers <NUM> includes at least four (<NUM>) sublayers, at least ten (<NUM>) sublayers, at least twenty (<NUM>) sublayers, at least forty (<NUM>) sublayers, and/or at least sixty (<NUM>) sublayers.

The cushioning elements 140a-<NUM> can be produced from the barrier layers <NUM> using any suitable technique, such as thermoforming (e.g. vacuum thermoforming), blow molding, extrusion, injection molding, vacuum molding, rotary molding, transfer molding, pressure forming, heat sealing, casting, low-pressure casting, spin casting, reaction injection molding, radio frequency (RF) welding, and the like. In an aspect, the barrier layers <NUM> can be produced by coextrusion followed by vacuum thermoforming to form the profile of the cushioning elements 140a-<NUM>, which can optionally include one or more valves (e.g., one way valves) that allows the cushioning elements 140a-<NUM> to be filled with the fluid (e.g., gas).

The cushioning elements 140a-<NUM> desirably have a low gas transmission rate to preserve their retained gas pressure. In some embodiments, the cushioning elements 140a-<NUM> have a gas transmission rate for nitrogen gas that is at least about ten (<NUM>) times lower than a nitrogen gas transmission rate for a butyl rubber layer of substantially the same dimensions. In an aspect, cushioning elements 140a-<NUM> have a nitrogen gas transmission rate of <NUM> cubic-centimeter/square-meter•atmosphere•day (cm<NUM>/m<NUM>•atm•day) or less for an average film thickness of <NUM> micrometers (based on thicknesses of barrier layers <NUM>). In further aspects, the transmission rate is <NUM><NUM>/m<NUM>•atm•day or less, <NUM><NUM>/m<NUM>•atm•day or less, or <NUM><NUM>/m<NUM>•atm•day or less.

In the illustrated example, the interior surfaces of the barrier layers <NUM> of the cushioning elements 140a-<NUM> are joined together at discrete locations to form an outer peripheral seam defining shapes of the cushioning elements 140a-<NUM>. The barrier layers <NUM> are spaced apart from each other to define respective interior voids <NUM> of each of the cushioning elements 140a-<NUM>. Optionally, the interior voids <NUM> of the cushioning elements 140a-<NUM> may receive a tensile element <NUM> therein. Each tensile element <NUM> may include a series of tensile strands <NUM> extending between an upper tensile sheet <NUM> and a lower tensile sheet <NUM>. The upper tensile sheet <NUM> may be attached to the first barrier layer <NUM> while the lower tensile sheet <NUM> may be attached to the second barrier layer <NUM>. In this manner, when the cushioning element 140a-<NUM> receives a pressurized fluid, the tensile strands <NUM> of the tensile elements <NUM> are placed in tension. Because the upper tensile sheet <NUM> is attached to the first barrier layer <NUM> and the lower tensile sheet <NUM> is attached to the second barrier layer <NUM>, the tensile strands <NUM> retain a desired shape of the respective cushioning element 140a-<NUM> when the pressurized fluid is injected into the interior void <NUM>.

While <FIG> represents an upper <NUM> where each of the resilient pads 124a-<NUM> includes an independently formed cushioning element 140a-<NUM>, in other examples, the resilient pads 124a-<NUM> may be directly pressurized. In these examples, the liners <NUM>, <NUM> of the carcass layer <NUM> function as the barrier layers for enclosing an interior void of the resilient pads 124a-<NUM>. As provided above, the resilient pads 124a-<NUM> may be directly filled with a compressible material, as represented by <FIG>, or may have the tensile element <NUM> directly attached to the liners <NUM>, <NUM>, as represented in <FIG>. Any one or more of the resilient pads 124a-<NUM> may include the cushioning elements 140a-<NUM> (<FIG>), be directly filled with the compressible fluid (<FIG>), or include the directly attached tensile element (<FIG>).

Where the resilient pads 124a-<NUM> include compressible fluids (e.g., the resilient pads 124a-<NUM> are filled with air), either in the form of direct pressurization or by including independently formed fluid-filled chambers 140a-<NUM>. The resilient pads 124a-<NUM> can be filled to include any suitable fluid, such as a gas or liquid. In an aspect, the gas can include air, nitrogen (N<NUM>), or any other suitable gas. The fluid provided to the resilient pads 124a-<NUM> can result in the resilient pads 124a-<NUM> being pressurized.

In the illustrated example, the interior voids of the resilient pads 124a-<NUM> may include the same or different pressures from each other. For instance, a first pressure within the interior void of one of the resilient pads 124a-<NUM> may be less than a second pressure within a different one of the resilient pads 124a-<NUM> when the carcass layer <NUM> is in an uncompressed (i.e., natural) state. Additionally or alternatively, the resilient pads 124a-<NUM> may be formed with different thicknesses. The combination of different pressures and/or thicknesses provide zonal performance characteristics along the exterior ball control surface <NUM>. For example, the toe pads 124a, 124d and/or the forefoot pads 124b, 124e may have a greater pressure and/or lesser thickness than the mid-foot pads 124c, 124f to provide a greater energy return while kicking a ball with the toe or forefoot of the foot. Conversely, the mid-foot pads 124c, 124f may be tuned with a lower pressure and/or greater thickness than the toe pads 124a, 124d and/or the forefoot pads 124b, 124e to provide less energy return (i.e., damping) when handling or receiving a passed ball.

With particular reference to <FIG>, an article of footwear 10a is provided and includes an upper 100a and a sole structure <NUM> attached to the upper 100a. In view of the substantial similarity in structure and function of the components associated with the article of footwear <NUM> with respect to the article of footwear 10a, like reference numerals are used hereinafter and in the drawings to identify like components while like reference numerals containing letter extensions are used to identify those components that have been modified.

The upper 100a of the article of footwear 10a shown in <FIG> can be constructed in a substantially similar fashion as upper <NUM> of the article of footwear <NUM> discussed previously, and includes an inner carcass layer 120a and an outer shell 122a cooperating to define a plurality of resilient pads 124i-124p. In the example of the upper 100a shown in <FIG>, the resilient pads 124i-124p may be formed as one or more groups of the resilient pads 124i-124p arranged in different regions of the upper 100a. Each of the resilient pads 124i-124p extend and are exposed through a corresponding opening 128i-128p formed in the web area <NUM>.

With reference to <FIG>, the lateral side <NUM> of the upper 100a includes a first group of pads 124i disposed in the toe portion <NUM>T, a second group of pads 124j disposed in the ball portion <NUM>B, and a third group of pads <NUM> disposed in the mid-foot region <NUM>. Similarly, the medial side <NUM> of the upper 100a includes a fourth group of pads <NUM> disposed in the toe portion <NUM>T, a fifth group of pads <NUM> disposed in the ball portion <NUM>B, and a sixth group of pads 124n disposed in the mid-foot region <NUM>. Thus, unlike the upper <NUM> discussed above, where a single pad 124a-124f is disposed in each of the ball control zones <NUM>T, <NUM>B, <NUM> of the upper <NUM>, each of the ball control zones <NUM>T, <NUM>B, <NUM> of the upper 100a includes a plurality of the resilient pads 124i-124n that cooperate to form the primary ball control surface 118a. Each of the pads 124i-124n may be described as including an elongate shape extending along the periphery of the upper 100a. The upper <NUM> includes one or more throat pads 124o, 124p formed on the tongue or throat <NUM> of the upper <NUM>, similar to the throat pads <NUM>, <NUM> above.

Optionally, the groups of the resilient pads 124i-124n of the upper <NUM> may also be arranged to form segmented rows 125a, 125b of the resilient pads 124i-124n extending continuously around a periphery of the upper <NUM>. For example, the upper 100a may include a first row 125a of the resilient pads 124i-124n extending from the ball portion <NUM>B on the lateral side <NUM> and around the anterior end <NUM> to the mid-foot region <NUM> on the medial side <NUM>. As shown in FIGS. 8A and 8B, the first row 125a includes a lateral forefoot pad 124j, a lateral toe pad 124i, a medial toe pad <NUM>, a medial forefoot pad <NUM>, and a pair of medial mid-foot pads 124n arranged in series around the periphery of the upper 100a. A second row 125b is disposed above the first row 125a and is vertically spaced from the first row 125a by the web area 126a. The second row 125b includes a lateral mid-foot pad <NUM>, a lateral forefoot pad 124j, a lateral toe pad 124i, a medial toe pad <NUM>, a medial forefoot pad <NUM>, and a pair of medial mid-foot pads 124n arranged in a second series around the periphery of the upper 100a, above the first row 125a.

In some examples, corresponding pads 124i-124n of each row 125a, 125b may be vertically aligned with each other. For example, the medial mid-foot pads 124n of the first row 125a are vertically aligned with the medial-mid-foot pads 124n of the second row 125b. More specifically, ends of the corresponding pads 124i-124n of the first and second rows 125a, 125b may be aligned with each other such that the web area 126a extends continuously through and intersects the upper and lower rows 125a, 125b.

With reference to <FIG>, an example system <NUM> and method for forming the upper <NUM> of <FIG> is shown. While the system <NUM> and method are described with respect to the upper <NUM> of <FIG>, the same system <NUM> and method could be used to form the upper 100a of FIGS. The system <NUM> is a press <NUM> and includes a first mold half <NUM> and a second mold half <NUM>. As shown, each mold half <NUM>, <NUM> includes a platen <NUM>, <NUM> having a substantially planar mold surface. Accordingly, as discussed below, the same system <NUM> can be easily adapted for manufacturing uppers having any configuration of resilient pads <NUM> without needing specialized tooling.

In a first step, the components for forming the carcass layer <NUM> are provided to the press <NUM>. Here, the inner liner <NUM> and the outer liner 138a each includes a first portion 136a, 138a for forming a boot including the toe cap <NUM>, quarter panels <NUM>, heel side panels <NUM>, and heel counter <NUM> of the upper <NUM>. Respective second portions 136b, 138b of the liners <NUM>, <NUM> are configured to form the throat or tongue <NUM> of the upper <NUM>. In this example, the upper <NUM> is formed with a plurality of the cushioning elements 140a-<NUM>, which are positioned between the liners <NUM>, <NUM> within the press <NUM> in areas corresponding to the desired locations of the resilient pads 124a-<NUM> of the finished upper <NUM>. The interior surfaces of the liners <NUM>, <NUM> may be provided with a thermo adhesive film or coating configured to join or attach the interior surface of the inner liner <NUM> to the inner surface of the exterior liner <NUM>. With the components <NUM>, <NUM>, 140a-<NUM> of the carcass layer <NUM> arranged in the press <NUM>, the press <NUM> is moved to the closed position and the components <NUM>, <NUM>, 140a-<NUM> are subjected to heat and/or pressure to join the liners <NUM>, <NUM> together with the cushioning elements 140a-<NUM> disposed therebetween.

6B, the assembled carcass layer <NUM>, including a boot portion 120a and tongue portion 120b, is attached to the shell <NUM>, which includes a corresponding boot portion 122a and tongue portion 122b. Here, another layer of the thermo adhesive film or coating may be disposed between the carcass layer <NUM> and the shell <NUM>, whereby, when the press <NUM> is closed, the thermo adhesive film or coating is melted to join the carcass layer <NUM> and the shell <NUM> together. In some examples, all of the components <NUM>, <NUM>, <NUM>, 140a-<NUM> of the upper <NUM> may be simultaneously pressed in a single operation to join the components together with the melted thermo adhesive film or coating. Optionally, one or both of the platens <NUM>, <NUM> of the press <NUM> may have a mold surface including the embossing pattern for forming the gripping features <NUM>. Thus, when the shell <NUM> is joined to the carcass layer <NUM>, the gripping features <NUM> are formed over the entire ball control surface <NUM> of the upper <NUM>.

As shown in <FIG>, the carcass layer <NUM> and the shell <NUM> cooperate to define a blank for forming the entire upper, including the toe cap <NUM>, the quarter panels <NUM>, the heel side panels <NUM>, the heel counter <NUM>, and the throat or tongue <NUM>. Thus, unlike conventional uppers that may include a plurality of independently formed components joined or stitched to define the various components of the upper, the upper <NUM> of the present disclosure can consist of a unitary piece including the carcass layer <NUM>, the shell <NUM>, and the cushioning elements 140a-<NUM>.

Referring now to <FIG>, a system <NUM> and method or process for using the system <NUM> to form a generic example of a carcass layer <NUM> according to the principles of the present disclosure is provided. Unlike the examples of the carcass layers <NUM>, 120a shown above with respect to the articles of footwear <NUM>, 10a, where the resilient pads 124a-124p include independently formed cushioning elements 140a-140p disposed therein, the system <NUM> is configured to directly form resilient pads <NUM> of a carcass layer 120b using the liners <NUM>, <NUM>. In other words, the liners <NUM>, <NUM> function as barrier layers defining the resilient pads <NUM> of the carcass layer 120b.

The system <NUM> includes a mold <NUM> and a vacuum source <NUM>. As shown, the mold <NUM> includes an opposing pair of platens 406a, 406b which cooperate with each other to define a mold chamber <NUM>. As shown, a first one of the platens 406a includes geometries for forming geometries of the resilient pads <NUM> in the exterior liner <NUM> of the carcass layer, while the second platen 406b is provided with a planar mold surface <NUM> corresponding to the flat inner liner <NUM>. However, in other examples, geometries of both of the platens 406a, 406b may include mold cavities <NUM> and/or geometries of one of the platens 406a, 406b may be different from geometries of the other one of the platens 406a, 406b to impart different characteristics and geometries to the carcass layer 120b.

With reference to <FIG>, the lower platen 406a includes a base <NUM>, a chamber wall <NUM> extending from the base <NUM>, and a cavity wall <NUM> extending from the base <NUM>. As described in greater detail below, the chamber wall <NUM> provides a fixturing surface for components <NUM>, <NUM> of a carcass layer 120b, while the base <NUM>, the chamber wall <NUM>, and the cavity wall <NUM> cooperate to define the mold chamber <NUM> having a plurality of mold cavities <NUM>, <NUM>.

As shown in <FIG>, the base <NUM> of the lower platen 406a includes an inner surface <NUM> and an outer surface <NUM> formed on an opposite side of the base <NUM> from the inner surface <NUM>. As shown, the base <NUM> includes a manifold <NUM> extending along a length of the base <NUM> between the inner surface <NUM> and the outer surface <NUM>. The manifold <NUM> is in communication with the vacuum source <NUM>. As discussed in greater detail below, the base <NUM> of the first platen 406a includes a plurality of ports <NUM> extending from the manifold <NUM> and through the inner surface <NUM> of the base <NUM>, thereby fluidly connecting the manifold <NUM> to each of the mold cavities <NUM>, <NUM>. Accordingly, each of the mold cavities <NUM>, <NUM> is in fluid communication with the vacuum source <NUM> via the manifold <NUM>.

With continued reference to <FIG>, the chamber wall <NUM> of the first platen 406a extends from a first end <NUM> at the inner surface <NUM> of the base <NUM> to a distal end <NUM> at the opposite end of the chamber wall <NUM> from the first end <NUM>. The chamber wall <NUM> further includes an inner peripheral surface <NUM> and an outer peripheral surface <NUM> formed on an opposite side of the chamber wall <NUM> from the inner peripheral surface <NUM>. The chamber wall <NUM> defines an outer perimeter of the mold chamber <NUM>, whereby the chamber wall <NUM> is continuous and completely surrounds the mold chamber <NUM>. As explained below, the distal end <NUM> of the chamber wall <NUM> is configured to interface with components <NUM>, <NUM> for forming the carcass layer 120b during assembly of the carcass layer 120b. In some examples, the distal end <NUM> is substantially planar, whereby the height of the chamber wall <NUM> is constant. In other examples, a profile of the distal end <NUM> may be contoured. For example, the distal end <NUM> may be concave across the width to form a channel extending along a length of the chamber wall <NUM>.

With continued reference to <FIG>, the cavity wall <NUM> of the first platen 406a extends from a first end <NUM> at the inner surface <NUM> of the base <NUM> to a distal end <NUM> at the opposite end of the cavity wall <NUM> from the first end <NUM>. A distance from the inner surface <NUM> of the base <NUM> to the distal end <NUM> of the cavity wall <NUM> defines a height H<NUM> of the cavity wall <NUM>. As shown, the height H<NUM> of the cavity wall <NUM> is greater than the height H<NUM> of the chamber wall <NUM>. The cavity wall <NUM> further includes an opposing pair of side surfaces <NUM> extending from the inner surface <NUM> of the base <NUM> to the distal end <NUM>. A distance between the side surfaces <NUM> defines a width W<NUM> of the cavity wall <NUM>.

In the illustrated example, the cavity wall <NUM> includes a peripheral portion 414a and one or more interior portions 414b. The peripheral portion 414a of the cavity wall <NUM> is spaced inwardly from the chamber wall <NUM> to define a transitional cavity <NUM> between the chamber wall <NUM> and the cavity wall <NUM>. The distal end <NUM> of the peripheral portion 414a is continuously formed and is configured to form the peripheral seam <NUM> around the perimeter of the formed carcass layer 120b, as described in greater detail below. Accordingly, a path along which a length of the peripheral portion 414a extends corresponds to a desired peripheral shape of the carcass layer 120b.

The interior portions 414b of the cavity wall <NUM> extend inwardly (i.e., in an opposite direction from the chamber wall <NUM>) from the peripheral portion 414a of the cavity wall <NUM>, and cooperate with the peripheral portion 414a to define the profiles of individual ones of the mold cavities <NUM>. As discussed below, the interior portions 414b of the cavity wall <NUM> correspond to the desired locations of interior bonds forming the web area <NUM> of the carcass layer 120b. Accordingly, the arrangement (i.e., size, shape, location) of the interior portions 414b is selected based on desired shapes of the resilient pads <NUM> of the carcass layer 120b.

In some examples, the distal end <NUM> of the interior portions 414b of the cavity wall <NUM> extend continuously between the peripheral portion 414a of the cavity wall <NUM>, whereby the resulting web area <NUM> also extends continuously around the resilient pads <NUM>. Thus, adjacent ones of the resilient pads <NUM> defined by the respective interior portions 414b of the cavity wall <NUM> may be fluidly isolated from each other after the carcass layer 120b is formed. In some examples, the interior portions 414b of the cavity wall <NUM> may be discontinuous, or include one or more notches formed in the distal end <NUM> that extend continuously across the entire width of the interior portion 414b. These notches allow fluid communication between adjacent mold cavities <NUM> when the platens 406a, 406b of the mold <NUM> are in a closed position, and result in the formation of conduits that extend through the web area <NUM> and fluidly connect adjacent ones of the resilient pads <NUM> to each other.

The cavity walls <NUM> of each platen 406a, 406b are operable to bond the liners <NUM>, <NUM> of the carcass layer 120b together at discrete locations to define the resilient pads <NUM>. Particularly, the distal ends <NUM> of the cavity walls <NUM> provide energy E to the liners <NUM>, <NUM> (i.e., barrier layers) to bond the liners <NUM>, <NUM> to each other when the liners <NUM>, <NUM> are compressed between opposing distal ends <NUM> of respective platens 406a, 406b. In the illustrated example, the distal ends <NUM> of the cavity walls <NUM> are configured for radio frequency (RF) welding such that when the liners <NUM>, <NUM> are compressed between the distal ends <NUM> of cavity wall <NUM>, high-frequency radio waves are supplied to the liners <NUM>, <NUM> and the liners <NUM>, <NUM> are welded together between the distal ends <NUM> to form the web area <NUM>. In other examples, the cavity walls <NUM> may be configured for thermally bonding (i.e., melding) the liners <NUM>, <NUM> together with each other. For example, the cavity walls <NUM> may have one or more elements for heating the distal ends <NUM> above a desired temperature for melding material(s) of the liners <NUM>, <NUM> together.

With reference to <FIG>, the method of using the system <NUM> to form the carcass layer 120b is shown. The system <NUM> is provided with a first sheet <NUM> of material and a second sheet <NUM> of material corresponding to the liners <NUM>, <NUM> of the formed carcass layer 120b. Each sheet <NUM> includes an inner surface <NUM> and an outer surface <NUM> disposed on an opposite side of the sheet <NUM> from the inner surface <NUM>. A distance between the inner surface <NUM> and the outer surface <NUM> defines a thickness of the sheet <NUM>. As discussed above, the material of the sheets <NUM> includes one or more thermoplastic polymers and/or one or more cross-linkable polymers.

As described in greater detail below, a gasket <NUM> is configured to be disposed between a distal end <NUM> of the chamber wall <NUM> of the first platen 406a and the mold surface <NUM> of the second platen 406b when the mold <NUM> is moved to a closed position. Accordingly, a length of the gasket <NUM> extends along a path corresponding to a length of the distal end <NUM> of the chamber wall <NUM>. The gasket <NUM> includes a pair of sealing surfaces <NUM> formed on opposite sides of the gasket <NUM>, whereby a distance from one sealing surface <NUM> to the other sealing surface <NUM> defines a thickness T<NUM> of the gasket <NUM>. The gasket <NUM> further includes an inner peripheral surface <NUM> and an outer peripheral surface <NUM>, each extending between the sealing surfaces <NUM> on opposite sides of the gasket <NUM>. One or more conduits <NUM> are formed through the gasket <NUM> from the inner peripheral surface <NUM> to the outer peripheral surface <NUM>.

In an initial step, shown in <FIG>, the mold <NUM> is provided in a fully opened position. Here, a first platen 406a is provided as a lower platen 406a so that the components <NUM>, <NUM> for forming the carcass layer 120b can be provided to the mold <NUM>. As shown, a first one of the sheets <NUM> of material is laid atop the chamber wall <NUM> and covers the mold chamber <NUM>. The lower sheet <NUM> may be described as having a peripheral region <NUM> disposed on and supported by the chamber wall <NUM>, and an inner region <NUM> surrounded by the peripheral region <NUM> and supported by the cavity wall <NUM>. Because the height of the cavity wall <NUM> is greater than the height of the chamber wall <NUM>, the inner region <NUM> may be vertically offset from the peripheral region <NUM>. Accordingly, the lower sheet <NUM> may also have a transition region <NUM> extending between the peripheral region <NUM> and the inner region <NUM>.

As shown in <FIG>, the transition region <NUM> of the lower sheet <NUM> may span the transitional cavity <NUM> that separates the chamber wall <NUM> from the peripheral portion 414a of the cavity wall <NUM>. As explained in greater detail below, the transitional cavity <NUM> of the first platen 406a is configured to accommodate flexure and expansion of the sheets <NUM> during manufacturing of the carcass layer 120b, but is not associated with forming a resilient pad <NUM> of the completed carcass layer 120b.

With the first one of the sheets <NUM> in place atop the lower platen 406a, the gasket <NUM> is disposed on the sheet <NUM> so that a bottom one of the sealing surfaces <NUM> is in contact with the inner surface <NUM> of the first sheet <NUM> along the peripheral region <NUM>. Thus, the gasket <NUM> is also supported on the distal end <NUM> of the chamber wall <NUM> and surrounds the inner region <NUM> and the transition region <NUM> of the first sheet <NUM>. When the gasket <NUM> is in a natural, uncompressed state, the gasket <NUM> will have a first thickness T<NUM> and the conduit <NUM> formed through the gasket <NUM> will be unrestricted.

With the gasket <NUM> in place, a second, upper sheet <NUM> is placed in the mold <NUM>. As shown in <FIG>, the inner surface <NUM> of the upper sheet <NUM> contacts the upper sealing surface <NUM> of the gasket <NUM> in the peripheral region <NUM> of the upper sheet <NUM>, while the inner surface <NUM> of the upper sheet <NUM> faces the inner surface <NUM> of the lower sheet <NUM> in the inner region <NUM>.

Referring now to <FIG>, once all of the components <NUM>, <NUM> are positioned within the mold <NUM>, the mold <NUM> is moved to a first position by moving the platens 406a, 406b towards each other, as indicated by the arrows D<NUM>. In the first position, a preload force F<NUM> is applied to the components <NUM>, <NUM> by the mold plates 406a, 406b such that the peripheral region <NUM> of the lower sheet <NUM>, the gasket <NUM>, and the peripheral region <NUM> of the upper sheet <NUM> are compressed between the distal end <NUM> of the chamber wall <NUM> and the mold surface <NUM> of the respective platens 406a, 406b, thereby sealing the sheets <NUM> and the gasket <NUM> between the platens 406a, 406b. Here, the preload force F<NUM> is sufficient to form a seal between the sealing surfaces <NUM> of the gasket and the respective inner surfaces <NUM> of the sheets <NUM>, while maintaining the conduit <NUM> of the gasket <NUM> in a substantially decompressed state.

Referring still to <FIG>, in the first position, the inner regions <NUM> of the sheets <NUM> will not be compressed by the distal ends <NUM> of the cavity wall <NUM>. Accordingly, the inner surfaces <NUM> of the sheets <NUM> can be separated from each other to form a space <NUM> between the inner regions <NUM> of the sheets <NUM>. Particularly, the sheets <NUM> are separated from each other by the space <NUM> between the distal end <NUM> of the cavity wall <NUM> and the mold surface <NUM> to allow for fluid to pass freely through the space <NUM> from one cavity <NUM> to another during the vacuum forming step of <FIG>.

Turning now to <FIG>, when the mold is in the first position and the peripheral regions <NUM> of the sheets <NUM> are sealed against the gasket <NUM>, the vacuum source <NUM> is activated to provide a negative first pressure P<NUM> within the manifolds <NUM> of each of the platens <NUM>. The first pressure P<NUM> may be any pressure that is less than a second pressure P<NUM> within the space <NUM> between the sheets <NUM>. In the illustrated example, the second pressure P<NUM> within the space <NUM> is atmospheric or ambient pressure and the first pressure P<NUM> is a negative pressure relative to atmospheric pressure. However, in some examples, the space <NUM> may be pressurized with a positive pressure (i.e., greater than atmospheric). The first pressure P<NUM> is communicated to each of the cavities <NUM>, <NUM> of the mold <NUM> through respective ones of the ports <NUM>. Consequently, the pressure differential between the first pressure P<NUM> within the cavities <NUM> and the second pressure P<NUM> within the space <NUM> causes the sheets <NUM> to be drawn towards surfaces <NUM>, <NUM>, <NUM> defining each of the cavities <NUM>, <NUM>.

Here, the magnitude of the first pressure P<NUM> determines the amount that the bottom sheet <NUM> is drawn into the cavity <NUM> of the lower platen 406a and, ultimately, the shape and pressure of the chambers <NUM> of the carcass layer <NUM>. As discussed above, the sheets <NUM> that form the liners <NUM>, <NUM> of the carcass layer <NUM> include an elastomeric material. Accordingly, when the first pressure P<NUM> is provided within the cavity <NUM> of the first platen 406a, the sheet <NUM> corresponding to the exterior liner <NUM> is drawn into the cavities <NUM> by an amount corresponding to the magnitude of the first pressure P<NUM>. For example, a first pressure P<NUM> having a greater magnitude will draw the sheets <NUM> farther into the mold cavities <NUM> by stretching the sheets <NUM> to a greater degree. In the example of <FIG>, the magnitude of the first pressure P<NUM> is sufficient to draw the outer surfaces <NUM> of the sheets <NUM> against the surfaces <NUM>, <NUM> defining the mold cavities <NUM>. However, in other examples, the magnitude of the first pressure P<NUM> may be different, such that the sheets <NUM> are not stretched against the surfaces <NUM>, <NUM> of the mold <NUM>.

As the sheets <NUM> are drawn into the cavities <NUM> by the first pressure P<NUM>, fluid, such as air and/or nitrogen, flows into the space <NUM> between the sheets <NUM> through the conduit <NUM> formed through the gasket <NUM>. Accordingly, a volume of the space <NUM> is able to increase without causing the second pressure P<NUM> within the space <NUM> to decrease, thereby allowing the chambers <NUM> of the carcass layer <NUM> to be formed within the cavity <NUM>. In the illustrated example, the conduit <NUM> is in communication with atmospheric pressure, whereby the second pressure P<NUM> will remain substantially equal to atmospheric pressure as the chambers <NUM> are formed. However, in other examples, the conduit <NUM> may be in communication with a positive pressure source, such as a pump (not shown), whereby the pressure within the space <NUM> is greater than atmospheric pressure.

With continued reference to <FIG>, the first pressure P<NUM> may also be applied to the transitional cavity <NUM>, thereby drawing the transition region <NUM> of the sheet <NUM> corresponding to the exterior liner <NUM> into the transitional cavities <NUM>. In some examples, the transitional cavities <NUM> may not be in communication with the vacuum source <NUM>, and may simply provide spaces for flexure of the transition regions <NUM> of the sheets <NUM> when the mold <NUM> is moved between positions. Although the transitional regions <NUM> of the sheets <NUM> are not formed into resilient pads <NUM> of the carcass layer <NUM>, allowing the transition regions <NUM> to flex and move within the transitional cavity <NUM> may accommodate expansion and shifting of the sheets <NUM> during the vacuum forming step.

Referring to <FIG>, once the inner region <NUM> of the sheet <NUM> corresponding to the exterior liner <NUM> is drawn into the cavity <NUM>, thereby forming the shapes of the resilient pads <NUM> of the carcass layer <NUM>, the mold <NUM> is moved to a second position to seal the inner surfaces <NUM> of the sheets <NUM> together, as indicated by the directional arrows D<NUM>. In the second position, a sealing force F<NUM> is applied to the components <NUM>, <NUM> of the mold such that the inner regions <NUM> of the sheets <NUM> are compressed together by the opposing distal ends <NUM> of the cavity walls <NUM> to seal the interior void of each chamber <NUM>. The sealing force F<NUM> is greater than the preload force F<NUM>. For example, the sealing force F<NUM> may be approximately <NUM> pounds-force (<NUM> Newtons) while the preload force is approximately <NUM> pounds-force (<NUM> Newtons). Under the sealing force F<NUM>, the peripheral portions 414a of the cavity walls <NUM> seal a portion of the inner region <NUM> corresponding to the peripheral web area <NUM> of the carcass layer <NUM>, while the interior portion 414b of the cavity wall <NUM> seals portions of the inner region <NUM> corresponding to the inner web area <NUM> of the carcass layer <NUM>.

As shown in <FIG>, with the resilient pads <NUM> formed and the inner regions <NUM> of the sheets <NUM> sealed between the cavity walls <NUM> and the mold surface <NUM>, energy E is provided to the distal ends <NUM> of the cavity wall <NUM> and/or the mold surface <NUM> to bond the compressed regions of the sheets <NUM> together, thereby forming the web area <NUM> of the carcass layer <NUM>. As discussed above, the energy E provided to the distal ends <NUM> of the cavity wall <NUM> and/or the mold surface <NUM> may be high frequency electromagnetic energy for radio-frequency (RF) welding the sheets <NUM> together. In other examples, the energy E may be a thermal energy, whereby the sheets <NUM> are melded together at the web area <NUM>.

At <FIG>, the molded components <NUM>, <NUM>, which include the formed carcass layer <NUM>, are removed from the mold <NUM> for post-processing. As discussed above, during the mold process a first pressure P<NUM> is applied to the outer surfaces <NUM> of the elastomeric sheets <NUM> to draw the sheets <NUM> into the mold cavities <NUM>. The first pressure P<NUM> is maintained on the sheets <NUM> while the sheets <NUM> are formed into liners <NUM>, <NUM> of the carcass layer <NUM>, such that the second pressure P<NUM> within the space <NUM> between the sheets <NUM> is sealed within the interior voids <NUM> of the resilient pads <NUM> while the sheets <NUM> are in a stretched state (i.e., the bladder has a first thickness T120b-<NUM> in the mold). Upon removal of the molded carcass layer <NUM> from the mold <NUM>, the first pressure P<NUM> is released and the elasticity of the material forming the sheets <NUM> may cause the sheets (now liners <NUM>, <NUM>) to contract (i.e., the carcass layer <NUM> has a second thickness T120b-<NUM> when removed from the mold).

Upon contraction, the fluid within the interior voids of the resilient pads <NUM> is compressed by the sheets <NUM>, such that the pressure of the fluid may increase from the second pressure P<NUM> to a third pressure P<NUM>. The magnitude of the pressure increase in the resilient pad <NUM> is directly related to the strain imparted on the sheet <NUM> corresponding to the exterior liner <NUM> by the first pressure P<NUM>, as well as the modulus of elasticity of the material forming the sheets <NUM>. For example, where the sheets <NUM> are formed of an inelastic material, the pressure increase may be negligible as the sheets <NUM> remain in the stretched state upon release of the negative pressure. However, for materials having a relatively low modulus of elasticity, applying a greater first pressure P<NUM> to the sheets <NUM> causes increased strain in the elastomeric material during the molding process, which results in a greater pressure increase within the interior void when the first pressure P<NUM> is released and the material contracts.

With continued reference to <FIG>, the carcass layer <NUM> is finished by trimming the sheets <NUM> at the cut line L along the peripheral seam <NUM> to separate the peripheral regions <NUM> of the sheets <NUM> and the gasket <NUM> from the formed carcass layer <NUM>. Because the gasket <NUM> and the peripheral regions <NUM> of the sheets <NUM> are not bonded to each other during the molding process, the gasket <NUM> can be separated from the trimmed peripheral portions <NUM> of the sheets <NUM> for reuse in subsequent molding operations.

Claim 1:
An upper (<NUM>) for an article of footwear, the upper (<NUM>) comprising:
a carcass layer (<NUM>) including an interior liner (<NUM>) defining an interior void of the upper (<NUM>) and an exterior liner (<NUM>) joined to the interior liner (<NUM>) to define a plurality of resilient pads (124a-<NUM>; 124i-124p) protruding from an exterior surface (<NUM>) of the upper (<NUM>); wherein the carcass layer (<NUM>) comprises a plurality of cushioning elements (140a-<NUM>) disposed within the interior voids of each of the resilient pads (124a-<NUM>); and
an outer shell (<NUM>) attached to the exterior liner (<NUM>) of the carcass layer (<NUM>) and including a plurality of openings (128a-<NUM>; 128i-128p) each configured to receive a respective one of the resilient pads (124a-<NUM>; 124i-124p) therethrough,
wherein the plurality of resilient pads (124a-<NUM>; 124i-124p) includes at least one lateral pad disposed on a lateral side (<NUM>) of the upper (<NUM>), at least one medial pad disposed on a medial side (<NUM>) of the upper (<NUM>), and at least one throat pad (<NUM>, <NUM>; 124o, 124p) disposed on a tongue (<NUM>) of the upper (<NUM>).