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

<CIT> discloses an article of footwear including an upper and the sole structure, the sole structure, and a method for manufacturing the sole structure and a method for manufacturing the article of footwear. The sole structure includes a fluid-filled chamber and an outsole that at least partially surrounds the chamber. The fluid-filled chamber has an edge, an upper surface, and a lower surface. The outsole is co-molded to at least a part of the lower surface of the fluid-filled chamber and to at least a part of the edge of the fluid-filled chamber and is at least partially co-extensive with the lower surface of the chamber and with at least a part of the edge of the chamber.

The claimed invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the claimed invention.

Additional embodiments are set forth in the dependent claims.

"A," "an," "the," "at least one," and "one or more" are used interchangeably to indicate that at least one of the items is present.

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.

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.

In an exemplary article of footwear,, the shaped article may be a cushioning layer and an outsole of an article of footwear. <FIG> illustrates such an exemplary article of footwear. <FIG> is a cross-sectional view of an article of footwear including a co-molded article. An article of footwear <NUM> includes an upper <NUM> and a sole structure <NUM>. Upper <NUM> provides a comfortable and secure covering for a foot of a wearer. As such, the foot may be located within upper <NUM> to effectively secure the foot within article of footwear <NUM> or otherwise unite the foot and article of footwear <NUM>. Sole structure <NUM> is secured to a lower area of upper <NUM> and extends between the foot and the ground to attenuate ground reaction forces (i.e., cushion the foot), provide traction, enhance stability, and influence the motions of the foot, for example. In effect, sole structure <NUM> is located under the foot and supports the foot.

Upper <NUM> is depicted as having a substantially conventional configuration. A majority of upper <NUM> incorporates various material elements (e.g., textiles, foam, leather, and synthetic leather) that are stitched or adhesively bonded together to produce an interior void for securely and comfortably receiving a foot. The material elements may be selected and located in upper <NUM> to selectively impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort, for example. The void in upper <NUM> is shaped to accommodate the foot. When the foot is located within the void, therefore, upper <NUM> extends along a lateral side of the foot, along a medial side of the foot, over the foot, around the heel, and under the foot. A lace <NUM> extends over a tongue <NUM>. Lace <NUM> and the adjustability provided by tongue <NUM> may be utilized in a conventional manner to modify the dimensions of the interior void, thereby securing the foot within the interior void and facilitating entry and removal of the foot from the interior void. Sockliner <NUM> may enhance the comfort of article of footwear <NUM>.

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

Sole structure <NUM> includes outsole <NUM> attached to fluid-filled chamber <NUM>. Outsole <NUM> has ground-engaging protuberances <NUM> associated therewith.

<FIG> illustrates an alternative exemplary tank-type article <NUM> having top <NUM> associated with tank <NUM>. Tank <NUM> is at least partially surrounded by case <NUM> having protuberances <NUM> extending therefrom. <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, and the accompanying descriptions, explain this alternative exemplary co-molded article of an article of footwear.

<FIG> and <FIG> illustrate a way of producing a sole structure such as but not limited to sole structure <NUM> of <FIG>. <FIG> and <FIG> depict a cross-section of a mold for co-molding fluid-filled chamber <NUM> with outsole <NUM> with
protuberances <NUM> thereon. Outsole <NUM> may be produced by a number of pre-formed objects or elements assembled in the mold. In some examples, outsole <NUM> wraps at least a portion of edge <NUM> on fluid-filled chamber <NUM>. Molded article <NUM> is an exemplary article having outsole <NUM> wrapping a significant portion of the edge of fluid-filled chamber <NUM>. As the components are produced of thermoplastic materials, they may be softened to aid in producing the shapes in the mold.

<FIG> and <FIG> are cross-sectional depictions of mold <NUM> for article <NUM>. As shown in <FIG> and <FIG>, fluid-filled chamber <NUM> is co-molded with outsole <NUM> present in the mold. Adhesive also may be present on appropriate surfaces.

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

A variety of manufacturing processes may be utilized to produce sole structure <NUM>. In some exemplary processes, mold <NUM> that may be utilized in the manufacturing process is depicted as including a first mold portion <NUM> and a second mold portion <NUM>. Mold <NUM> is utilized to produce fluid-filled chamber <NUM> from a first polymer layer <NUM> and a second polymer layer <NUM>, which are the polymer layers producing fluid-filled chamber upper surface <NUM> and fluid-filled chamber lower surface <NUM>, respectively. More particularly, mold <NUM> facilitates the manufacturing process by (a) shaping first polymer layer <NUM> and second polymer layer <NUM> in areas corresponding with edges <NUM> of the fluid-filled chambers <NUM>, flange <NUM>, and conduits between chambers, and (b) joining first polymer layer <NUM> and second polymer layer <NUM> in areas corresponding with flange <NUM> and web area <NUM>.

Various surfaces or other areas of mold <NUM> will now be defined for use in discussion of the manufacturing process. First mold portion <NUM> includes a first mold portion surface <NUM>, which shapes the top surface of the co-molded article. Various parts of a first element, such as outsole <NUM>, and a second element, such as a fluid-filled chamber <NUM>, are illustrated in <FIG>. Second mold portion <NUM> is shaped so as to receive protuberances <NUM> in close engagement with slots <NUM> in second mold portion <NUM>. Outsole <NUM> then is placed in the mold. Outsole <NUM> fits within undercut <NUM>. Then, second element precursor or first polymer layer <NUM> is put into place to become the top surface of the article and second element precursor or second polymer layer <NUM> produces the bottom or lower surface <NUM> of the second element, herein the fluid-filled chamber, when the article is molded.

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

As first mold portion <NUM> and second mold portion <NUM> continue to move toward each other, first polymer layer <NUM> and second polymer layer <NUM> are pinched between first mold portion <NUM> and second mold portion <NUM>. More particularly, first polymer layer <NUM> and second polymer layer <NUM> are compressed between pinch surface <NUM> and pinch edge <NUM>. In addition to beginning the process of separating excess portions of first polymer layer <NUM> and second polymer layer <NUM> from portions that form fluid-filled chamber <NUM>, the pinching of first polymer layer <NUM> and second polymer layer <NUM> begins the process of bonding or joining first polymer layer <NUM> and second polymer layer <NUM> in the area of flange <NUM>.

Following the pinching of first polymer layer <NUM> and second polymer layer <NUM>, first mold portion <NUM> and second mold portion <NUM> proceed with moving toward each other and into a closed configuration, as depicted in <FIG>. As the mold closes, pinch surface <NUM> contacts and slides against a portion of second seam-forming surface <NUM>. The contact between pinch surface <NUM> and second seam-forming surface <NUM> effectively severs excess portions of first polymer layer <NUM> and second polymer layer <NUM> from portions that form fluid-filled chamber <NUM>. The material forming first polymer layer <NUM> and second polymer layer <NUM> compacts or otherwise collects to form flange <NUM>. In addition to forming flange <NUM>, first polymer layer <NUM> and second polymer layer <NUM> are (a) shaped to produce fluid-filled chamber <NUM> and (b) compressed and joined to produce web area <NUM>.

When producing of fluid-filled chamber <NUM> is complete, mold <NUM> is opened. Fluid then may be injected into fluid-filled chamber <NUM> to pressurize forefoot component fluid-filled chambers <NUM>, thereby completing the manufacture of structure <NUM>. As a final step in the process, structure <NUM> may be incorporated into a sole structure of an article of footwear <NUM>.

Co-molded articles may have many uses. <FIG> illustrates a tank or other container. <FIG> depicts molding of a tank or other container. Mold <NUM> includes first mold portion <NUM> having mold surface <NUM>. Second mold portion <NUM> includes slots <NUM> to securely engage protuberances <NUM> on first element <NUM>. Second polymer layer <NUM> and first polymer layer <NUM> are in position in the open mold. After first element <NUM> is inserted into the mold, second polymer layer <NUM> will form the layer of the tank in contact with first element <NUM>. First polymer layer <NUM> will form the upper surface of the tank.

<FIG> illustrates mold <NUM> closed to form tank or article <NUM> within the mold. Surface <NUM> of first mold portion <NUM> shapes upper surface <NUM> of top layer <NUM> of the article. A sealed tank may be produced by fusing or adhering the polymer layers at flange <NUM>, which may extend around the periphery of the tank. Protuberances <NUM> on first element <NUM> fit closely in slots <NUM> in the second portion <NUM> of the mold.

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

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

In some exemplary co-molded articles, a sole structure for an article of footwear may be made in accordance with a method for co-molding a first element and a second element to produce a co-molded article. <FIG>, <FIG>, and <FIG> depict stages of this method for co-molding a sole structure of an article of footwear. Mold <NUM> may have a first mold portion <NUM> and a second mold portion <NUM>. Shape <NUM> on first mold portion <NUM> may form the top surface <NUM> of the co-molded article.

The first element <NUM> may have top surface <NUM>, edge surface <NUM>, and protuberance <NUM> having base <NUM> opposite top surface <NUM>. Edge surface <NUM> may extend any distance away from top surface <NUM>. First element <NUM> also may have bottom surface <NUM>. The second element <NUM> may have edge <NUM>, upper surface <NUM>, and lower surface <NUM>.

Any suitable polymeric material may be used to produce the first element, which would be an outsole as depicted in <FIG>. Although each feature is illustrated in the figures as a single layer, each such feature may comprise a single layer of material or multiple layers, and may be thermoformed or otherwise shaped. Examples of polymeric materials that may be utilized for such a sole structure include any of polyurethane, urethane, polyester, polyester polyurethane, polyether, polyether polyurethane, latex, polycaprolactone, polyoxypropylene, polycarbonate macroglycol, and blends thereof. These and other polymeric materials, an exemplary outsole, and a method for manufacturing them, may be found in <CIT>.

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

As depicted in <FIG>, <FIG>, and <FIG>, first element <NUM> may be an outsole. For such an exemplary co-molded article, in accordance with the method, outsole <NUM> is located in second mold portion <NUM> with base <NUM> of protuberance <NUM> in contact with surface <NUM> of second mold portion <NUM>. Surface <NUM> of second mold portion <NUM> is shaped so as to not contact a significant fraction of protuberance <NUM> other than base <NUM>. Protuberance <NUM> may be considered to be a ground-engaging portion, with an end thereof being a base <NUM> that engages the ground. As depicted with particularity in <FIG> and <FIG>, outsole <NUM> may have a slight arc or curve that cause edge <NUM> to not contact edge <NUM> of second mold portion <NUM>. Not all bases <NUM> may touch surface <NUM> simultaneously before molding with a second element.

Precursor for a second element, a fluid-filled chamber, is placed in the mold and the mold is closed. First polymer layer <NUM> may form top surface <NUM> of second element <NUM>. Second polymer layer <NUM> may form edge <NUM> of second element <NUM> and lower surface or bottom <NUM> of second element or fluid-filled chamber <NUM>.

Each of first polymer layer <NUM> and second polymer layer <NUM> are initially located between first mold portion <NUM> and second mold portion <NUM>, which are in a spaced or open configuration, as depicted in <FIG>. In this position, first polymer layer <NUM> is positioned adjacent or closer to first mold portion <NUM>, and second polymer layer <NUM> is positioned adjacent or closer to second mold portion <NUM>. A shuttle frame or other device may be utilized to properly position first polymer layer <NUM> and second polymer layer <NUM>. As part of the manufacturing process, one or both of first polymer layer <NUM> and second polymer layer <NUM> are heated to a temperature that facilitates shaping and bonding. As an example, various radiant heaters or other devices may be utilized to heat first polymer layer <NUM> and second polymer layer <NUM>, possibly prior to being located between first mold portion <NUM> and second mold portion <NUM>. As another example, mold <NUM> may be heated such that contact between mold <NUM> and first polymer layer <NUM> and second polymer layer <NUM> at a later potion of the manufacturing process raises the temperature to a level that facilitates shaping and bonding.

Once first polymer layer <NUM> and second polymer layer <NUM> are properly positioned, first mold portion <NUM> and second mold portion <NUM> translate or otherwise move toward each other and begin to close on first polymer layer <NUM> and second polymer layer <NUM>. Fluid under pressure may be introduced into fluid-filled chamber <NUM> to conform upper surface <NUM> of fluid-filled chamber <NUM> to the shape <NUM> of the first mold portion <NUM>, to conform lower surface <NUM> of fluid-filled chamber or second element <NUM> to the shape of top surface <NUM> of first element <NUM>, and to conform edge <NUM> of fluid-filled chamber <NUM> to edge surface <NUM> of first element <NUM> or edge <NUM> of second mold portion <NUM>.

Upon injection of fluid into fluid-filled chamber <NUM>, second polymer layer <NUM> may be urged toward top surface <NUM> of outsole <NUM>, edge <NUM> of outsole <NUM>, and edge <NUM> of second mold portion <NUM>. As the pressure in fluid-filled chamber <NUM> increases, pressure on outsole top surface <NUM> may urge bases <NUM> on protuberances <NUM> toward surface <NUM> of second mold portion <NUM>. Similarly, pressure in fluid-filled chamber <NUM> may urge edge <NUM> of fluid-filled chamber <NUM> toward edge <NUM> of outsole <NUM>, and may urge both toward edge <NUM> of second mold portion. Edge <NUM> also may be urged into contact with edge <NUM> of second mold portion <NUM> where edge <NUM> of outsole <NUM> does not preclude contact therewith.

As can be seen with particularity in <FIG> and <FIG>, bottom surface <NUM> of outsole <NUM> typically may not contact bottom surface <NUM> of second mold portion <NUM> even after the fluid-filled chamber is fully molded. Although outsole <NUM> is held in position, demolding is carried out with less force than demolding from a mold that exerts forces on such protuberances, such as in <FIG> and <FIG>. Fluid pressure in fluid-filled chamber <NUM> may be adjusted after the sole structure is demolded.

<FIG> and <FIG> illustrate another example of a co-molded article in the produce of a sole structure for an article of footwear that may be made in accordance with a method for co-molding a first element and a second element to produce a co-molded article. Mold <NUM> may have a first mold portion <NUM> and a second mold portion <NUM>. Shape <NUM> on first mold portion <NUM> may produce the top surface <NUM> of the co-molded article.

Outsole <NUM> may have top surface <NUM>, edge surface <NUM>, and protuberance <NUM> having base <NUM> opposite top surface <NUM>. The second element <NUM> may have edge <NUM>, upper surface <NUM>, and lower surface <NUM>. Any suitable polymeric material may be used to produce the sole structure, as described with regard to <FIG>, <FIG>, and <FIG>.

In some exemplary co-molded articles, such as in the exemplary co-molded articles depicted in <FIG> and <FIG>, first element <NUM> may be an outsole. For such an exemplary co-molded article, in accordance with the method, outsole <NUM> is located in second mold portion <NUM> with base <NUM> of protuberance <NUM> in contact with surface <NUM> of second mold portion <NUM>. Surface <NUM> of second mold portion <NUM> is shaped so as to not contact a significant fraction of protuberance <NUM> other than base <NUM>. Protuberance <NUM> may be a ground-engaging portion, with the end thereof being a base <NUM> that engages the ground. As depicted with particularity in <FIG>, outsole <NUM> may have a slight arc or curve that cause edge <NUM> to not contact edge <NUM> of second mold portion <NUM>. Outsole <NUM> may include flange <NUM>, which may provide additional support to the sole structure.

Precursor for a second element, a fluid-filled chamber, is placed in the mold and the mold is closed. First polymer layer <NUM> may produce top surface <NUM> of second element <NUM>. Second polymer layer <NUM> may form edge <NUM> and lower surface or bottom <NUM> of second element or fluid-filled chamber <NUM>.

Each of first polymer layer <NUM> and second polymer layer <NUM> are initially located between each of first mold portion <NUM> and second mold portion <NUM>, which are in a spaced or open configuration, as depicted in <FIG> and <FIG>. The polymer layers are placed and heated as described in relationship to <FIG>, <FIG>, and <FIG>.

Fluid under pressure may be introduced into fluid-filled chamber <NUM> as it forms to conform upper surface <NUM> of fluid-filled chamber <NUM> to the shape <NUM> of the first mold portion, to conform lower surface <NUM> of fluid-filled chamber or second element <NUM> to the shape of top surface <NUM> of first element or outsole <NUM>, and to conform edge <NUM> of fluid-filled chamber <NUM> to edge surface <NUM> of outsole <NUM> or edge <NUM> of second mold portion <NUM>.

As can be seen with particularity in <FIG>, bottom surface <NUM> of outsole <NUM> typically may not contact bottom surface <NUM> of second mold portion <NUM> even after the fluid-filled chamber is fully molded. Although outsole <NUM> is held in position during molding, demolding is carried out with less force than demolding from a mold that exerts forces on such protuberances. Fluid pressure in fluid-filled chamber <NUM> may be adjusted after the sole structure is demolded. Fluid pressure in fluid-filled chamber <NUM> may be adjusted after the sole structure is demolded.

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

In some exemplary co-molded articles , the shape of the co-molded article may produce a container. <FIG> and <FIG> depict a container having feet. The container may be first element <NUM>, which may be characterized as case <NUM>. As depicted in <FIG>, first element or case <NUM> has been placed in second mold portion <NUM>. Case <NUM> may have a foot or protuberance <NUM>, with the foot having a bottom <NUM>. Second mold portion <NUM> may include bottom surface <NUM>. In some exemplary co-molded articles, bottom surface <NUM> may not contact each bottom <NUM> of feet <NUM>. Case <NUM> may have a shape that includes a slight arc. Thus, whether each bottom <NUM> of feet <NUM> touches bottom surface <NUM> depends upon the arrangement of feet <NUM> and whether case <NUM> may have an arc when placed in second mold portion <NUM>. In such exemplary co-molded articles, an arc may be exhibited in object edge <NUM>. As depicted in <FIG>, object edge <NUM> illustrates such an arc, as object edge <NUM> is not in contact with mold edge <NUM>.

Placement of first and second polymer webs between first mold portion <NUM> and second mold portion <NUM> in mold <NUM> before closing the mold, as depicted in <FIG>, is carried out in essentially the same manner as is the method described with regard to <FIG>, <FIG>, and <FIG>.

In some exemplary co-molded articles, box top <NUM>, produced from a first polymer layer, may be adhered or otherwise affixed to a second polymer layer <NUM> that forms the remainder of the box at flange <NUM>. The top surface of box top <NUM> is shaped by surface <NUM> to form box surface <NUM>.

Fluid may be injected into the volume formed by second polymer layer <NUM> and box top <NUM>. The fluid may be a gas, a liquid, or a gel. Injection of fluid into box <NUM> may urge second polymer layer <NUM> toward top surface <NUM> of case <NUM>, edge <NUM> of case <NUM>, and edge <NUM> of second mold portion <NUM>. As the pressure in box <NUM> increases, pressure on first element bottom surface <NUM> may urge bases <NUM> on protuberances <NUM> toward surface <NUM> of second mold portion <NUM>. Similarly, pressure in case <NUM> may urge edge <NUM> of second polymer layer toward edge <NUM> of object <NUM>, and may urge both toward edge <NUM> of second mold portion <NUM>. Edge <NUM> also may be urged into contact with edge <NUM> of second mold portion <NUM> where edge <NUM> of case <NUM> does not preclude contact therewith.

As can be seen with particularity in <FIG>, bottom surface <NUM> of case <NUM> typically may not contact bottom surface <NUM> of second mold portion <NUM> even after the case is fully molded. Although case <NUM> is held in position, demolding is carried out with less force than demolding from a mold that exerts forces on such protuberances <NUM>. Fluid pressure in box <NUM> may be adjusted after the co-molded article is demolded.

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

<FIG> illustrates an article of footwear <NUM> having a sole structure <NUM>, which is secured to the outer periphery of an upper <NUM>, also shown in <FIG>, or upper <NUM> of <FIG>. The sole structure <NUM> may be secured to a bottom surface of the upper <NUM>, or a strobel, lasting board, or foam layer may be secured to the upper <NUM> and the sole structure <NUM> may secure to the bottom surface of the strobel, lasting board, or foam layer. Sole structure <NUM> is located under the foot and supports the foot. The primary elements of sole structure <NUM> are a forefoot sole structure <NUM> and a heel sole structure <NUM>. The sole structure <NUM> has a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM> and extends from a medial side <NUM> to a lateral side <NUM>.

The forefoot sole structure <NUM> includes a forefoot midsole, which, in the embodiment shown, is a polymeric bladder element <NUM>, and is also referred to as a forefoot component, forefoot bladder element, or a fluid-filled chamber. The polymeric bladder element <NUM> is best shown in <FIG>. The polymeric bladder element <NUM> is best shown in <FIG>. The bladder element <NUM> encloses a fluid-filled interior cavity <NUM> indicated in <FIG> and <FIG>. Similarly, the heel sole structure <NUM> includes a heel midsole, which, in the embodiment shown, is a polymeric bladder element <NUM>, and is also referred to as a heel component, heel bladder element, or a fluid-filled chamber. The bladder element <NUM> encloses a fluid-filled interior cavity <NUM> indicated in <FIG> and <FIG>. The bladder elements <NUM>, <NUM> are between the outsole components of the bottom view of <FIG> and the upper <NUM>, as best shown in <FIG>.

The bladder elements <NUM> and <NUM> are separate from one another and are not in fluid communication with one another. The bladder element <NUM> has multiple tubular portions with arcuate shapes (e.g., generally U shaped) so that the fluid-filled interior cavity <NUM> has corresponding tubular portions 3142A, 3142B, 3142C, 3142D, and 3142E interconnected and in fluid communication with one another by channels <NUM> as best shown in <FIG>. The bladder element <NUM> has multiple interconnected portions arranged in a U-shape so that the fluid-filled interior cavity <NUM> has multiple portions 3152A, 3152B, 3152C, 3152D and 3152E interconnected and in fluid communication with one another by channels <NUM>, as best shown in <FIG>. The polymeric bladder element <NUM> is configured so that arcuate portions of the fluid-filled interior cavity <NUM> are at an outer periphery in the forefoot region <NUM> of the sole structure <NUM> as shown in <FIG>. The bladder element <NUM> has arcuate tubular portions <NUM> in the forefoot region of the sole structure, as best shown in <FIG>. The arcuate tubular portions <NUM> have inner curved walls <NUM> with tighter curvature than the outer walls of the arcuate tubular portions <NUM>. Stated differently, the inner curved walls <NUM> are at the inside of the U-shaped arcuate tubular portions <NUM>. The side surface <NUM> of the bladder element <NUM> to which the first wall of the first outsole component is secured is at the inner curved wall <NUM>. The second wall <NUM> can thus support and reinforce both the second wall <NUM> and the inner curved wall <NUM> of the bladder element <NUM> at the arcuate tubular portion during flexing of the forefoot region. This support and reinforcement should reduce stresses on the second wall <NUM> to prevent cracking of the second wall <NUM>.

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

Moreover, in one embodiment, the bladder elements <NUM>, <NUM> can be formed of one or more sheets having layers of different materials. The sheets may be laminate membranes formed from thin films having one or more first layers that comprise thermoplastic polyurethane layers and that alternate with one or more second layers, also referred to herein as barrier layers, gas barrier polymers, or gas barrier layers. The second layers may comprise a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein as disclosed in <CIT>. The first layer may be arranged to form an outer surface of the polymeric sheet. That is, the outermost first layer may be the outer surface of the bladder element <NUM> or <NUM>. The bladder elements <NUM>, <NUM> may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in <CIT> and <CIT> Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. Each sheet may also be a flexible microlayer membrane that includes alternating layers of a gas barrier polymer material such as second layers and an elastomeric material such as first layers, as disclosed in <CIT> and <CIT> Additional suitable materials for the bladder elements <NUM>, <NUM> are disclosed in <CIT> and <CIT>. Further suitable materials for the bladder elements <NUM>, <NUM> include thermoplastic films containing a crystalline material, as disclosed in <CIT> and <CIT>, and polyurethane including a polyester polyol, as disclosed in <CIT>,<CIT>, and<CIT> In selecting materials for the bladder elements <NUM>, <NUM>, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. When the bladder element <NUM> or <NUM> is formed from sheets, the thicknesses of the sheets used to form the bladder element <NUM> or <NUM> can be selected to provide these characteristics.

Forefoot bladder element <NUM> and heel bladder element <NUM> are formed from a polymer material that encloses a fluid, which may be a gas, liquid, or gel. During walking and running, for example, forefoot bladder element <NUM> and heel bladder element <NUM> may compress between the foot and the ground, thereby attenuating ground reaction forces. That is, after thermoforming, forefoot bladder element <NUM> and heel bladder element <NUM> are inflated and generally pressurized with the fluid to cushion the foot. <FIG> shows sealed inflation ports <NUM> through which fluid is introduced into the interior cavities <NUM>, <NUM> prior to sealing.

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

The forefoot sole structure <NUM> also includes a first outsole component <NUM> secured to the bladder element <NUM>, and multiple second outsole components <NUM> secured to the first outsole component <NUM> as described herein. The first outsole component <NUM> is shown in isolation in <FIG>. The second outsole component <NUM> is secured to the first outsole component in <FIG>. The heel sole structure <NUM> includes a first outsole component <NUM>, and a second outsole component <NUM> secured to the first outsole component <NUM> as described herein. The first outsole component <NUM> is shown in <FIG>. The second outsole component <NUM> is secured to the first outsole component <NUM> as shown in <FIG>. <FIG> shows the first outsole components <NUM>, <NUM> secured to the bladder elements <NUM> and <NUM>, with the second outsole components <NUM>, <NUM> removed.

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

Forefoot outsole component <NUM> is secured to a lower surface of forefoot bladder element <NUM>. In some embodiments, forefoot sole structure <NUM> may extend into a midfoot region. The forefoot outsole component <NUM> also may be secured to lower areas of forefoot bladder element <NUM> in a midfoot region. Heel outsole component <NUM> is secured to lower areas of heel bladder element <NUM>. Both heel bladder elements <NUM> and heel outsole component <NUM> may extend into a midfoot region. Forefoot outsole component <NUM> and heel outsole component <NUM> may be formed from a wear-resistant material. The wear-resistant material may be transparent or translucent to provide a visually appealing effect. The wear-resistant material may be textured on the ground-engaging surface to impart traction, such as by including integral tread elements <NUM>, <NUM> as described herein. Any or all of the components of forefoot sole structure <NUM> and heel sole structure <NUM> may be translucent or transparent, and may be colored or patterned for aesthetic appeal.

<FIG>, <FIG> also illustrate gas escape openings <NUM> in the first outsole component <NUM> of the forefoot sole structure <NUM>, and <FIG>, <FIG> illustrate gas escape openings <NUM> in the first outsole component <NUM> of the heel sole structure <NUM> only some of which are indicated with reference numbers. These gas escape openings allow air or other gases trapped between a bladder element and the corresponding outsole component during manufacturing to escape. The inside surface of an outsole component may be shaped in a manner that may accumulate trapped gas and direct the entrapped gas to a gas escape opening. For example, small interconnected grooves <NUM> may be formed on the inside surface of the outsole component <NUM> during injection molding, or may be provided in the surface by removal of material after molding. The gas escape openings <NUM> are in the bottom of the grooves <NUM>, as shown in <FIG>. The second outsole component <NUM> also has grooves <NUM> on the inner surface, as shown in <FIG>, that direct entrapped gas to the gas escape openings <NUM>. The gas escape openings <NUM> are in fluid communication with the grooves <NUM>.

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

In the embodiment shown in <FIG> and manufactured as described with respect to <FIG>, the configuration of the first outsole components <NUM> and <NUM> supports the respective bladder elements <NUM> and <NUM> and allows a second outsole component <NUM> or <NUM> to be received and nested partially within a recess <NUM> in the first outsole component <NUM>, or within a recess <NUM> in the first outsole component <NUM>. The recesses <NUM> and <NUM> provide positioning guidance during assembly and, as discussed herein, protect the second outsole components <NUM> and <NUM> from delamination during wear. Moreover, both the first outsole components <NUM>, <NUM> and the second outsole components <NUM>, <NUM> have tread elements <NUM>, <NUM>, respectively, that establish a ground-engaging surface of the sole structure (contacting the ground G in <FIG>), enabling different tractive properties to be provided at the locations of the tread elements <NUM><NUM>, <NUM>, by using different shapes, sizes of the tread elements <NUM>,<NUM>, and/or by using different materials for the first and second outsole components <NUM> and <NUM>. The tread elements <NUM>, <NUM> may be protrusions, ridges, or ground-engaging lugs or sections that impart traction. As shown in <FIG>, the tread elements <NUM> have different sizes and shapes including rectangular and trapezoidal. The tread elements <NUM> are generally larger than the tread elements <NUM>. Depending on the materials used for the outsole components <NUM>, <NUM>, <NUM>, <NUM>, the second outsole components <NUM>, <NUM> may provide increased traction relative to the first outsole components <NUM>, <NUM>, or decreased traction.

The tread elements <NUM> of the first outsole component <NUM>, <NUM> are an integral portion of the first outsole component (i.e., formed together with the base and walls by injection molding of the first outsole component) as best shown in <FIG> and <FIG>, and the tread elements <NUM> of the second outsole component <NUM> or <NUM> are likewise an integral portion of the one-piece, unitary second outsole component <NUM> or <NUM>. Configuration of the outsole components in this manner simplifies manufacturing and lessens the possibility of separation of the tread elements from the base of the outsole component during wear.

<FIG> show the first outsole component <NUM> prior to attachment of the second outsole component <NUM>. <FIG> show the first outsole component <NUM> prior to attachment of the second outsole component <NUM>. <FIG> and <FIG> show the first outsole component <NUM> attached to a bottom surface <NUM> of the bladder element <NUM> and to side surfaces <NUM>, <NUM> of the bladder element <NUM>. More specifically, the first outsole component <NUM> has a first base <NUM> attached to the bottom surface <NUM> of the bladder element <NUM>, a first wall <NUM> integral with the first base <NUM> secured to a side surface <NUM> of the bladder element <NUM>, and a second wall <NUM> integral with the first base <NUM> and secured to a side surface <NUM> of the bladder element <NUM>. As indicated by the location of the cross-sections of <FIG> and <FIG> in <FIG>, and as shown in <FIG>, the first wall <NUM> and the second wall <NUM> are at the arcuate portion of the fluid-filled interior cavity <NUM>. The second wall <NUM> of the second outsole component <NUM> is at the arcuate portion.

The first outsole component <NUM> has integral tread elements <NUM> at predetermined portions of the bottom surface <NUM> of the first outsole component, while other portions are free from tread elements. <FIG> shows a base <NUM> of the first outsole component <NUM> attached to the first bladder element <NUM> and having integral tread elements <NUM> at first portion <NUM> of a bottom surface <NUM> of base <NUM>. Second portion <NUM> of the bottom surface <NUM> of base <NUM> is free from any tread elements <NUM>. The other portion of the first outsole component <NUM> shown attached to the bladder element <NUM> also has a base <NUM> and walls <NUM>, <NUM> integral with the base <NUM>, with a first portion <NUM> of the base <NUM> with integral tread elements <NUM> and a second portion <NUM> free from any tread elements. At least some of the tread-free portions are free from tread elements <NUM> specifically because a second outsole component <NUM> with its own integral tread element(s) is to be attached at the second portion <NUM>, as shown in <FIG>. As such, no tread elements of the first outsole component <NUM> will interfere with attachment of the second outsole component <NUM>.

The second outsole component <NUM> has a second base <NUM> and optionally includes one or more integral tread elements <NUM>. The second base <NUM> is secured to the second portion <NUM> of the bottom surface <NUM> of the first base <NUM>. The second outsole component <NUM> has a second wall <NUM> integral with the second base <NUM>. The second wall <NUM> is secured to the outer surface <NUM> of the first wall <NUM> of the first outsole component <NUM>. The outer surface <NUM> is adjacent the second portion <NUM> of the bottom surface <NUM>. With this configuration, a ground-engaging surface <NUM> of the sole structure <NUM> includes integral tread elements <NUM> of the first outsole component <NUM>, and integral tread elements <NUM> of the second outsole component <NUM>.

Similarly, as best shown in <FIG>, the first outsole component <NUM> of the heel sole structure <NUM> has integral tread elements <NUM> at predetermined portions of the bottom surface <NUM> of the first outsole component <NUM>, such as at first area <NUM>, and has a second area <NUM> free from any tread elements. The first outsole component <NUM> has a first base <NUM> and an integral first wall <NUM> extending from the first base adjacent the second area <NUM>. The first wall <NUM> is an outer wall. The first outsole component <NUM> also has a second wall, referred to as an inner wall <NUM>, which is integral with the first base <NUM>.

The second outsole component <NUM> has a second base <NUM> secured to the first base <NUM>. The second outsole component <NUM> has a second wall <NUM> (i.e., outer wall) integral with the second base <NUM> and secured to the outer surface <NUM> of the first wall <NUM>. The second outsole component <NUM> has an inner wall <NUM> integral with the second base <NUM> and secured to the outer surface <NUM> of the second wall <NUM> as is evident in <FIG>, <FIG>, and <FIG>.

As best shown in <FIG>, the first outsole component <NUM> has an arcuate shape corresponding to the arcuate shape of the fluid-filled interior cavity <NUM> with the first wall <NUM> at the outer periphery of the arcuate portion of the fluid-filled interior cavity <NUM>. The second wall <NUM> of the second outsole component <NUM> is also at the arcuate portion. The first wall <NUM> and second wall <NUM> are thus outer walls. The second wall <NUM> of the first outsole component <NUM> is an inner wall located at the inner curve of the arcuate portion. The second wall <NUM> of the second outsole component <NUM> is also at the inner curve of the arcuate portion. Supporting the tubular arcuate portions of the bladder elements with the outer and inner walls of the outsole components <NUM>, <NUM> provides support, acting as a geometric constraint on the bladder element <NUM>, and provides stiffness, tuning the cushioning response of the bladder element <NUM>.

Reinforcement of the outsole components <NUM>, <NUM>, <NUM>, <NUM> (for example, inclusion of structural elements, such as ribs), apertures, the height of the walls <NUM>, <NUM>, <NUM>, <NUM> of the outsole components <NUM>, <NUM>, <NUM>, <NUM>, the number and location of overlapping walls of outsole components <NUM>, <NUM>, <NUM>, <NUM> and of the bladder elements <NUM>, <NUM> (also referred to as edges of the bladder elements), or other features of outsole components <NUM>, <NUM>, <NUM>, <NUM> all may be used to tune the responses of the sole structures <NUM> and <NUM>. In particular, overlap of a wall <NUM>, <NUM>, <NUM>, <NUM> of a first outsole component <NUM>, <NUM> away from the respective base portion <NUM> and up the side surface <NUM>, <NUM> of a forefoot bladder element <NUM>, or the side surface of a heel bladder element <NUM>, and overlap of a wall <NUM>, <NUM>, <NUM> of a second outsole component <NUM>, <NUM> away from the respective base portion and up the wall <NUM>, <NUM>, <NUM>, <NUM> of the respective first outsole component <NUM>, <NUM> such as described and illustrated at least in <FIG>, may be used to tune the elastic response and cushioning response of the resultant sole structure <NUM>, <NUM>. With the guidance provided herein, these and other properties and characteristics of the outsole components <NUM>, <NUM>, <NUM>, <NUM> in combination with the properties and characteristics of the fluid-filled bladder elements <NUM>, <NUM> can be selected and configured to provide a desired cushioning response.

The first outsole component <NUM> and the second outsole component <NUM> are cooperatively configured to fit together to assist with locating the second outsole component <NUM> on the first outsole component <NUM> and to reduce the possibility of the second outsole component <NUM> separating from the first outsole component <NUM> during wear. More specifically, and as best shown in <FIG>, the outer surface of <NUM> the first wall <NUM> of the first outsole component <NUM> has a recess <NUM>. When the forefoot sole structure <NUM> is thermoformed, the recess <NUM> is adjacent the second portion <NUM> of the bottom surface <NUM> of the first outsole component <NUM> as shown in <FIG>. With reference to <FIG>, the recess <NUM> is provided due to the shape of the injection mold <NUM> in which the first outsole component <NUM> is injection molded. In an embodiment, the injection mold <NUM> may have upper and lower molds <NUM>, <NUM> with mold surfaces <NUM>, <NUM>, respectively. TPU material is injected through ports <NUM> in molding the first outsole component <NUM> to the contours of the mold surfaces <NUM>, <NUM>. A protrusion <NUM> in the lower mold <NUM> causes the recess <NUM> in the first wall <NUM> of the medial side of the first outsole component <NUM>. A similar protrusion <NUM> causes the recess <NUM> in the first wall <NUM> of the lateral side of the first outsole component <NUM>. The mold surface <NUM> also has recesses <NUM> that create the tread elements <NUM>. Additionally, the mold surfaces <NUM>, <NUM> are shaped so that the second walls <NUM> (i.e., the inner walls) of the first outsole component <NUM> have a greater height than the first walls <NUM> (i.e., the outer walls) of the first outsole component <NUM> and so that an upper end <NUM>, <NUM> of the walls <NUM>, <NUM> are tapered.

The second wall <NUM> of the second outsole component <NUM> is configured so that it can fit in and be secured to the outer surface of the first wall <NUM> of the first outsole component <NUM> in the recess <NUM>. The first outsole component <NUM> and the second outsole component <NUM> of the heel sole structure <NUM> are cooperatively configured in the same manner.

Moreover, as shown in <FIG>, the second wall <NUM> has a first thickness T1 and the recess <NUM> has a first depth D1. The first thickness T1 is greater than the first depth D1 so that second outsole component <NUM> protrudes outward of the first outsole component <NUM> at the first wall <NUM>. The upper edge <NUM> of the second outsole component <NUM> is abutted against or just below a lip <NUM> of the first outsole component <NUM> in the recess <NUM>. The lip <NUM> protects the upper edge <NUM> from direct applied forces during use, reducing the possibility of delamination or other dislocation of the second outsole component <NUM>.

As best shown in <FIG>, the second wall <NUM> (i.e. the inner wall) of the second outsole component <NUM> extends upward from the second base <NUM> of the second outsole component further than the first wall <NUM> (i.e. the outer wall) of the second outsole component. Support for the bladder element <NUM> at the inner wall <NUM> is desirable to limit inward movement of the bladder element <NUM> during compression and deformation. The second outsole component <NUM> of the bladder element <NUM> may be similarly configured, with inner walls that extend upward along inner walls of the first outsole component <NUM> further than outer walls.

In the embodiment shown, the recess <NUM> extends across the bottom surface and up the outer surface of the inner wall <NUM> of the first outsole component <NUM>. Accordingly, only a portion of the thickness T2 of the inner wall <NUM> of the second outsole component <NUM> protrudes from the outer surface of the inner wall <NUM> of the first outsole component <NUM> as shown in <FIG>. Alternatively, the recess <NUM> may end at the bottom surface so that the inner wall <NUM> may be configured without a recess. Both the outer wall <NUM> and the inner wall <NUM> of the first outsole component <NUM> have a tapered upper end <NUM>, <NUM>, shown in <FIG>, helping to prevent delamination of the first outsole component <NUM> from the bladder element <NUM>. The first outsole component <NUM> is similarly configured with a tapered upper end <NUM> at the first wall <NUM>. The upper end <NUM> of the first outsole component <NUM> continues up the inner wall of the tubular portion of the lower polymer sheet <NUM> of the bladder element <NUM> to the lower surface of the lower polymer sheet <NUM> adjacent the tubular portion as indicated in <FIG> and <FIG>, providing maximum support against the inner wall of the bladder element <NUM>.

A method of manufacturing an article of footwear that includes the sole structure <NUM> and/or the sole structure <NUM> as described above includes placing a preformed first outsole component <NUM> into a thermoforming mold <NUM>, <NUM>. In <FIG>, the thermoforming mold is schematically depicted as including an upper mold <NUM> and a lower mold <NUM>. As described with respect to <FIG> and shown in <FIG>, the first outsole component <NUM> is preformed with a base <NUM> having integral tread elements <NUM> protruding from a first portion <NUM> of a bottom surface <NUM> of the base, with a second portion <NUM> of the bottom surface <NUM> free of any tread elements, and with a wall <NUM> integral with the base <NUM> and adjacent the second portion <NUM> of the bottom surface. As used herein, "preformed" means that the first outsole component <NUM> has the features prior to the thermoforming process (i.e., prior to placement in the thermoforming mold <NUM>, <NUM>).

In an embodiment, the lower mold <NUM> may have one or more positioning markers to orient the first outsole component <NUM>. As shown in <FIG>, the second mold surface <NUM> has a positioning marker <NUM>, and placing the first outsole component <NUM> into the lower mold <NUM> includes placing a predetermined portion of the first outsole component <NUM> at the positioning marker <NUM>, thereby orienting the first outsole component <NUM> in a predetermined position in the thermoforming mold <NUM>. The positioning marker <NUM> is a cavity in the second mold surface <NUM>, and the predetermined portion of the first outsole component <NUM> is one of the tread elements <NUM>. Other alternative positioning markers may be used instead of or in addition to positioning marker <NUM>.

The method further includes placing polymeric material in the thermoforming mold <NUM>, <NUM> with the first outsole component <NUM>. The polymeric material may be a first polymeric sheet <NUM> and a second polymeric sheet <NUM> also referred to as an upper polymeric sheet and a lower polymeric sheet due to their relative positions in the completed article of footwear. Alternatively, the polymeric material may be a preform (e.g., polymeric material not in sheet form).

The thermoforming mold <NUM>, <NUM> is then closed by placing the upper and lower molds <NUM>, <NUM> together as shown in <FIG> to enclose the polymeric material (i.e., an enclosed portion of the sheets <NUM>, <NUM> and the first outsole component <NUM> in a mold cavity <NUM> defined between the mold surface <NUM> of the upper mold <NUM> and the mold surface <NUM> of the lower mold <NUM>. The method then includes forming the sheets <NUM>, <NUM> by a combined thermoforming and vacuuforming process, which includes applying a vacuum to conform a first portion of the polymeric material (i.e., the enclosed portion of the first sheet <NUM>) to the first mold surface (i.e., the surface <NUM>) of the thermoforming mold and conform a second portion of the polymeric material (i.e., the bottom surface <NUM> of the enclosed portion of the second sheet <NUM>) to an upper surface <NUM> of the first outsole component <NUM> and to the second mold surface <NUM> with the interior cavity <NUM> between the first sheet <NUM> and the second sheet <NUM>. In <FIG>, the lip <NUM> of the first outsole component <NUM> is not apparent as it is compressed against the mold surface <NUM>. The interior cavity <NUM> may be inflated after the thermoforming process is complete (i.e., after removal of the bladder element <NUM> and first outsole component <NUM> from the thermoforming mold <NUM>, <NUM>). Gaps may exist between the bottom surface of the first outsole component <NUM> and the mold surface <NUM> to ease removal of the sole surface after thermoforming.

In an embodiment in which the polymeric material is the first and second polymer sheets <NUM>, <NUM>, the method then includes thermally bonding the first polymeric sheet <NUM> to the second polymeric sheet <NUM> to enclose the interior cavity <NUM>, and thermally bonding the lower surface <NUM> of the second polymer sheet <NUM> to the upper surface <NUM> of the first outsole component.

The first and second polymer sheets <NUM>, <NUM> are thermally bonded to one another around the peripheral flange <NUM> formed between the pinch surface <NUM> and the seam-forming surface <NUM> and at web areas <NUM> between the portions of the fluid-filled interior cavity <NUM>. As the mold <NUM>, <NUM> closes, pinch surface <NUM> contacts and slides against a portion of second seam-forming surface <NUM>. The contact between pinch surface <NUM> and second seam-forming
surface <NUM> effectively severs excess portions <NUM>, <NUM> of first and second polymer sheets <NUM>, <NUM> from portions that form bladder element <NUM>. The material forming first polymer sheet <NUM> and second polymer sheet <NUM> compacts or otherwise collects to form flange <NUM>. In addition to forming flange <NUM>, first polymer sheet <NUM> and second polymer sheet <NUM> are (a) shaped to produce bladder element <NUM> and (b) compressed and joined to produce web area <NUM>.

The thermoformed sheets <NUM>, <NUM> are allowed to cool, and then the mold <NUM>, <NUM> is opened by separating the upper and lower molds <NUM>, <NUM>, and the thermally bonded upper and lower polymer sheets <NUM>, <NUM> and first outsole component <NUM> are removed from the mold <NUM>, <NUM> as a unit after a predetermined cooling period. If the mold <NUM>, <NUM> is configured to mold multiple sole structures <NUM>, <NUM> simultaneously, additional trimming may be necessary around the flange <NUM> or between the adjacent sole structures. The bladder element <NUM> with the attached first outsole component <NUM> may be inflated after thermoforming and prior to attachment of the second outsole component <NUM>, or may be inflated after attachment of the second outsole component <NUM>.

After the first outsole component <NUM> is attached to the bladder element <NUM>, the second outsole component <NUM> is positioned on the second portion <NUM> of the bottom surface <NUM> of the first outsole component <NUM>. Positioning the second outsole component <NUM> is by nesting the second outsole component <NUM> in the recess <NUM>. Nesting includes abutting the upper edge <NUM> of the second outsole component <NUM> against the lip <NUM> of the first outsole component <NUM> at an upper extent of the recess <NUM>, as indicated with respect to one of the outsole components <NUM> in <FIG>. The upper edge <NUM> of the second outsole component <NUM> is abutted against a lip <NUM> of the first outsole component <NUM> in the recess <NUM>, as shown in <FIG>, <FIG>, and <FIG>. The second outsole component <NUM> is adhered to the first outsole component <NUM>. As shown in <FIG>, the footwear upper <NUM> is then secured to the upper surface <NUM> of the first polymer sheet <NUM>. In <FIG>, the flange <NUM> is shown at the lateral side of the sole structure <NUM> and is adhered to the lower lateral side of the upper <NUM>.

The method has been described with respect to the forefoot sole structure <NUM>. The method may also include injection molding the first outsole component <NUM>, vacuum/thermoforming the bladder element <NUM> and thermally bonding the first outsole component <NUM> to the bladder element <NUM> in a thermoforming mold, attaching the second outsole component to the <NUM> as described, and then securing the heel sole structure <NUM> to the heel region of the upper <NUM> with a forward edge <NUM> of the heel sole structure adjacent a rearward edge <NUM> of the forefoot sole structure as shown in <FIG> and <FIG>.

Claim 1:
A sole structure (<NUM>) for an article of footwear (<NUM>), the sole structure (<NUM>) comprising:
a polymeric bladder element (<NUM>) enclosing a fluid-filled interior cavity (<NUM>); wherein the polymeric bladder element (<NUM>) is configured with an arcuate portion at an outer periphery of the sole structure (<NUM>), the arcuate portion having an inner curved wall;
a first outsole component (<NUM>) including a first base (<NUM>) attached to a bottom surface (<NUM>) of the bladder element (<NUM>), the first base having a first portion (<NUM>) and a second portion (<NUM>), a first wall (<NUM>) integral with the first base (<NUM>) and secured to a first side surface (<NUM>) of the bladder element (<NUM>), and a second wall (<NUM>) integral with the first base (<NUM>) and secured to a second side surface (<NUM>) of the bladder element (<NUM>); and
a second outsole component (<NUM>) including a second base (<NUM>) secured to the second portion (<NUM>) of the bottom surface (<NUM>) of the first base (<NUM>), and a second wall (<NUM>) integral with the second base (<NUM>) and secured to an outer surface (<NUM>) of the first wall (<NUM>) of the first outsole component (<NUM>),
wherein the outer surface (<NUM>) is adjacent the second portion (<NUM>) of the bottom surface (<NUM>).