Patent Description:
The present teachings generally relate to a cushioning article and a method of manufacturing a cushioning article.

Fluid-filled bladders used for cushioning in footwear or other articles provide the advantage of lightweight cushioning and resiliency. Those skilled in the footwear arts strive to simplify manufacturing methods while providing repeatability, reliability, and aesthetically pleasing cushioning articles.

<CIT> discloses a method of manufacturing a cushioning article, wherein the body or tubular part of such a cushioning article is made by wrapping a laminated sheet around a forming mandrel and heat-sealing overlapping portions of the sheet to form a tubular body.

Cushioning articles that includes sealed, fluid-filled bladders made from sheets of multi-layer polymeric films are typically welded or thermoformed. The multiple layers may include one or more gas barrier layers that retain the fluid in the bladder. Because the multiple layers are welded or thermoformed to provide the desired shape of the bladder, weld seams typically are disposed at the periphery of the bladder. If the bladder is exposed for viewing when assembled in the article, it may be more aesthetically pleasing to view a portion of the bladder without weld seams, but it can be difficult to locate the weld seams so that they will not show.

A method of manufacturing a cushioning article for an article of footwear according to the claimed invention is defined in claim <NUM>. Dependent claims <NUM>-<NUM> define advantageous embodiments of the method according to the claimed invention. A cushioning article for an article of footwear according to the claimed invention is defined in claim <NUM>. Dependent claims <NUM>-<NUM> define advantageous embodiments of the cushioning article according to the claimed invention. A method of manufacturing disclosed herein provides a cushioning
article that has side walls that are free from any weld seams. The method of manufacturing a cushioning article comprises wrapping a polymeric sheet around a support so that the polymeric sheet surrounds a perimeter of the support. A first portion of the polymeric sheet adjacent a first side edge of the polymeric sheet overlaps and is stacked on a second portion of the polymeric sheet adjacent a second side edge of the polymeric sheet. The method includes welding the first portion to the second portion at a first weld disposed between the first side edge and the second side edge while the polymeric sheet is wrapped around the support so that the polymeric sheet forms an open-ended sheath with a top wall, a bottom wall, a first side wall and a second side wall with the first weld disposed at only one of the top wall and the bottom wall. The polymeric sheet is then removed from the support, and, after removing the polymeric sheet from the support, the top wall is welded to the bottom wall at a first transverse weld and a second transverse weld. Both the first transverse weld and the second transverse weld cross the first weld and extend from the first side wall to the second side wall so that the polymeric sheet defines and encloses an interior cavity capable of retaining a fluid, and the first side wall and the second side wall are weld-free.

The method may include, prior to removing the polymeric sheet from the support, welding the first portion to the second portion at a second weld that is disposed between the first side edge and the second side edge and is spaced apart from the first weld. Welding the first weld may be contemporaneous with welding the second weld.

The method may include, prior to welding the first weld, knurling at least one of the first portion of the polymeric sheet and the second portion of the polymeric sheet. Knurling one or both portions helps roughen the surface of the polymeric sheet, which may enable a stronger weld seam.

The first side edge and the second side edge may both extend from a top edge of the polymeric sheet to a bottom edge of the polymeric sheet. The method may further comprise, contemporaneously with welding the first transverse weld, welding a first outer weld between the first transverse weld and the top edge. The first outer weld may extend from the first side wall to the second side wall, and the polymeric sheet may form a flange extending outward from the first transverse weld to the first outer weld, with the flange having a recess between the first transverse weld and the first outer weld.

Similarly, the method may further comprise, contemporaneously with welding the second transverse weld, welding a second outer weld between the second transverse weld and the bottom edge. The second outer weld may extend from the first side wall to the second side wall. The polymeric sheet may form a flange extending outward from the second transverse weld to the second outer weld, with the flange having a recess between the second transverse weld and the second outer weld.

The method may further comprise, after welding the polymeric sheet at the first transverse weld and the second transverse weld, trimming the polymeric sheet at the top edge, at the bottom edge, or at both the top edge and the bottom edge. Additionally, the method may include inflating the interior cavity with the fluid and sealing the interior cavity such that the interior cavity retains the fluid.

According to the claimed invention, the method further comprises welding the top wall to the bottom wall at an intermediate weld that extends across the first weld and terminates inward of each of the first side wall, the second side wall, the first transverse weld, and the second transverse weld. Welding the top wall to the bottom wall at the intermediate weld may be contemporaneous with welding the polymeric sheet at the first transverse weld and the second transverse weld. By securing the top wall to the bottom wall between the side walls, the intermediate welds control the maximum height of the bladder when the bladder is inflated, helping it to stay flatter than it would otherwise.

In one or more embodiments, the method may further comprise disposing the cushioning article in a footwear sole structure, wherein the footwear sole structure is configured with an opening, and at least one of the first side wall and the second side wall is positioned at the opening. Because the welds are located at the top wall or the bottom wall and not at either of the side walls, no welds will extend across the opening, and the weld-free surface of one of the side walls may be viewable at the opening.

Within the scope of the disclosure a cushioning article comprises a polymeric sheet having a first portion overlapped with a second portion and welded to the second portion at a first weld, the first portion adjacent a first side edge of the polymeric sheet and the second portion adjacent a second side edge of the polymeric sheet. The polymeric sheet forms a top wall, a bottom wall, a first side wall, and a second side wall. The first side wall and the second side wall extend between the top wall and the bottom wall, and the first weld is disposed at only one of the top wall or the bottom wall. The polymeric sheet has a first transverse weld at which the top wall is welded to the bottom wall and a second transverse weld at which the top wall is welded to the bottom wall. Both the first transverse weld and the second transverse weld cross the first weld and extending from the first side wall to the second side wall so that the polymeric sheet defines and encloses an interior cavity capable of retaining a fluid, and the first side wall and the second side wall are weld-free.

In one or more embodiments, the cushioning article may include a second weld at which the first portion is welded to the second portion, the second weld disposed between the first side edge and the second side edge and spaced apart from the first weld.

In one or more embodiments of the cushioning article, the first side edge and the second side edge both extend from a top edge of the polymeric sheet to a bottom edge of the polymeric sheet, and a first outer weld is between the first transverse weld and the top edge and extends from the first side wall to the second side wall. The polymeric sheet forms a flange extending outward from the first transverse weld to the first outer weld. The flange has a recess between the first transverse weld and the first outer weld.

In one or more embodiments, the cushioning article further comprises a second outer weld between the second transverse weld and the bottom edge and extending from the first side wall to the second side wall. The polymeric sheet forms a flange extending outward from the second transverse weld to the second outer weld. The flange has a recess between the second transverse weld and the second outer weld.

According to the claimed invention, the cushioning article further comprises an intermediate weld securing the top wall to the bottom wall and that extends across the first weld and terminates inward of each of the first side wall, the second side wall, the first transverse weld, and the second transverse weld.

According to the claimed invention, the polymeric sheet comprises a multi-layer polymeric sheet. The multi-layer polymeric sheet may be a laminate membrane having at least a first layer comprising a thermoplastic polyurethane, and at least a second layer comprising a gas barrier polymer. The gas barrier polymer may be an ethylene-vinyl alcohol copolymer.

A method of manufacturing <NUM> disclosed herein provides a cushioning article that has side walls that are free from any weld seams. Referring to the drawings, wherein like reference numbers refer to like components, <FIG> shows a polymeric sheet <NUM> that is subjected to the method of manufacturing <NUM> shown in the flowchart of <FIG> to form a cushioning article <NUM> shown in <FIG>. The cushioning article <NUM> has no welds or seams on its side walls. This is difficult to achieve for a cushioning article that is not injection molded. The polymeric sheet <NUM> is a multi-layer sheet and, as such, is not conducive to injection molding. For example, the polymeric sheet <NUM> may be a multi-layer polymeric sheet that is a laminate membrane having at least a first layer <NUM> comprising a thermoplastic polyurethane, and at least a second layer <NUM> comprising a gas barrier polymer. In the embodiment shown, the sheet includes alternating first layers <NUM> and second layers <NUM>. The sheet <NUM> can include any of various polymeric materials that can retain a fluid at a predetermined pressure, including a fluid that is a gas, such as air, nitrogen, or another gas. For example, the sheet <NUM> can include thermoplastic polymeric material, such as a urethane, polyurethane, polyester, polyester polyurethane, and/or polyether polyurethane.

<FIG>, which is a close-up fragmentary cross-sectional portion of the cushioning article <NUM> formed from the sheet <NUM> in an article of footwear <NUM> taken at lines <NUM>-<NUM> in <FIG>, shows that the polymeric sheet <NUM> is a laminate membrane formed from thin films having one or more first layers <NUM> that comprise thermoplastic polyurethane layers <NUM> and that alternate with one or more second layers <NUM>, also referred to herein as barrier layers, gas barrier polymers, or gas barrier layers, that comprise a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein as disclosed in <CIT>. One of the first layers <NUM> may be arranged to form an outer surface of the polymeric sheet <NUM>. That is, the outermost first layer <NUM> shown in <FIG> may be a portion of the outer surface of the cushioning article <NUM>. The polymeric sheet <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. The polymeric sheet <NUM> may also be a flexible microlayer membrane that includes alternating layers of a gas barrier polymer material such as second layers <NUM> and an elastomeric material such as first layers <NUM>, as disclosed in <CIT> and <CIT>al. Additional suitable materials for the polymeric sheet <NUM> are disclosed in <CIT> and <CIT>. Further suitable materials for the polymeric sheet <NUM> include thermoplastic films containing a crystalline material, as disclosed in <CIT> and <CIT> to Rudy, and polyurethane including a polyester polyol, as disclosed in <CIT>, <CIT>, and <CIT>. In selecting materials for the polymeric sheet <NUM>, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thickness of the polymeric sheet <NUM> used to form the cushioning article <NUM> can be selected to provide these characteristics.

Referring again to <FIG>, the polymeric sheet <NUM> begins in a flat, planar configuration, and has a top edge <NUM>, a bottom edge <NUM>, a first side edge <NUM>, and a second side edge <NUM>. In <FIG>, the side of the sheet <NUM> facing upward is the inner side of the surface of the cushioning article <NUM> when manufactured according to the method <NUM>, and so the surface facing upward in <FIG> is referred to as the inner surface <NUM>. The surface <NUM> on the opposite side is the outer surface when the cushioning article <NUM> is manufactured according to the method <NUM> and is therefore referred to as the outer surface <NUM>.

The method <NUM> begins with step <NUM>, in which portions of the polymeric sheet <NUM> are knurled in preparation for subsequent welding. More specifically, the polymeric sheet <NUM> has a first portion <NUM> adjacent the first side edge <NUM> and a second portion <NUM> adjacent the second side edge <NUM>. The portions <NUM>, <NUM> are shown extending from the respective side edges <NUM>, <NUM> to phantom lines parallel with the side edge. A knurling tool <NUM> is used to knurl the portions <NUM>, <NUM>. At least the inner surface <NUM> at the first portion <NUM> and the outer surface <NUM> at the second portion <NUM> are knurled, although the portions <NUM>, <NUM> may each be knurled at both surfaces <NUM>, <NUM>.

The method <NUM> then proceeds to step <NUM>, wrapping the polymeric sheet <NUM> around a support <NUM> so that the polymeric sheet <NUM> surrounds a perimeter <NUM> of the support <NUM>, and so that the first portion <NUM> of the polymeric sheet <NUM> overlaps and is stacked on the second portion <NUM> of the polymeric sheet <NUM>. Wrapping the polymeric sheet <NUM> around the support <NUM> is depicted in <FIG> and <FIG>. In <FIG>, the polymeric sheet <NUM> is generally centered under the support <NUM>, and the side edges <NUM>, <NUM> are moved upward and around the support <NUM>, as indicated by arrows A in <FIG>, until the second portion <NUM> rests on the support <NUM>, and the first portion <NUM> overlaps and rests on the second portion <NUM> as shown in <FIG>. In this arrangement, the knurled inner surface <NUM> at the first portion <NUM> lays against the knurled outer surface <NUM> at the second portion <NUM>.

With the polymeric sheet wrapped on the support <NUM> as shown in <FIG>, the method <NUM> proceeds to step <NUM>, in which a first longitudinal weld W1 (also referred to herein as a first weld or a first weld seam) welds the first portion <NUM> to the second portion <NUM>. Because one or both of the portions <NUM>, <NUM> are knurled, the material of the sheet <NUM> may bond together at the weld W1 more strongly than if the surfaces were smoother.

The method <NUM> may include step <NUM>, in which, prior to removing the polymeric sheet <NUM> from the support <NUM>, the first portion <NUM> is also welded to the second portion <NUM> at a second weld W2 that is disposed between the first side edge <NUM> and the second side edge <NUM> and is spaced apart from the first weld W1. Welding the first weld W1 may be contemporaneous with welding the second weld W2, as each may be welded using the same welding tool <NUM>. The first and second welds W1, W2 are parallel with one another and with the first and second side edges <NUM>, <NUM>. The first and second welds W1, W2 extend from the top edge <NUM> to the bottom edge <NUM>.

<FIG> shows a welding tool <NUM> used to create the first weld W1 and the second weld W2. Two parallel protrusions <NUM> of the welding tool <NUM> create the welds W1, W2 when the welding tool <NUM> is powered by a power source <NUM> to provide power for radio frequency welding (also referred to as high frequency or dielectric welding) of the first portion <NUM> to the second portion <NUM>. The power source <NUM> supplies energy creating an alternating electric field that heats the polymeric sheet <NUM> at the overlapping portions <NUM>, <NUM> where the protrusions <NUM> are applied to the polymeric sheet <NUM>. Alternatively, but not according to the claimed invention, the portions <NUM>, <NUM> may be secured to one another by another manner of thermal or adhesive bonding.

After step <NUM>, the method <NUM> proceeds to step <NUM> in which the polymeric sheet <NUM> is removed from the support <NUM>. Due to the first and second welds W1, W2, the polymeric sheet <NUM> forms an open-ended sheath, best shown in <FIG>, with a top wall <NUM>, a bottom wall <NUM>, a first side wall <NUM>, and a second side wall <NUM>. The first side wall <NUM> and the second side wall <NUM> extend between the top wall <NUM> and the bottom wall <NUM>. The flexible polymeric sheet <NUM> may almost flatten at the side walls <NUM>, <NUM> in the state following step <NUM>. The polymeric sheet <NUM> may be referred to as being folded at the side walls <NUM>, <NUM>. However, there are no creases at the side walls <NUM>, <NUM>, but the flexible nature of the polymeric sheet <NUM> allows it to change direction from the bottom wall to the top wall along the side walls <NUM>, <NUM> without creasing.

Because the polymeric sheet <NUM> is wrapped around the support <NUM> during welding, the opposite side of the polymeric sheet <NUM> is protected from the welding tool <NUM> by the support <NUM> and is unaffected by the welding of the first weld W1 and the second weld W2. The first weld W1 and the second weld W2 are disposed at only the top wall <NUM>. If the polymeric sheet <NUM> is instead wrapped around the support <NUM> from above and welded at a lower side of the support <NUM>, then the first weld W1 and the second weld W2 would be disposed only at the bottom wall <NUM>.

With the polymeric sheet <NUM> now removed from the support <NUM>, the method proceeds to step <NUM>, in which the top wall <NUM> is welded to the bottom wall <NUM> at a first transverse weld TW1 and a second transverse weld TW2, shown in <FIG>. Both the first transverse weld TW1 and the second transverse weld TW2 cross the first weld W1 and the second weld W2 and extend from the first side wall <NUM> to the second side wall <NUM>. This causes the polymeric sheet <NUM> to define and encloses an interior cavity <NUM> capable of retaining a fluid, while leaving the first side wall <NUM> and the second side wall <NUM> weld-free, as best shown in <FIG> and <FIG>.

<FIG> shows a welding tool <NUM> used to create the first transverse weld TW1 and the second transverse weld TW2. The polymeric sheet <NUM> is placed on a welding table <NUM> and the welding tool <NUM> is powered by the power source <NUM> to provide power for radio frequency welding. The power source <NUM> supplies energy creating an alternating electric field that heats the polymeric sheet <NUM> at the stacked top and bottom walls <NUM>, <NUM> where two parallel protrusions <NUM> of the welding tool <NUM> are applied to the top wall <NUM> to create the welds TW1, TW2. The entire cushioning article <NUM> is formed from the single polymeric sheet <NUM>.

Because the welding tool <NUM> has additional protrusions, the method <NUM> may further comprise step <NUM> which may occur contemporaneously with welding the first transverse weld TW1 and the second transverse weld TW2, and includes welding a first outer weld OW1 between the first transverse weld TW1 and the top edge <NUM>, and welding a second outer weld OW2 between the second transverse weld TW2 and the bottom edge <NUM>. More specifically, the parallel protrusions <NUM> are spaced from one another and from the protrusions <NUM>, further toward the top and bottom edges <NUM>, <NUM>. Like the transverse welds TW1, TW2, the first outer welds OW1 and OW2 cross the first and second longitudinal welds W1 and W2, and extend from the first side wall <NUM> to the second side wall <NUM>. The polymeric sheet <NUM> forms a flange 70A extending outward from the first transverse weld TW1 to the first outer weld OW1 and outward to the top edge <NUM>. The polymeric sheet <NUM> also forms a flange 70B extending outward from the first transverse weld TW2 to the first outer weld OW2 and outward to the bottom edge <NUM>. As best shown in <FIG>, the flange 70A has a recess 72A between the first transverse weld TW1 and the first outer weld OW1. Flange 70B has a similar recess 72B between the second transverse weld TW2 and the second outer weld OW2. The first transverse weld TW1 and the first outer weld OW1 serve as a double seal of the interior cavity <NUM> near the top edge <NUM>, and the second transverse weld TW2 and the second outer weld OW2 serve as a double seal of the interior cavity <NUM> near the bottom edge <NUM>. Stated differently, the outer welds OW1 and OW2 provide redundant sealing of the interior cavity <NUM>. The recesses 72A and 72B may serve as guides at which the cushioning article <NUM> may be secured to other components with which it is subsequently assembled, such as a midsole, and upper, etc..

In addition to the transverse welds TW1 and TW2 and the outer welds OW1 and OW2, the method <NUM> according to the claimed invention further comprises step <NUM>, welding the top wall <NUM> to the bottom wall <NUM> at one or more intermediate welds IW that extends across the first weld W1 and the second weld W1 and terminate inward of each of the first side wall <NUM>, the second side wall <NUM>, the first transverse weld TW1, and the second transverse weld TW2. The intermediate welds IW thus do not create sub-chambers within the interior cavity <NUM>. Step <NUM>, welding the top wall <NUM> to the bottom wall <NUM> at the one or more intermediate welds IW may be contemporaneous with step <NUM>, welding the polymeric sheet at the first transverse weld TW1 and the second transverse weld TW2, and contemporaneous with step <NUM>, welding the first outer weld OW1 and the second outer weld OW2. As shown in <FIG>, the welding tool <NUM> includes protrusions <NUM> that are parallel with and spaced from one another, and are also parallel with and spaced from the protrusions <NUM>, <NUM> and are generally thicker and shorter than the protrusions <NUM> and <NUM>. The protrusions <NUM> do not extend to the side walls <NUM>, <NUM>, but extend across the longitudinal welds W1 and W2. The protrusions <NUM> result in intermediate welds IW shown in <FIG> that secure the top wall <NUM> to the bottom wall <NUM> and the ability of the top control the maximum height H1 of the cushioning article <NUM> when the cushioning article <NUM> is inflated, as shown in <FIG>, helping it to stay flatter than it would otherwise.

The method <NUM> may further comprise, step <NUM>, which occurs after welding the polymeric sheet at the first transverse weld and the second transverse weld, and includes trimming the polymeric sheet <NUM> at the top edge <NUM>, at the bottom edge <NUM>, or at both the top edge and the bottom edge. The trimming occurs between the outward weld OW1 and the top edge <NUM>, and between the outward weld OW2 and the bottom edge <NUM> and OW2. The trimming step is best illustrated in <FIG>, where the polymeric sheet <NUM> has been trimmed to the outward welds OW1 and OW2. Apertures <NUM> have also been punched or otherwise provided at ends of each of the intermediate welds IW, as shown in <FIG>. After trimming in step <NUM>, the method <NUM> proceeds to step <NUM> in which the interior cavity is inflated by filling it with a gas or air to a predetermined pressure. Inflation may occur through an inflation port (not shown) at either flange 70A or 70B provided by a short fill tube laid between the top wall and the bottom wall where the welding tool <NUM> forms the transverse weld TW1 or TW2 and the corresponding outward weld OW1 or OW2. Alternatively, step <NUM> can be omitted if the interior cavity <NUM> is to be at ambient pressure. The inflated interior cavity <NUM> is subsequently sealed in step <NUM>, such as by sealing the plug.

If the cushioning article <NUM> is for an article of footwear, the method <NUM> may move from step <NUM> to step <NUM>, in which the cushioning article is disposed in a sole structure <NUM> of the article of footwear <NUM> of <FIG>. The sole structure <NUM> is secured to a footwear upper <NUM>. The sole structure <NUM> has a midsole <NUM> that is configured with an opening <NUM>, as best illustrated in the cross-section of <FIG>. Either the first side wall <NUM> or the second side wall <NUM> is positioned at the opening <NUM>, depending on the configuration. In the embodiment shown, the first side wall <NUM> is positioned at the opening <NUM> so that it is visible through the opening from the exterior of the article of footwear <NUM>. As is evident in <FIG>, because the welds (including longitudinal welds W1, W2, transverse welds TW1, TW2, and outer welds OW1, OW2), are located at the top wall <NUM> or the bottom wall <NUM> and not at either of the side walls <NUM>, <NUM>, no welds will extend across the opening <NUM>, and the weld-free surface of the side wall <NUM> is viewable at the opening <NUM>.

<FIG> illustrate that multiple cushioning articles <NUM> may be manufactured from the same single polymeric sheet <NUM>, according to the same method <NUM>. Two identical cushioning articles referred to as cushioning articles 12A and 12B are formed according to the same steps described with respect to method <NUM>. The first and second longitudinal welds W1 and W2 extend through both of the cushioning articles 12A and 12B. The welding tool used has a different pattern of protrusions, and the transverse welds that result near the top edge <NUM> and the bottom edge <NUM> are nonlinear. The polymeric sheet <NUM> is turned <NUM> degrees relative to <FIG> in <FIG>. Excess polymeric material between the top edge <NUM> and the first transverse weld W1, between the bottom edge <NUM> and the second transverse weld W2, and between some of the interior welds IW is trimmed, as shown in <FIG>. The two cushioning articles 12A, 12B may be doubled over at a welded joint <NUM> at which they are connected or may be separated by cutting at the joint to provide two disjoined cushioning articles, one of which (cushioning article 12B) is shown in <FIG>. Neither of the cushioning articles 12A, 12B have any welds along the side walls <NUM>, <NUM>.

Assembled, ready to wear footwear articles (e.g., shoes, sandals, boots, etc.), as well as discrete components of footwear articles (such as a midsole, an outsole, an upper component, etc.) prior to final assembly into ready to wear footwear articles, are considered and alternatively referred to herein in either the singular or plural as "article(s) of footwear" or "footwear".

The term "longitudinal" refers to a direction extending a length of a component. For example, a longitudinal direction of an article of footwear extends between a forefoot region and a heel region of the article of footwear. The term "forward" or "anterior" is used to refer to the general direction from a heel region toward a forefoot region, and the term "rearward" or "posterior" is used to refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

The term "transverse" refers to a direction extending a width of a component. For example, a transverse direction of an article of footwear extends between a lateral side and a medial side of the article of footwear. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

The term "vertical" refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole structure is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole structure. The term "upward" or "upwards" refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term "downward" or "downwards" refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.

The "interior" of an article of footwear, such as a shoe, refers to portions at the space that is occupied by a wearer's foot when the article of footwear is worn. The "inner side" of a component refers to the side or surface of the component that is (or will be) oriented toward the interior of the component or article of footwear in an assembled article of footwear. The "outer side" or "exterior" of a component refers to the side or surface of the component that is (or will be) oriented away from the interior of the article of footwear in an assembled article of footwear. In some cases, other components may be between the inner side of a component and the interior in the assembled article of footwear. Similarly, other components may be between an outer side of a component and the space external to the assembled article of footwear. Further, the terms "inward" and "inwardly" refer to the direction toward the interior of the component or article of footwear, such as a shoe, and the terms "outward" and "outwardly" refer to the direction toward the exterior of the component or article of footwear, such as the shoe. In addition, the term "proximal" refers to a direction that is nearer a center of a footwear component, or is closer toward a foot when the foot is inserted in the article of footwear as it is worn by a user. Likewise, the term "distal" refers to a relative position that is further away from a center of the footwear component or is further from a foot when the foot is inserted in the article of footwear as it is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposing terms to describe relative spatial positions.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims. Also, various modifications and changes may be made within the scope of the attached claims.

Claim 1:
A method of manufacturing (<NUM>) a cushioning article (<NUM>) for an article of footwear (<NUM>), the method (<NUM>) comprising:
wrapping a multi-layer polymeric sheet (<NUM>) around a support (<NUM>) so that the polymeric sheet (<NUM>) surrounds a perimeter (<NUM>) of the support (<NUM>) and a first portion (<NUM>) of the polymeric sheet (<NUM>) adjacent a first side edge (<NUM>) of the polymeric sheet (<NUM>) overlaps and is stacked on a second portion (<NUM>) of the polymeric sheet (<NUM>) adjacent a second side edge (<NUM>) of the polymeric sheet (<NUM>);
welding the first portion (<NUM>) to the second portion (<NUM>) at a first weld (W1) disposed between the first side edge (<NUM>) and the second side edge (<NUM>) while the polymeric sheet (<NUM>) is wrapped around the support (<NUM>) so that the polymeric sheet (<NUM>) forms an open-ended sheath with a top wall (<NUM>), a bottom wall (<NUM>), a first side wall (<NUM>) and a second side wall (<NUM>) and with the first weld (W1) disposed at only one of the top wall (<NUM>) and the bottom wall (<NUM>);
removing the polymeric sheet (<NUM>) from the support (<NUM>);
after removing the polymeric sheet (<NUM>) from the support (<NUM>), welding the top wall (<NUM>) to the bottom wall (<NUM>) at a first transverse weld (TW1) and a second transverse weld (TW2), both the first transverse weld (TW1) and the second transverse weld (TW2) crossing the first weld (W1) and extending from the first side wall (<NUM>) to the second side wall (<NUM>) so that the polymeric sheet (<NUM>) defines and encloses an interior cavity (<NUM>) capable of retaining a fluid, and the first side wall (<NUM>) and the second side wall (<NUM>) are weld-free; and
welding the top wall (<NUM>) to the bottom wall (<NUM>) at an intermediate weld (IW) that extends across the first weld (W1) and terminates inward of each of the first side wall (<NUM>), the second side wall (<NUM>), the first transverse weld (TW1), and the second transverse weld (TW2).