Patent Description:
Clothing, an accessory, and/or athletic wear are often a source of expression for the wearer. The clothing, accessory, and/or athletic wear may provide an association with a team, coordinate with another item, or provide the owner or user with an attractive or customized item.

Footwear typically includes a sole configured to be located under a wearer's foot to space the foot away from the ground or floor surface. Footwear sometimes utilizes polyurethane foam or other resilient materials in the sole to provide cushioning.

Document <CIT> describes a device for displaying an image on an apparel. The image displaying device includes a background layer that is substantially opaque. The device also includes a display layer that is semi-transparent. The display layer includes an inner surface facing the background layer, and the inner surface is substantially smooth. The display layer further includes an outer surface facing away from the background layer, and the outer surface includes a plurality of raised areas and a plurality of recessed areas. The display layer has increased light transmissivity through the recessed areas and decreased light transmissivity through the raised areas such that a contrast of light transmissivity between the raised and recessed areas generates an image. <CIT> discloses an air bladder device that includes a casing having a transparent or semi-transparent wall, an air bag received in the casing, and one or more patterns disposed between the wall and the air bag. The air bag is inflatable to move the patterns toward and away from the wall.

The invention is defined by the appended independent claim <NUM>. Additional embodiments are defined in the dependent claims. Not part of the claimed invention, a method of manufacturing an article comprises forming a fluid-filled bladder element from polymeric material, and securing an overlay to the polymeric material. At least one portion of the overlay is substantially transparent, and an image on one of the polymeric material and the overlay is aligned with the at least one portion of the overlay that is substantially transparent. The method comprises assembling the fluid-filled bladder element in the article so that a first portion of the fluid-filled bladder element and the image are exposed to view through the at least one portion of the overlay that is substantially transparent, and a second portion of the fluid-filled bladder element is blocked from view by the article.

In one example, the method includes applying the image to the first polymeric sheet prior to securing the overlay to the first polymeric sheet. In another example, the image is on the overlay and is transferred to the fluid-filled bladder element during forming of the fluid-filled bladder element.

In one example, the method may include forming the fluid-filled bladder element, and the overlay may be secured to an outer surface of the bladder element after forming the bladder element. Forming the fluid-filled bladder element in the mold assembly may include at least one of thermoforming or vacuum forming. Securing the overlay to the polymeric material may be by adhering the overlay to the outer surface of the fluid-filled bladder element, and may include placing an adhesive on one or both of the overlay or the outer surface of the fluid-filled bladder element prior to placing the overlay on the outer surface of the bladder element. The adhesive forms an adhesive layer that secures the overlay to the fluid-filled bladder element after the overlay is placed on the fluid-filled bladder element. The fluid-filled bladder element may be formed with a curved portion, and the overlay may be on the curved portion.

In one example, the method may include placing the overlay in a mold assembly with the polymeric material and forming the fluid-filled bladder element from the polymeric material in the mold assembly while the overlay is also present in the mold assembly. For example, placing the overlay in the mold assembly may include placing the overlay on a mold surface of the mold assembly. Additionally, the polymeric material may comprise a first polymeric sheet, and the method may include placing the first polymeric sheet in the mold assembly after placing the overlay in the mold assembly.

In one example, a releasable film is attached to the overlay and is in contact with the mold surface when the overlay is placed in the mold assembly. The method may include removing the releasable film from the overlay after the bladder element is formed.

Securing the overlay to the polymeric material may include thermally bonding the overlay and the first polymeric sheet by heating the overlay and the polymeric sheet in the mold assembly during forming of the fluid-filled bladder element. In one embodiment, the image may be initially on the overlay, and the image may be transferred from the overlay to the first polymeric sheet during thermal bonding of the overlay and the first polymeric sheet to one another.

In one embodiment, the polymeric material further comprises a second polymeric sheet. The method may further comprise placing the second polymeric sheet in the mold assembly and bonding the first polymeric sheet to the second polymeric sheet to form a peripheral seam that at least partially seals a fluid-filled cavity of the bladder element. The overlay may be spaced apart from the seam on the bladder element. Bonding of the first and second polymeric sheets may be by thermal bonding, compression bonding, radio-frequency welding, or other bonding method, including by the use of adhesive.

Spacing of the overlay apart from the seam allows the fluid-filled bladder element to be assembled in the article so that the seam is covered by the article but the overlay is uncovered. The article has an opening, and the fluid-filled bladder element may be assembled in the article so that the image and the portion of the overlay that is substantially transparent are aligned with and exposed to view through the opening. The article may be an article of footwear having a sole assembly and an upper, wither of which may include the opening, and the fluid-filled bladder element may be secured to the sole assembly. The sole assembly may include at least one of a midsole or an outsole, and the opening may be in the midsole or the outsole.

An outsole, at least one portion of which is substantially transparent, may be secured to the fluid-filled bladder element so that the at least one portion of the outsole that is substantially transparent is aligned with the image and the image is exposed to view through the at least one portion of the overlay that is substantially transparent.

In an embodiment, the overlay is secured to at least a portion of a bottom surface and at least a portion of a side surface of the fluid-filled bladder element to support the fluid-filled bladder element. In such an embodiment, the overlay may have a first
stiffness and the polymeric material may have a second stiffness, with the first stiffness at least ten percent greater than the second stiffness. Alternatively or in addition, the overlay may have a first thickness and the first polymeric sheet may have a second thickness, with the first thickness at least ten percent greater than the second thickness.

In an embodiment, the overlay has a first softness and the fluid-filled bladder element has a second softness greater than or equal to the first softness. In another embodiment, the overlay has a first softness and the fluid-filled bladder element has a second softness less than or equal to the first softness.

The polymeric material used to form the fluid-filled bladder element may be a variety of materials. For example, the polymeric material may comprise a thermoplastic polymeric material. In one embodiment, the thermoplastic polymeric material may be a thermoplastic polyurethane (TPU). In one embodiment, the polymeric material comprises a first polymeric sheet, and the TPU is present on at least an outer surface of the first polymeric sheet. The first polymeric sheet may comprise a multi-layer polymeric sheet. The multi-layer polymeric sheet may be a laminate membrane that comprises at least a first layer comprising the TPU, and at least a second layer comprising a gas barrier polymer. The gas barrier polymer may comprise an ethylene-vinyl alcohol copolymer. In one embodiment, the at least a first layer consists essentially of the TPU, and the at least a second layer consists essentially of the ethylene-vinyl alcohol copolymer.

The overlay may be a variety of different materials. For example, the overlay may comprise a TPU. The overlay and the first polymeric material may comprise the same material. The overlay may comprise a polyurethane, a polyester, or both. The overlay may comprise a woven fabric, a nonwoven fabric, a synthetic leather, or any combination thereof. The overlay may comprise a synthetic leather comprising a polyurethane coating over a polyester backing layer. The nonwoven fabric may comprise a nonwoven polyurethane fabric comprising thermoplastic polyurethane filaments. The nonwoven polyurethane fabric may have a fused region thereon that establishes a texture or an image on the overlay. The overlay may comprise a metal foil such as a TPU-backed metal foil.

The bladder element may have an outer surface with a first texture having a first level of roughness, and the overlay may have an outer surface at least a portion of which has a second texture having a second level of roughness at least ten percent greater than the first level of roughness.

Within the scope of the present teachings, an article comprises a fluid-filled bladder element comprising a polymeric material. A first portion of the fluid-filled bladder element has an image. An overlay is secured to the fluid-filled bladder element. At least one portion of the overlay is substantially transparent and is aligned with the image. The first portion of the fluid-filled bladder element and the image are exposed to view through the at least one portion of the overlay that is substantially transparent, and a second portion of the fluid-filled bladder element is blocked from view by the article. The article has an opening. The fluid-filled bladder element is secured to the article. The image and the at least one portion of the overlay that is substantially transparent are aligned with the opening and exposed to view through the opening. The polymeric material comprises a first polymeric sheet and a second polymeric sheet bonded to the first polymeric sheet at a peripheral seam that at least partially seals a fluid-filled cavity of the fluid-filled bladder element. The overlay is spaced apart from the peripheral seam, and the peripheral seam is covered by the article and blocked from view by the article. In one embodiment, the image is on an outer surface of the fluid-filled bladder element.

The overlay may be secured to an outer surface of the fluid-filled bladder element. In one embodiment, the outer surface of the fluid-filled bladder element has a curved portion, and the overlay is secured to the curved portion. The article may include an adhesive layer securing the overlay to the fluid-filled bladder element.

The article may be an article of footwear that further comprises a sole assembly with the fluid-filled bladder element secured to the sole assembly. In one embodiment, the peripheral seam is covered by the sole assembly.

The article of footwear may comprise an outsole that is secured to the fluid-filled bladder element, and that has at least one substantially transparent portion that is aligned with the image.

In an embodiment, the article is an article of footwear having a sole assembly that includes an outsole with an opening. The fluid-filled bladder element is secured to the outsole so that the image and the at least one portion of the overlay that is substantially transparent are aligned with the opening and exposed to view through the opening.

Similarly, in an embodiment, the article is an article of footwear having a sole assembly that includes a midsole with an opening. The fluid-filled bladder element is secured to the midsole so that the image and the at least one portion of the overlay that is substantially transparent are aligned with the opening and exposed to view through the opening.

Similarly, in an embodiment, the article is an article of footwear that includes a sockliner with an opening. The fluid-filled bladder element is secured to the article so that the image and the at least one portion of the overlay that are substantially transparent are aligned with the opening and exposed to view through the opening.

The various methods and articles described herein provide fluid-filled bladder elements, such as in an article of footwear, that have images covered and protected by a substantially transparent overlay. The methods and articles enable the image to be exposed to view through the overlay. A peripheral seam formed in the bladder element is covered by the article.

In one embodiment of the article, a colored medium applied to the fluid-filled bladder element established the image. Optionally, the colored medium may be applied to the fluid-filled bladder element after the fluid-filled bladder element is formed. The colored medium may comprise reflective particles. The colored medium may comprise ink. For example, the ink may comprise at least one of an isocyanate group, an isocyanate-reactive group, an alcohol-soluble ink, a polyamide ink, a dye-containing ink, an acrylic ink, or a water-based ink.

"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., are used descriptively relative to the figures, and do not represent limitations on the scope of the invention, as defined by the claims.

Referring to the drawings, wherein like reference numbers refer to like components throughout the several views, <FIG> shows a fluid-filled bladder element <NUM> that has an image 12A thereon. An overlay 14A is in contact with and secured to the bladder element <NUM> over the image 12A. As further described herein, at least a portion of the overlay 14A, or the entire overlay 14A, is substantially transparent. The transparent portion is aligned with the image 12A prior to securing the overlay 14A to the bladder element <NUM>. In the embodiment shown, the entire overlay 14A is substantially transparent. The image 12A can thus be viewed through the overlay 14A and is protected by the overlay 14A from scratching or scuffing. Additionally, as further described herein, the overlay, such as overlay 14A, can also add another image or a texture for aesthetic or tactile enhancement.

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". As used herein, a component is "substantially transparent" if it has a luminous transmittance (i.e., a percentage of incident light that is transmitted) of at least <NUM> percent and haze (i.e., percentage of transmitted light that is scattered) of not more than <NUM> percent. The various materials used for the bladder element <NUM>, and other embodiments of bladder elements discussed herein, may be substantially transparent. Those skilled in the art will readily understand a variety of methods to determine luminous transmittance and haze of an object, such as the bladder element <NUM>. For example, the luminous transmittance and haze of the bladder element <NUM> can be determined according to American Society for Testing and Materials (ASTM) Standard DI <NUM>-<NUM>, Standard Test Method for Haze and Luminous Transmittance of Transparent Plastics. Additionally, in some embodiments, the bladder element <NUM> may have a tinted color.

In addition to the portion of the overlay 14A, and other embodiments of overlays described herein, the various materials used for the bladder element <NUM>, and other embodiments of bladder elements discussed herein, may be substantially transparent. In the embodiment shown, the entire bladder element <NUM> to which the overlay 14A is secured is substantially transparent prior to any optional application of colored medium <NUM> as discussed herein. Additionally, in some embodiments, the substantially transparent overlay 14A or bladder element <NUM>, or both, may be have a tinted color.

The bladder element <NUM> with images 12A, 12B, 12C and overlays 14A, 14B, 14C may be included in a sole assembly <NUM> of an article of footwear <NUM>. As shown in <FIG>, the article of footwear <NUM> is an athletic shoe, and the bladder element <NUM> is a cushioning element. In other embodiments, the sole assembly <NUM> could be for an article of footwear that is a dress shoe, a work shoe, a sandal, a slipper, a boot, or any other category of footwear. Alternatively, the fluid-filled bladder element <NUM> could be used as a cushioning element in another article, such as but not limited to a shoulder strap, a backpack, a shoulder pad, a glove, an elbow pad, a knee pad, a shin guard, or other apparel, or a sports ball. The bladder element <NUM> is formed from a first polymeric sheet <NUM>, and a second polymeric sheet <NUM> secured to one another to define a fluid-filled cavity <NUM> (best shown in <FIG>) that sealingly retains a fluid such as gas, as described herein.

Within the scope of the present teachings, the bladder element <NUM> is formed from a first polymeric sheet <NUM> and a second polymeric sheet <NUM>. Although the bladder element <NUM> may only have one image, such as image 12A applied to the first polymeric sheet <NUM>, in the embodiment of <FIG>, the bladder element <NUM> has multiple images, including additional images 12B, and 12C. As used herein, an "image" may comprise one or more of numbers, letters, pictorial representations, and patterns, and may be created by ink, dye, or other mediums, and may have multiple colors, or contrasting textures. In the embodiment shown in <FIG>, the image 12A is a diamond pattern, and is provided by a colored medium <NUM> applied to the fluid-filled bladder element <NUM>. As indicated in the close-up view in <FIG>, the colored medium <NUM> includes an ink as a base and has reflective particles <NUM>. The ink of the colored medium <NUM> may comprise at least one of an isocyanate group, an isocyanate-
reactive group, an alcohol-soluble ink, a polyamide ink, a dye-containing ink, an acrylic ink, or a water-based ink. The reflective particles <NUM> allow for light to be cast back towards its source. The reflective particles <NUM> may also allow light to be scattered. In such embodiments, this provides a safety feature for low-light or full-light environments. The reflective particles <NUM> can be metal flakes or may include a phosphorescent material so that the reflective particles are a "glow-in-the-dark" material. In embodiments with reflective particles <NUM>, a curved portion <NUM> of the inflated bladder element <NUM>, discussed with respect to <FIG>, facilitates reflecting of the light by the reflective particles <NUM>. For example, during a normal gait, a foot on which the article of footwear <NUM> is worn is repeatedly lifted and planted. The motion of the normal gait creates an additional "flash" of reflected light from the reflective particles <NUM> and makes the article of footwear <NUM> more noticeable.

A second image 12B is applied to the second polymeric sheet <NUM>, and is covered by a second overlay 14B that is aligned with the image 12B and secured to the second polymeric sheet <NUM>. In the embodiment shown, the second image is a star shape. The second overlay 14B also has at least a portion that is substantially transparent so that the image 12B aligns with the substantially transparent portion and can be viewed through the overlay 14B. In the embodiment shown, the entire overlay 14B is substantially transparent. The second image 12B can be of the same or a different colored medium as described with respect to image 12A.

The third image 12C is applied to the first polymeric sheet <NUM>, and is covered by a third overlay 14C that is aligned with the image 12C and secured to the first polymeric sheet <NUM>. In the embodiment shown, the third image includes a number and a pictorial representation of a bird. For example, the third image may be a player number and a team logo. The third overlay 14C also has at least a portion that is substantially transparent so that the third image 12C aligns with the substantially transparent portion and can be viewed through the overlay 14C. In the embodiment shown, the entire overlay 14C is substantially transparent. The third image 12C can be of the same or a different colored medium as described with respect to image 12A. It is to be understood that the colored medium <NUM> could be of different colors or materials at the different areas of application on the first and second polymeric sheets <NUM>, <NUM>.

As is apparent in <FIG>, the third image 12C is originally applied to a surface <NUM> of the overlay 14C that is placed into contact with the first polymeric sheet <NUM>. The image 12C is applied in reverse on the surface <NUM> of the overlay 14C. That is, the parts of the image are arranged on the surface <NUM> with a reversal of right and left, as it would appear if seen in a mirror. When the overlay 14C is secured to the first polymeric sheet <NUM> with the surface <NUM> against the outer, bottom surface <NUM> of the first polymeric sheet <NUM>, the image 12C appears through the overlay 14C without the parts reversed right to left. Securing the overlay 14C to the bladder element <NUM> may transfer the image 12C from the overlay 14C to the surface of the first polymeric sheet <NUM>, such as if heat is used to thermally bond the overlay 14C to the first polymeric sheet <NUM>. As shown in <FIG>, although the second image 12B is on the second polymeric sheet <NUM>, the second image 12B can be viewed from an exterior of the bladder element <NUM> through the overlay 14C and the first polymeric sheet <NUM>.

The fluid-filled bladder element <NUM> can be formed from a variety of polymeric materials. In an embodiment shown and described at least with respect to <FIG>, the bladder element <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 element <NUM> can be thermoplastic polymeric material. The bladder element <NUM> can be a urethane, polyurethane, polyester, polyester polyurethane, and/or polyether polyurethane. Moreover, the bladder element <NUM> can be formed of layers of different materials. In an embodiment as illustrated in <FIG>, the bladder element <NUM> is formed from a first polymeric sheet <NUM> and a second polymeric sheet <NUM>. <FIG>, which is a close-up fragmentary cross-section portion of the bladder element <NUM> in an article of footwear <NUM>, shows that the first 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, that comprise a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein as disclosed in <CIT>et al, which is incorporated by reference in its entirety. The second polymeric sheet <NUM> may be formed from the same materials shown and described in <FIG> with respect to the first polymeric sheet <NUM>. The first layer <NUM> may be arranged to form an outer surface of the first polymeric sheet <NUM>. That is, the outermost first layer <NUM> shown in <FIG> may be the outer surface <NUM> of the bladder element <NUM> to which the overlay 14A is secured. The bladder element <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 bladder element <NUM> may also be a flexible microlayer membrane that includes alternating layers of a gas barrier material such as second layers <NUM> and an elastomeric material such as first layers <NUM>, as disclosed in <CIT> and <CIT>.

Additional suitable materials for the bladder element <NUM> are disclosed in <CIT> and <CIT>.

Further suitable materials for the bladder element <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 element <NUM>, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thicknesses of sheets <NUM>, <NUM> of materials used to form the bladder element <NUM> can be selected to provide these characteristics. For example, in various embodiments, the bladder element <NUM> may have a Shore A hardness of about <NUM> to about <NUM> when inflated. In one embodiment, the overlay 14A has a first softness and the fluid-filled bladder element <NUM> has a second softness greater than or equal to the first softness. In another embodiment, the overlay 14A has a first softness and the fluid-filled bladder element <NUM> has a second softness less than or equal to the first softness.

With reference to <FIG>, the first polymeric sheet <NUM> is bonded to the second polymeric sheet <NUM> to form a peripheral seam <NUM> around a periphery of the bladder element <NUM>. The seam <NUM> seals the internal cavity <NUM> of the bladder element <NUM>, assuming the fill tube <NUM> shown and described with respect to <FIG> is plugged, and helps the bladder element <NUM> retain its shape. The first and second polymeric sheets <NUM>, <NUM> can be bonded to one another by forming in a mold assembly <NUM> as shown in <FIG>. The mold assembly <NUM> includes a first mold half 32A and a second mold half 32B. The first mold half 32A has a mold cavity portion 36A with a mold surface 34A. The second mold half 32B has a mold cavity portion 36B with a mold surface 34B. In one embodiment, the overlay 14A is placed on the mold surface 34A in the mold cavity portion 36A of the first mold half 32A. The overlay 14A is placed on a curved portion <NUM> of the mold surface 34A. The third overlay 14C can also be placed in the mold assembly <NUM> with the surface <NUM> against the mold surface 34A so that surface <NUM> is exposed, as shown in <FIG>. The overlays 14A, 14C are positioned and spaced apart from one another in the same orientation as they will be positioned and spaced from one another when secured to the bladder element <NUM>.

Optionally, a respective releasable film <NUM> can be attached to any or each of the overlays 14A, 14B, and 14C. The releasable film <NUM> is placed in contact with the mold surface when the overlay 14A, 14B, 14C is placed in the mold assembly <NUM>. The releasable film <NUM> may be a material that will not stick to the mold surfaces 34A, 34B to enable the bladder element <NUM> with the overlays 14A, 14B, and 14C secured thereto to be easily released from the mold assembly <NUM>, and also serves to protect the images 12A, 12B from direct contact with the mold surfaces 34A, 34B. Suitable materials for the releasable film <NUM> include polymeric films or metal foils having a relatively low surface energy coating such as a silicone, polyolefin, or polybutadiene coating. Because the image 12C is on surface <NUM> rather than surface <NUM>, image 12C is not in contact with the mold surface 34A. The releasable film <NUM> is peeled off and removed from the bladder element <NUM> after the bladder element <NUM> is formed.

After the overlays 14A, 14C are placed on the surface 34A of the first mold cavity portion 36A, the first polymeric sheet <NUM> is then laid on the first mold half 32A, across the mold cavity portion 36A. The second polymeric sheet <NUM> is placed on the first polymeric sheet <NUM>. Both the first and the second polymeric sheets <NUM>, <NUM> are in their original, generally flat form when initially placed on the mold half 32A. The second overlay 14B can be placed on the second polymeric sheet <NUM>. Alternatively, in other embodiments, any or all of the overlays 14A, 14B, and 14C can be secured to the polymeric sheets <NUM> or <NUM> before the polymeric sheets <NUM>, <NUM> are placed in the mold assembly <NUM>. In another alternative embodiment, the bladder element <NUM> can be formed in the mold assembly <NUM> without the overlays 14A, 14B, 14C, and any or all of the overlays 14A, 14B, and 14C can be secured to the bladder element <NUM> with adhesive after the bladder element <NUM> is formed. In other embodiments, any or all of the overlays 14A, 14B, and 14C can be secured to the inner surfaces of the respective sheets <NUM>, <NUM>.

After the first and second polymeric sheets <NUM>, <NUM> and the overlays 14A, 14B, 14C are placed in the mold assembly <NUM>, the mold assembly <NUM> is closed. A forming process is then used to shape the first and second polymeric sheets <NUM>, <NUM> to the mold halves 32A, 32B, such as by the use of temperature and pressure control. For example, the forming process may include any or all of thermoforming, vacuum forming, compression forming, or radio-frequency welding. Vacuum ports <NUM> are shown extending through the mold halves 32A, 32B, and a vacuum may be applied through the ports <NUM> to pull the first and second polymeric sheets <NUM>, <NUM> against the mold surfaces 34A, 34B in the mold cavity portions 32A, 32B. The sheets <NUM>, <NUM> may be heated by the mold assembly <NUM> during the forming process. Additionally, a fill tube <NUM>, shown in <FIG>, may be formed by recesses 38A, 38B in the mold halves 32A, 32B that mate when the mold assembly <NUM> is closed. The portion of the sheets <NUM>, <NUM> surrounding the mold cavity portions 36A, 36B are bonded to one another by at least one of thermal bonding during thermoforming, radio frequency welding, or compression bonding, i.e., through pressure applied by the mold halves 32A, 32B or by a separate machine after removal from the mold halves 32A, 32B.

Because the overlays 14A, 14C are placed on the mold surface 34A and the overlay 14B is placed on the second sheet <NUM> prior to forming the bladder element <NUM>, the overlays 14A, 14B, and 14C become secured to an outer surface <NUM> of the bladder element <NUM>. Depending on the material used for the overlays 14A, 14B, 14C, the overlays 14A, 14B, 14C may be secured to the bladder element by thermal bonding during the thermoforming process of the bladder element <NUM>. Optionally, as indicated in <FIG>, adhesive may be placed on one or both of the outer surface <NUM> of the bladder element <NUM> or the inner surface <NUM> of the overlay 14A. The adhesive forms an adhesive layer <NUM> that secures the overlay 14A to the bladder element <NUM>. Adhesive may be used in a similar manner to secure the overlays 14B and 14C to the bladder element <NUM>.

After the sheets <NUM>, <NUM> are formed to the contours of the mold assembly <NUM> in the mold cavity portions 36A, 36B and, if heated, sufficiently cooled, the mold halves 32A, 32B are then separated, and excess material of the sheets <NUM>, <NUM> around the periphery of the seam <NUM> is trimmed. The releasable film <NUM>, if used, is then removed from the overlays 14A, 14B, and 14C. <FIG> illustrates the releasable film <NUM> in the process of being released from the overlays 14A and 14B. The fill tube <NUM> formed at the recesses 38A, 38B may be used to inflate the bladder element <NUM> with gas at or above ambient pressure, and then the fill tube <NUM> may be plugged and trimmed so that the bladder element <NUM> is in its final, formed state.

Alternatively, instead of placing the overlay 14A in the mold assembly <NUM> to secure the overlay 14A to the bladder element <NUM>, the bladder element <NUM> may be separately formed in the mold assembly <NUM>, removed from the mold assembly <NUM>, and then the overlay 14A can be secured to the outer surface <NUM> of the bladder element <NUM>. Alternatively, any or all of the images 12A, 12B, 12C can be applied to the bladder element <NUM> after the bladder element <NUM> is formed and inflated.

As best shown in <FIG>, <FIG> and <FIG>, at least the image 12A and the overlay 14A are on a curved portion <NUM> of the outer surface <NUM> of the bladder element <NUM>. Both the colored medium <NUM> used for the image 12A, such as the ink with reflective particles <NUM>, and the material used for the overlay 14A, are sufficiently flexible to form to the shape of the curved portion <NUM>. Additionally, the overlays 14A, 14B, 14C are each spaced from the seam <NUM> on the formed bladder element <NUM> due to their initial placement in the mold assembly <NUM> away from a perimeter 66A, 66B of the mold cavity portions 36A, 36B. The images 12A, 12B are applied on the first and second polymeric sheets <NUM>, <NUM> so that they are also spaced apart from the peripheral seam <NUM>, and the overlays 14A, 14B are aligned with the images 12A, 12B when secured to the bladder element <NUM> as described herein. All of the images 12A, 12B, 12C are thus spaced apart from the peripheral seam <NUM>.

The bladder element <NUM> can be secured in the sole assembly <NUM> such as by bonding to a midsole <NUM> of the sole assembly <NUM>. For example, the bladder element <NUM> can be bonded with adhesive to the formed midsole <NUM>. Alternatively, the bladder element <NUM> can be placed in a midsole mold assembly (not shown), and the midsole <NUM> may be formed around the bladder element <NUM>, such as by injecting foam into the midsole mold assembly. In still other embodiments, the bladder element <NUM> is secured to the sole assembly <NUM> by an interference fit. In all such embodiments, because the overlays 14A, 14B, 14C are spaced from the peripheral seam <NUM>, the images 12A, 12B, 12C can be aligned with openings in the sole assembly <NUM> as described herein and/or in a footwear upper extending over the sole assembly, such as represented by an insole or sockliner <NUM> as described herein, while the seam <NUM> can be covered by the sole assembly <NUM>. For example, as shown in <FIG> and <FIG>, the midsole <NUM> is formed with an opening 72A. The substantially transparent portion of the overlay 14A and image 12A are positioned at the opening 72A so that they are exposed at the exterior of the article of footwear <NUM>, while the seam <NUM> is covered by the midsole <NUM> and is not exposed at the opening 72A. Stated differently, a first portion of the bladder element <NUM> including the image 12A is aligned with the opening 72A and exposed to view (i.e., such as a viewpoint of a side view as in <FIG>) through the opening 72A. A second portion of the bladder element (i.e., the portion indicated with hidden lines in <FIG>) is blocked from view by the midsole <NUM>.

In another example shown in <FIG>, the sockliner <NUM> also has an opening 72B and the sole assembly <NUM> does not cover the overlay 14B so that the overlay 14B and the image 12B are aligned with and exposed to view through the opening 72B. The peripheral seam <NUM> is covered by and blocked from view by the article so that it is not exposed at the opening 72B.

As is apparent in <FIG>, the article of footwear <NUM> does not cover at least the substantially transparent portion of the overlay 14C secured to the bladder element <NUM> and the image 12C transferred to the bladder element <NUM> from the overlay 14C. The sole assembly <NUM> includes an outsole 76A secured to a lower surface <NUM> of the midsole <NUM> as also shown in <FIG>. In one embodiment, the outsole 76A has an opening 72C that is aligned with the overlay 14C and the image 12C so that a first portion of the bladder element <NUM> with the overlay 14C and the image 12C are exposed to view at the exterior of the article of footwear <NUM> and may be viewed, such as when a wearer of the article of footwear <NUM> lifts a heel portion <NUM> of the article of footwear <NUM>. A second portion of the bladder element <NUM> indicated by the hidden lines in <FIG> is covered by and blocked from view by the article of footwear <NUM>. The outsole 76A is shown with tread elements 78A having bottom surfaces that form a ground contact surface of the article of footwear <NUM>. The tread elements 78A can have various alternative shapes and can be arranged in various alternative arrangements. The outsole 76A shows grooves <NUM> formed in the outsole 76A.

<FIG> shows an alternative embodiment of an outsole 76B secured to the midsole <NUM> of <FIG> and to the bladder element <NUM>. The outsole 76B has at least a portion <NUM>, bounded by phantom lines, that is substantially transparent. The substantially transparent portion <NUM> is aligned with the overlay 14C so that the overlay 14C and the image 12C are exposed to view at an exterior of an article of footwear 18A, and may be viewed, such as when a wearer lifts the heel portion <NUM> of the article of footwear 18A. A remaining portion <NUM> of the outsole 76B, not bounded by the phantom lines, can also be substantially transparent. In the embodiment shown, the entire outsole 76B is substantially transparent. Alternatively, the remaining portion <NUM> could be opaque or not substantially transparent. The outsole 76B shows grooves <NUM> formed in the outsole 76B and a different arrangement of tread elements 78B. The article of footwear 18A has a different outsole 76B than the article of footwear <NUM>, but is otherwise the same as the article of footwear <NUM>.

<FIG> show an alternative embodiment of an overlay 14D secured to the first polymeric sheet <NUM> of the bladder element <NUM>, and having at least a portion that is substantially transparent and is aligned with the image 12A. The overlay 14D is secured to and surrounds a portion of a bottom surface <NUM> and portions of side surfaces 84A, 84B of the fluid-filled bladder element <NUM>, functioning as a supportive cage around the fluid-filled bladder element <NUM>. The bottom surface <NUM> and the side surfaces 84A, 84B are portions of the outer surface <NUM>. The overlay 14D is able to support the fluid-filled bladder element <NUM> as a supportive cage because it is relatively thick and stiff in comparison to the bladder element <NUM>. More specifically, the overlay 14D has a first stiffness. The first stiffness is at least <NUM> percent greater than the second stiffness. Additionally, the overlay 14D has a first thickness T1, indicated in <FIG>, and the first polymeric sheet <NUM> has a second thickness T2. The first thickness T1 is at least <NUM> percent greater than the second thickness T2. The greater thickness T1 of the overlay 14D, in addition to its greater stiffness, enables it to provide substantial support to the bladder element <NUM> in the heel portion <NUM> of the article of footwear <NUM>. In an alternative embodiment, one or multiple overlays in addition to overlay 14D could surround the bladder element <NUM>. In other words, in addition to surrounding the bottom surface <NUM> and side surfaces 84A, 84B of the first polymeric sheet <NUM>, the overlay 14D could extend to also surround the outer surface <NUM> of the second polymeric sheet <NUM> as well.

In any of the embodiments described herein, the overlays 14A, 14B, 14C, or 14D and the fluid-filled bladder element <NUM> may comprise the same material. For example, any of the overlays 14A, 14B, 14C, or 14D may be a multi-layer laminate such as shown in <FIG> having layers <NUM> of TPU alternating with layers <NUM> of a gas barrier polymer, such as EVOH. In one embodiment, the overlay 14A, 14B, 14C, or 14D comprises a polyurethane, a polyester, or both. In an alternative embodiment, the overlay 14A, 14B, 14C, or 14D comprises a TPU-backed metal foil.

In alternative embodiments, any of the overlays 14A, 14B, 14C, or 14D comprises a woven fabric, a nonwoven fabric, a synthetic leather, or any combination thereof. For example, <FIG> shows an embodiment of an overlay 14E that can be used in place of any of the overlays 14A, 14B, 14C, or 14D on the bladder element <NUM>. The overlay 14E is or includes a nonwoven polyurethane fabric <NUM> that includes thermoplastic polyurethane filaments <NUM>. The overlay 14E is fused used using one or more hot dies each of which has a shape that is imparted as a fused region in the overlay, establishing a texture or an image. For example, multiple hot dies each having a diamond shape with a recessed diamond center may be used to create each fused region 90A, 90B, 90C, 90D, 90E in the overlay 14E. The combined fused regions <NUM> may be referred to as an image 12E. Alternatively, a single heated die having a more complex shape of five interconnected diamonds with recessed diamond centers can be used to create the fused regions 90A, 90B, 90C, 90D, 90E. The fused regions 90A, 90B, 90C, 90D, 90E are compressed portions of the overlay 14E. In other words, fused regions 90A, 90B, 90C, 90D, 90E are compressed relative to and fused to a greater degree than the surrounding portion <NUM> of the overlay 14E, and relative to the diamond shaped centers 92A, 92B, 92C, 92D, and 92E, so that the fused regions 90A, 90B, 90C, 90D, 90E also create a texture on the outer surface <NUM> of the overlay 14E. <CIT>, discloses nonwoven textile fabrics having polyurethane filaments, and a process of creating fused regions in the nonwoven textile fabric, all of which may be used to create the overlay 14E.

The polymeric material used to form the bladder element <NUM>, and more particularly a TPU outer layer <NUM> shown in <FIG> can be formed so that the outer surface <NUM> of the bladder element <NUM> has a first texture having a first level of roughness. For example, the surface finish of the mold cavity portions 36A, 36B can be controlled to provide a corresponding texture on the outer surface <NUM>. For example, a Class A polish can be obtained, such as by sand blasting all or part of the mold cavity portions 36A, 36B in <NUM> inch increments. Any of the overlays 14A, 14B, 14C, 14D, 14E, 14F, <NUM> described herein can be formed with an outer surface, at least a portion of which has a second texture having a second level of roughness at least <NUM> percent greater than the first level of roughness of the bladder element <NUM>. For example, the second texture of the overlay 14E due to the fused regions 90A, 90B, 90C, 90D, 90E can be at least <NUM> percent greater than the first texture of the bladder element <NUM>. The texture of the overlay 14E can be selected to provide a desired tactile feel.

<FIG> shows another embodiment of an overlay 14F that can be used in place of any of the overlays 14A, 14B, 14C, 14D, or 14E on the bladder element <NUM>. The overlay 14F comprises a woven fabric having woven threads <NUM>. The colors or types of fabric are chosen and woven in a pattern that creates an image 12F similar to image 12A. <FIG> shows another embodiment of an overlay <NUM> that that can be used in place of any of the overlays 14A, 14B, 14C, 14D, 14E, or 14F on the bladder element <NUM>. The overlay <NUM> comprises a synthetic leather comprising a polyurethane coating <NUM> over a polyester backing layer <NUM>. An image <NUM> similar to image 12A can be applied to either or both of the polyurethane coating <NUM> and the polyester backing layer <NUM>. If the image is applied to the polyester backing layer <NUM>, then the polyurethane coating <NUM> may be substantially transparent over the image <NUM>.

In the embodiments of <FIG>, and <FIG>, the images 12E, 12F, and <NUM> are applied to the overlays 14E, 14F, <NUM> rather than to the first and second polymeric sheets <NUM>, <NUM> of the bladder element <NUM>. In other embodiments, the overlays 14E, 14F, <NUM> can be formed of the materials as described, and may be substantially transparent so that when the overlays 14E, 14F <NUM> are aligned with the images and secured to the bladder element <NUM>, the images on the bladder element <NUM> will be viewable through the overlays 14E, 14F, or <NUM>.

A method <NUM> of manufacturing an article, such as the article of footwear <NUM>, begins with step <NUM>, applying an image 12A to polymeric material, such as the first polymeric sheet <NUM>. Additional images 12B, 12C may be applied as described herein. Alternatively, the polymeric material such as the first and second polymeric sheets <NUM>, <NUM> may be obtained with the images 12A and 12B already applied thereon, in which case step <NUM> is not performed. Still further, step <NUM> may be performed after the fluid-filled bladder element is formed from the polymeric sheets <NUM>, <NUM>, i.e., after step.

Next, in step <NUM>, an overlay 14A is positioned in contact with the polymeric material used to form the bladder element <NUM>, such as the first polymeric sheet <NUM>. In some embodiments as described herein, the overlay is placed in contact with an outer surface <NUM> the bladder element <NUM> after the bladder elements <NUM> is formed. In the embodiment described in <FIG>, however, the overlay 14A is placed in the mold assembly <NUM> in sub-step <NUM>. The overlay 14A is positioned in the mold assembly <NUM> so that it will be secured to a curved portion <NUM> of the bladder element <NUM> when the bladder element <NUM> is formed. In other words, the overlay 14A is positioned on a corresponding curved portion <NUM> of the mold surface 34A. If any releasable film <NUM> is on the overlay 14A, the releasable film <NUM> is in contact with the mold surface 34A. If the third overlay 14C is included, it is also placed on the mold surface 34A spaced from the first overlay 14A.

The first polymeric sheet <NUM> is then placed in the mold assembly <NUM> in sub-step <NUM> so that a portion of the overlay 14A that is substantially transparent will be aligned with the image 12A on the first polymeric sheet <NUM> when the bladder element <NUM> is formed. The second polymeric sheet <NUM> is then placed on the first polymeric sheet <NUM> in sub-step <NUM>. If the second overlay 14B is included, it is then placed on the second polymeric sheet <NUM> in step <NUM>.

Next, in optional step <NUM>, the overlay 14A is secured to the first polymeric sheet <NUM> with adhesive. The securing in step <NUM> may be accomplished at least in part by adhesive that may be placed on one or both of the outer surface <NUM> of the bladder element <NUM> and the overlay <NUM> prior to placing the first polymeric sheet <NUM> on the overlay 14A in sub-step <NUM>. The adhesive forms the adhesive layer <NUM> described with respect to <FIG>. Alternatively, no adhesive is used and the overlay 14A is secured to the first polymeric sheet <NUM> by thermal bonding in step <NUM>.

The method <NUM> also includes forming the bladder element <NUM> in the mold assembly <NUM> in step <NUM>. Forming the bladder element <NUM> may be by thermoforming, vacuum forming, or both with the overlay 14A and the polymeric sheets <NUM>, <NUM> in the mold assembly <NUM> and the mold assembly <NUM> closed. Additionally, the securing of the overlay 14A to the first polymeric sheet <NUM> may be accomplished at least in part via the thermoforming of the bladder element <NUM>, as the heat of thermoforming causes heating of the first polymeric sheet <NUM> and the overlay 14A sufficient to thermally fuse the overlay 14A to the outer surface <NUM> of the first polymeric sheet <NUM>. If overlays 14B and 14C are included, they may also thermally bond to the second polymeric sheet <NUM> and the first polymeric sheet <NUM>, respectively.

After any cooling period, the mold assembly <NUM> is opened, and the bladder element <NUM> is removed from the mold assembly <NUM> in step <NUM>. If any releasable film <NUM> is on any of the overlays 14A, 14B, 14C, the releasable film <NUM> is removed from the overlays 14A, 14B, 14C in step <NUM>. The bladder element <NUM> with the overlays 14A, 14B, 14C secured thereto over the image 12A is now complete. If alternative overlays 14D, 14E, 14F, or <NUM> are used, the method <NUM> proceeds in the same manner with steps <NUM>-<NUM> as described with respect to overlay 14A.

Optionally, if the same entity carrying out steps <NUM>-<NUM> also assembles the bladder element <NUM> in an article such as the article of footwear <NUM>, then the method <NUM> can proceed with steps <NUM> and <NUM>. In step <NUM>, the fluid-filled bladder element <NUM> is assembled in the sole assembly <NUM> of the article of footwear <NUM> by securing the bladder element <NUM> to the midsole <NUM>. In various embodiments, securing the bladder element <NUM> to the midsole <NUM> can be accomplished with adhesive or with adhesive, such as by forming the midsole <NUM> around the bladder element <NUM> in a midsole mold assembly (not shown). In all of these embodiments, the bladder element <NUM> may be assembled in the article of footwear <NUM> so that the seam <NUM> is covered and the image 12A as well as image 12B, if included, are exposed at openings such as openings 72A, 72B in the midsole <NUM> as described with respect to the embodiment of <FIG> and <FIG>. In other words, the substantially transparent portion of the overlay 14A is aligned with opening 72A so that the image 12A can be viewed from an exterior of the article of footwear <NUM>. Similarly, the substantially transparent portion of the overlay 14B is aligned with the opening 72B so that the image 12B can be viewed at the opening 72B.

Next, in step <NUM>, an outsole can be secured to the midsole <NUM>. If outsole 76A of <FIG> is used, the opening 72C is aligned with the image 12C. If outsole 76B of <FIG> is used, the substantially transparent portion <NUM> of the outsole 76B is aligned with the image 12C. As discussed above, the entire outsole 76B may be substantially transparent.

Claim 1:
An article comprising:
a fluid-filled bladder element (<NUM>) comprising a polymeric material; wherein a first portion of the fluid-filled bladder element (<NUM>) has an image (12A, 12B, 12C, 12D, 12E, 12F, <NUM>);
an overlay (14A, 14B, 14C, 14D, 14E, 14F, <NUM>) secured to the fluid-filled bladder element (<NUM>); wherein at least one portion of the overlay (14A, 14B, 14C, 14D, 14E, 14F, <NUM>) is substantially transparent and is aligned with the image (12A, 12B, 12C, 12D, 12E, 12F, <NUM>);
wherein the first portion of the fluid-filled bladder element (<NUM>) and the image (12A, 12B, 12C, 12D, 12E, 12F, <NUM>) are exposed to view through the at least one portion of the overlay (14A, 14B, 14C, 14D, 14E, 14F, <NUM>) that is substantially transparent, and a second portion of the fluid-filled bladder element (<NUM>) is blocked from view by the article;
wherein the article has an opening (72A, 72B, 72C);
wherein the fluid-filled bladder element (<NUM>) is secured to the article;
wherein the image (12A, 12B, 12C, 12D, 12E, 12F, <NUM>) and the at least one portion of the overlay (14A, 14B, 14C, 14D, 14E, 14F, <NUM>) that is substantially transparent are aligned with the opening (72A, 72B, 72C) and exposed to view through the opening (72A, 72B, 72C);
wherein the polymeric material comprises a first polymeric sheet (<NUM>) and a second polymeric sheet (<NUM>) bonded to the first polymeric sheet (<NUM>) at a peripheral seam (<NUM>) that at least partially seals a fluid-filled cavity (<NUM>) of the fluid-filled bladder element (<NUM>); and
wherein the overlay (14A, 14B, 14C, 14D, 14E, 14F, <NUM>) is spaced apart from the peripheral seam (<NUM>), and the peripheral seam (<NUM>) is covered by the article and blocked from view by the article.