Patent Description:
The present disclosure generally relates to a mold assembly with a removable mold tool, a method of manufacturing a bladder for a wearable article, and to a wearable article including the bladder.

Wearable articles may include structure configured to cushion the wearer and may often be a source of expression for the wearer. For example, clothing and/or footwear may provide an association with a team, coordinate with another item, or provide the owner or user with an attractive or customized item.

An article of footwear typically includes a sole structure configured to be located under a wearer's foot to space the foot away from the ground. Sole structures in athletic footwear are typically configured to provide cushioning, motion control, and/or resiliency.

<CIT> describes that a fluid-filled chamber includes a first barrier layer, a second barrier layer attached to the first barrier layer and cooperating with the first barrier layer to define an interior void, and a third layer attached to one of the first barrier layer and the second barrier layer including mineral mica that provides the one of the first barrier layer and the second barrier layer with an iridescent appearance caused by differential refraction of light waves.

<CIT> describes that a first removable insert forms at least a substantial portion of a medial side wall of the first recess and defines an exterior surface of a medial side wall of a first sole formed in the first cavity. A second removable insert forms at least a substantial portion of a medial side wall of the second recess and defines an exterior surface of a medial side wall of a second sole formed in the second cavity.

<CIT> describes a modular mold assembly comprising a base having a mold surface that partially defines a mold cavity for thermoforming a polymeric bladder with a fluid-filled chamber, and a first removable mold tool that has an inner wall with a mold surface having a topography different than a topography of the mold surface of the base, wherein the first removable mold tool includes an outer wall opposite the inner wall, a front wall, a rear wall opposite the front wall, a top wall, and a bottom wall opposite the top wall, wherein each of the front wall, the rear wall, the top wall, and the bottom wall extends from the outer wall to the mold surface.

A modular mold assembly according to the claimed invention is defined in claim <NUM>. Dependent claims <NUM>-<NUM> relate to advantageous embodiments of the modular mold assembly according to the claimed invention.

A method of manufacturing a wearable article according to the claimed invention is defined in claim <NUM>. Dependent claims <NUM>-<NUM> relate to advantageous embodiments of method of manufacturing a wearable article according to the claimed invention.

Some sole structures include sealed, fluid-filled bladders. Mold assemblies are often used to form the bladders. A traditional mold assembly is capable of forming only one size bladder and may not be configured to provide different bladders with different characteristics. It can be expensive and time consuming to manufacture bladders with different configurations or characteristics, as each such bladder may require a different mold assembly. The present disclosure generally relates to a modular mold assembly, a wearable article that includes a bladder having a nonuniform topography, a method of manufacturing the wearable article with the bladder that has the nonuniform topography using removable mold tools in the modular mold assembly to avoid the need for a completely different mold assembly to achieve bladders with different configurations or characteristics.

As used herein, for the purposes of this application and its claims, a "wearable article" is an article that is configured to be worn on a human body and does not include durable goods not intended to be worn on a human body, such as furniture and automotive upholstery. Non-limiting examples of wearable articles include footwear, apparel, sporting equipment such as shin guards and baseball mitts, carry bags such as backpacks, purses, duffel bags, fanny packs, and other types of portable containment structures intended to be worn on a human body.

In an example, a modular mold assembly comprises a base having a mold surface that partially defines a mold cavity for thermoforming a polymeric bladder with a fluid-filled chamber. The base includes a side wall defining a first opening that opens into the mold cavity. The modular mold assembly further comprises a first removable mold tool that has an inner wall with a mold surface having a topography different than a topography of the mold surface of the base. The first removable mold tool fits in the first opening in the side wall of the base with less than a predetermined clearance and with the mold surface of the first removable mold tool adjacent to the mold surface of the base and further defining the mold cavity. The first removable mold tool includes an outer wall opposite from the inner wall, a front wall, a rear wall opposite from the front wall, a top wall, and a bottom wall opposite from the top wall. Each of the front wall, the rear wall, the top wall, and the bottom wall extends from the outer wall to the mold surface. The rear wall is wider than the front wall and the bottom wall is wider than the top wall. A removable mold tool with such dimensions and shape provides several advantages. First, the first removable mold tool may be wedged into the first opening in a direction toward the mold cavity, easily providing a correct alignment of the mold surface of the first removable mold tool with the mold surface of the base. Additionally, the first removable mold tool fits into the first opening in only one orientation. The base may have a second opening opposite from the first opening and configured as a mirror image of the first opening. Due to its dimensions and shape, the first removable mold tool will not fit into the second opening, preventing inadvertent misplacement of the first removable mold tool during manufacturing. Additionally, due to its dimensions and shape, the first removable mold tool will not fit into the first opening if placed upside down or backward.

According to the claimed invention, the first removable mold tool defines channels extending through the first removable mold tool to the mold surface of the first removable mold tool. Additionally, the base may define at least one conduit in fluid communication with the channels of the first removable mold tool. The channels allow a vacuum to be applied, pulling polymeric material used to form the bladder against the mold surface to provide a more exact imparting of the nonuniform topography of the mold surface onto the polymeric material.

In one or more embodiments, the front wall may have a surface area less than a surface area of the rear wall. The top wall may have a surface area less than a surface area of the bottom wall. For example, a projected surface area of the top wall projected onto a plane extending through the first removable mold tool between the top wall and the bottom wall may be less than a projected surface area of the bottom wall projected onto the plane. Similarly, a projected surface area of the front wall projected onto a plane extending through the first removable mold tool between the front wall and the rear wall may be less than a projected surface area of the rear wall projected onto the plane. Stated differently, the footprint of the top wall may be less than that of the bottom wall, and the footprint of the front wall may be less than that of the rear wall.

In an example, the mold surface of the first removable mold tool may be concave in a direction from the front wall to the rear wall and concave in a direction from the top wall to the bottom wall. A portion of the bladder formed by the first removable mold tool may thus be convex along its height and along its length, for example.

In one or more embodiments, at least one of the front wall or the rear wall is non-planar. For example, at least a portion of the front wall may be convex and at least a portion of the rear wall may be convex. This allows the first removable mold tool to be wedged into the first opening in a direction toward the mold cavity, easily providing a correct alignment of the mold surface of the first removable mold tool with the mold surface of the base. A length of the outer wall may be greater than a length of the inner wall, further contributing to the ability to wedge the first removable mold tool into the first opening to align the mold surface of the first removable mold tool with the mold surface of the base. When properly aligned with the first removable mold tool in the first opening of the side wall of the base, the outer wall of the first removable mold tool may be flush with the side wall of the base.

The modular mold assembly may be configured with two removable mold tools for imparting a nonuniform topography to two different portions of a wearable article such as to two side walls of a bladder thermoformed in the modular mold assembly. For example, the side wall of the base may be a first side wall and the base may further include a second side wall opposite from the first side wall. The second side wall may define a second opening that opens into the mold cavity. The modular mold assembly may further comprise a second removable mold tool that has an inner wall with a mold surface having a topography different than a topography of the mold surface of the base. The second removable mold tool may fit lengthwise in the second opening with the mold surface of the second removable mold tool adjacent to the mold surface of the base and further defining the mold cavity. The second removable mold tool may include an outer wall opposite from the inner wall, a front wall, a rear wall opposite from the front wall, a top wall, and a bottom wall opposite from the top wall. Each of the front wall, the rear wall, the top wall, and the bottom wall of the second removable mold tool may extend from the outer wall to the mold surface, with the rear wall of the second removable mold tool wider than the front wall of the second removable mold tool and the bottom wall of the second removable mold tool wider than the top wall of the second removable mold tool.

In one or more embodiments, the top wall, the bottom wall, the front wall, and the rear wall of the second removable mold tool may be mirror images in shape and dimension of the top wall, the bottom wall, the front wall, and the rear wall, respectively, of the first removable mold tool. The mold surfaces of the removable mold tools may be but need not be the same as each mold tool is separately inserted and removed from the base. For example, the mold surface of the second removable mold tool may have a nonuniform topography different from the nonuniform topography of the first removable mold tool. The mold surface of the first removable mold tool may impart a nonuniform topography to a first outer side wall of a bladder thermoformed in the modular mold assembly, and the mold surface of the second removable mold tool may impart a nonuniform topography to a second outer side wall of the bladder. For example, the nonuniform topologies may be at outer side walls at the medial and lateral side, respectively, of a bladder for an article of footwear.

According to the claimed invention, a method of manufacturing a wearable article includes providing a modular mold assembly of any one of claims <NUM> to <NUM>. The method includes disposing polymeric material at the mold cavity, and then thermoforming a bladder in the mold cavity from the polymeric material. The bladder has an outer surface with a nonuniform topography imparted by the topography of the mold surface of the first removable mold tool.

As used herein, a nonuniform topography may be a topography that includes depressions and protrusions, may include more than one inflection point, and may include both inflection points that are at depressions and inflection points that are at protrusions. Accordingly, a nonuniform topography may have a repeating pattern of depressions and protrusions, such as ribs, pyramidical, or other protrusions (e.g., a uniform pattern), or may not have a discernable pattern (e.g., may be a random, nonrepeating nonuniform topography).

In one example, the polymeric material may include a first polymeric sheet and a second polymeric sheet that maybe joined together at a peripheral flange during thermoforming in the modular mold assembly, defining an interior cavity capable of retaining a fluid. For example, when the bladder is sealed, ambient or pressurized fluid may be retained in the interior cavity.

In one aspect, the method may include removing the removable mold tool from the modular mold assembly and inserting a second removable mold tool into the modular mold assembly. The second removable mold tool may include a different mold surface disposed at and partially defining the mold cavity of the modular mold assembly. A topography of the mold surface of the second removable mold tool may be different than the topography of the mold surface of the first removable mold tool so that a bladder with a different nonuniform topography can be thermoformed in the mold assembly. The production of bladders with different nonuniform topographies can be accomplished more quickly and with less expense than with traditional (nonmodular) mold assemblies, as only new removable mold tools rather than an entirely different mold assembly need be provided to achieve a different nonuniform topology.

For example, after manufacturing the bladder using the first removable mold tool, removing the bladder from the modular mold assembly, removing the first removable mold tool and inserting the second removable mold tool, the method may include disposing additional polymeric material at the mold cavity, and thermoforming the additional polymeric material in the mold cavity into a different bladder having a wall with an outer surface with a nonuniform topography imparted by the topography of the mold surface of the second removable mold tool and configured differently than the nonuniform topography of the bladder thermoformed using the first removable mold tool.

In a further aspect, the method may include removing the first removable mold tool from the modular mold assembly, and inserting the first removable mold tool into an alternate modular mold assembly so that the mold surface of the first removable mold tool is disposed at and partially defines an alternate mold cavity of the alternate modular mold assembly, the alternate mold cavity having a different shape or volume than the mold cavity of the modular mold assembly. The method may include disposing additional polymeric material at the alternate mold cavity, and thermoforming the additional polymeric material in the alternate mold cavity into a different bladder having the different shape or volume of the alternate mold cavity and having a wall with an outer surface having the nonuniform topography imparted by the topography of the mold surface of the first removable mold tool. Stated differently, a removable mold tool may be used in different mold assemblies to make bladders of different configurations (shapes and/or volumes) but with the same nonuniform topography at the portion of the bladder thermoformed against the removable mold tool.

In the method according to the claimed invention, the first removable mold tool defines channels extending through the removable mold tool to the mold surface. The method may include applying a vacuum to the mold cavity through the channels to pull the polymeric material against the mold surface.

In a configuration, the topography of the mold surface of the first removable mold tool may include pyramidical cavities and the nonuniform topography of the outer surface of the bladder may include pyramidical shapes corresponding with the pyramidical cavities of the mold surface of the first removable mold tool, the pyramidical shapes having peaks extending outward from the bladder.

In a configuration, the topography of the mold surface of the removable mold tool may include grooves and the nonuniform topography of the outer surface of the bladder may include ribs corresponding with the grooves of the mold surface of the removable mold tool. For example, the nonuniform topography of the outer surface of the bladder may be at a side wall of the bladder and the ribs may extend lengthwise in a direction extending from a front wall of the bladder to a rear wall of the bladder, or the ribs may extend vertically in a direction from a top wall of the bladder to a bottom wall of the bladder. In some embodiments, the ribs may be parallel.

In still another configuration, the mold surface may include a plurality of flat regions defining irregular polygons. At least some of the flat regions may be angled relative to one another. In addition to providing an aesthetically pleasing outer surface of the side wall of the bladder, the nonuniform topography may affect the compressive stiffness of the side wall of the bladder, may provide increased traction at the side wall and/or may increase the surface roughness of the side wall in comparison to a bladder formed in a mold assembly having the mold surface of the base defining the entire cavity (e.g., a nonmodular mold assembly without the removable mold tool). In comparison to a bladder with side walls that are smooth (e.g., do not have a nonuniform topography), a bladder having a side wall with the nonuniform topography may provide a greater resiliency (e.g., quicker spring back) of the bladder to its uncompressed shape when dynamic compressive loading is removed.

In an aspect, the method may include inflating the bladder and sealing the bladder to retain fluid in the bladder. In another aspect, the method may include disposing the bladder within a sole structure of an article of footwear at an opening defined by the sole structure so that the nonuniform topography of the outer surface of the bladder is aligned with the opening.

In an example, a wearable article may include a bladder having a peripheral flange enclosing a sealed, fluid-filled interior cavity. The bladder may have a side wall that has an outer surface with a nonuniform topography. For example, the bladder may include a first polymeric sheet bonded to a second polymeric sheet at the peripheral flange, with one of the first or second polymeric sheets defining the side wall.

The nonuniform topography may include pyramidical shapes having peaks extending outward from the bladder. The nonuniform topography may include grooves extending lengthwise in a direction from a front wall to a rear wall of the bladder. The nonuniform topography may include grooves extending vertically between a top wall and a bottom wall of the bladder. The outer surface of the bladder may include a plurality of flat regions defining irregular polygons. At least some flat regions may be angled relative to one another.

In an example, the wearable article may be an article of footwear. The nonuniform topography of the bladder may be disposed at a side of a sole structure of the article of footwear. This may be achieved, for example, by disposing the side of the bladder with the nonuniform topography at the medial side or the lateral side of the sole structure.

In an example, a thickness of the side wall of the bladder at the outer surface with the nonuniform topography may be equal to or greater than a thickness of the bladder adjacent to the nonuniform topography.

Referring to the drawings, wherein like reference numbers refer to like components, <FIG> shows a modular mold assembly <NUM> configured to be used for thermoforming bladders with a variety of different surface topographies through the use of removable mold tools as discussed herein. The modular mold assembly <NUM> has a lower portion <NUM> and a base <NUM>. The lower portion <NUM> may include a plurality of interconnected vent passages in fluid communication with passages in the base that are in turn in fluid communication with channels in the removable mold tools discussed herein. The base <NUM> is secured to the lower portion <NUM> via fasteners such as bolts that extend through through-hole openings <NUM> in the base <NUM> into threaded blind holes in the lower portion <NUM>. The through-hole openings <NUM> are shown at the corners of the base <NUM> of the modular mold assembly <NUM>. No fasteners are shown in the openings <NUM> on <FIG>. Fasteners may also extend through another mold portion <NUM> shown in <FIG> and <FIG> (not shown in <FIG>) to secure the mold portion <NUM> to the base <NUM> in <FIG> to cover and enclose the mold cavities 20A-20C.

The modular mold assembly <NUM> includes one or more removable mold tools 18A-18F (referred to collectively as removable mold tools <NUM>) that interfit with the base <NUM> and are removably secured to the lower portion <NUM> by fasteners <NUM> that extend through the base <NUM> and into the lower portion <NUM> though openings part or all of which may be threaded. The extension of one such fastener <NUM> through the base <NUM> and into the lower portion <NUM> is indicated with hidden lines in <FIG>. Each of the mold tools 18A-18F has an inner wall <NUM> with a mold surface with the same nonuniform topography that is shown and discussed in greater detail with respect to <FIG> (e.g., the mold surface 32A). In other embodiments, some or all of the mold tools 18A-18F may be removed and replaced with another mold tool having an inner wall <NUM> with a mold surface with a different nonuniform topography. For example, as shown in <FIG>, mold tools 18A and 18B have an inner wall 31A, 31B, respectively, with a mold surface 32A with a nonuniform topography, the mold tools 118C and 118D have an inner wall 31C and 31D, respectively, each having a mold surface 32C with the nonuniform topography discussed with respect to <FIG>, which is different than the nonuniform topography of the mold surface 32A. The mold tools 118E and 118F have an inner wall 31E, 31F, respectively, each having a mold surface 32E with the nonuniform topography discussed with respect to <FIG>, which is different than the nonuniform topography of the mold surface 32A. In other embodiments, fewer or more of the removable mold tools may have mold surfaces with different nonuniform topographies. For example, the mold tools placed opposite one another may have different nonuniform topographies than one another. For example, mold tool 118D may be placed opposite mold tool 18A (e.g., in place of mold tool 18B) to partially define the mold cavity <NUM>, or other combinations of the mold tools may be used.

Together, the base <NUM>, the mold portion <NUM>, and the removable mold tools 18A-18F or 118C-118F define mold cavities. In the embodiment of the modular mold assembly <NUM>, there are six removable mold tools <NUM> labelled 18A, 18B, 18C, 18D, 18E, and 18F and three mold cavities <NUM> labelled 20A, 20B, and 20C. As shown in <FIG>, the mold portion <NUM> includes six recessions <NUM>. Each recession <NUM> aligns with a different one of the two primary volumes of the mold cavities 20A, 20B, and 20C (e.g., encloses the top thereof) as illustrated with respect to mold cavity 20A in <FIG>. Openings to channels <NUM> (only some of which are labelled in <FIG>) may be at the surface of the mold portion <NUM> in the recessions <NUM> and in communication with the vacuum <NUM> of <FIG> in order to pull the polymeric sheet <NUM> against the surface of the mold portion <NUM> during thermoforming.

The base <NUM>, mold portion <NUM>, (<FIG>) and the removable mold tools 18A and 18B together define a first mold cavity 20A. The base <NUM>, mold portion <NUM>, and the removable mold tools 18C and 18D together define a second mold cavity 20B. The base <NUM>, mold portion <NUM>, and the removable mold tools 18E and 18F together define a third mold cavity 20C. Each mold cavity 20A, 20B, and 20C has two primary volumes interconnected by multiple cross-passages 20E as shown in <FIG>. Longitudinal passages 20F extend between adjacent mold cavities and at the front and rear of the mold cavities. One of the longitudinal passages 20F1 extends out of an end wall of the mold assembly <NUM>. The mold cavities 20A, 20B, 20C are thus interconnected by the longitudinal passages 20F. The end longitudinal passage 20F1 will mold an inflation port on a bladder thermoformed in the modular mold assembly <NUM>. The inflation port permits access to a source of inflation gas to allow inflation of the bladder, and may then be sealed.

Because the base <NUM> and the removable mold tools <NUM> define the respective mold cavities 20A, 20B, and 20C, the dimensional tolerances of the removable mold tools 18A-18F and the base <NUM> are relatively narrow at the interfaces <NUM> of the removable mold tools 18A-18F and the base <NUM>. For example, the dimensional tolerance of the removable mold tools 18A-18F and of the base <NUM> may be <NUM> millimeters. Some of the interfaces <NUM> are indicated in <FIG>. The interfaces <NUM> are between the front and rear walls of each mold tool <NUM> in <FIG> and the faces of the side walls of the base <NUM> at the openings into which each removable mold tool <NUM> is inserted. With a dimensional tolerance of <NUM> millimeters for each of the tools 18A-18F and the base <NUM>, the maximum gap between the faces of the mold tool <NUM> and the side wall of the base <NUM> at the interface <NUM> is <NUM> millimeters. Alternatively, the dimensional tolerance for each of the tools 18A-18F and the base <NUM> may be such that the maximum gap at the interface <NUM> is <NUM> millimeters (e.g., each having a dimensional tolerance of <NUM> millimeters). Because these interfaces <NUM> extend to the mold surfaces in the mold cavities 20A, 20B, 20C, the fit of the removable mold tools <NUM> to the base <NUM> should be sufficiently precise so that the interfaces do not result in a mark (protrusion or depression) in the walls of the bladder formed in the modular mold assembly <NUM>. The nonuniform mold surfaces of the removable mold tools <NUM> discussed herein extend to the interfaces <NUM> (e.g., across the entire portion of the removable mold tool <NUM> presented at and forming part of the mold cavity <NUM>). This may help make any marking due to gaps at the interfaces <NUM> less noticeable, as the interfaces <NUM> are a boundary between nonuniform topographies of the mold surfaces <NUM> of the removable mold tools <NUM> and the more uniform/smoother topographies of the mold surfaces <NUM> of the base <NUM>.

The base <NUM> also includes a mold surface <NUM> that partially defines the mold cavity <NUM>, 20A. The removable mold tool 18A has a mold surface <NUM>, 32A that is disposed at and further defines the mold cavity 20A. Likewise, the removable mold tool 18B has a mold surface <NUM>, 32B that is disposed at and further defines the mold cavity 20A. The removable mold tools 18C-18F have similar mold surfaces 32C, 32D that define the mold cavity 20B and mold surfaces 32E, 32F that define the mold cavity 20C, respectively. The base <NUM> has mold surfaces 30B and 30C that further define the mold cavities 20B and 20C, respectively. The mold surfaces 32A-32F of the various removable mold tools <NUM> are collectively referred to as mold surface <NUM>. The nonuniform topography of the mold surface <NUM> of each of the removable mold tools 18A-18F is different than the topography of the mold surface <NUM> of the base <NUM>.

<FIG> shows the base <NUM> and lower portion <NUM> with the removable mold tools removed. The base <NUM> has a first side wall 21A that defines three openings 22A, 22B, and 22C into which the respective removable mold tools 18A, 18C and 18E fit. As shown in <FIG>, removable mold tools 118C and 118E also fit into openings 22B and 22C, respectively. In fact any of the mold tools 18A, 18C, 18E, 118C, and 118E fit into and can be inserted into any of the openings 22A, 22B, and 22C. Similarly, the base <NUM> has a second side wall 21B (labelled in <FIG>) opposite from the first side wall 21A, and that defines three openings 22D, 22E, and 22F that are mirror images of the openings 22A, 22B, and 22C, respectively. Respective removable mold tools 18B, 18D and 18F fit into openings 22D, 22E and 22F, respectively, as shown in <FIG>. As shown in <FIG>, removable mold tools 118D and 118F also fit into openings 22E and 22F, respectively. In fact any of the mold tools 18B, 18D, 18F, 118D, and 118F fit into and can be inserted into any of the openings 22D, 22E, and 22F.

The first removable mold tool 18A fits in the first opening 22A in the first side wall 21A of the base <NUM> with less than a predetermined clearance at each interface <NUM>, and with the mold surface 32A of the first removable mold tool 18A adjacent to the mold surface 30A of the base <NUM> and further defining the mold cavity <NUM>. The additional removable mold tools 18B, 18C, 18D, 18E, and 18F fit into the respective openings 22D, 22B, 22E, 22C, and 22F with a similar precise fit at the interfaces <NUM>.

In <FIG>, the removable mold tools 18A-18F are selected to provide identical nonuniform topographies on the outer surfaces of the side walls of bladders 64A formed in the mold cavity 20A as described herein with respect to <FIG>. In <FIG>, the removable mold tools 18C, 18D, 18E, and 18F are removed and alternate removable mold tools 118C, 118D, 118E, and 118F (which may be referred to as second removable mold tools) are inserted into the modular mold assembly <NUM> in their respective places. The nonuniform topography of the mold surface of the removable mold tools 118C, 118D imparts a different nonuniform topography on the outer surface of the side walls of bladders 64B formed in the mold cavity 20B as described with respect to <FIG>. The nonuniform topography of the mold surface of the removable mold tools 118E, 118F imparts yet another different nonuniform topography on the outer surface of the side walls of bladders 64C thermoformed in the mold cavity 20C as described with respect to <FIG>. Accordingly, bladders with side walls having outer surfaces with different nonuniform topographies can be provided by inserting different removable mold tools into the modular mold assembly <NUM>. This may allow production of various differently configured bladders at a lower tooling expense, as some portions of the modular mold assembly (e.g., the lower portion <NUM> and the base <NUM>) are used in forming all of the different bladders, and only the removable mold tools 18A-18F need be specifically configured for the desired surface topography of the bladder side walls.

Referring to <FIG>, the mold tool 18A is shown with the mold surface 32A having a topography that includes a plurality of pyramidical cavities <NUM> extending into the mold tool 18A. The mold surface <NUM> includes four small angled walls at each cavity <NUM> that converge at a point <NUM> at the bottom of each cavity <NUM>. Ridges <NUM> at the base of each cavity <NUM> separate the cavities <NUM>. As shown in <FIG>, the mold surface 32A with the pyramidical cavities <NUM> extends from a front wall <NUM> to a rear wall <NUM> of the mold tool 18A. Through holes <NUM> extend through the mold tool 18A from a top wall <NUM> to a bottom wall <NUM> (shown in <FIG>) and are sized for receiving the fasteners <NUM> of <FIG> to mount the mold tool 18A to the lower portion <NUM>. As shown in <FIG>, the outer wall <NUM> of the mold tool 18A is generally flat and is exposed at the outside of the modular mold assembly <NUM> in line with (e.g., flush with) the side wall 21A of the base <NUM> as shown in <FIG>.

As is apparent from the combined views of <FIG>, the mold surface 32A is concave in two directions. That is, the mold surface 32A is slightly concave in a direction from the front wall <NUM> to the rear wall <NUM> (e.g., from a front edge 50A to a rear edge 50B of the mold surface 32A, as shown in <FIG>), and is also concave in a vertical direction from the top wall <NUM> to the bottom wall <NUM> (e.g., from top edge 52A to the bottom edge 52B of the mold surface 32A, as best shown in <FIG>). The mold tool 18A is thus able to produce bladders 64A with a portion that is convex along both its height and width, such as side walls that are slightly concave (e.g., rounded) in the same two directions.

The first removable mold tool 18A includes the outer wall <NUM> opposite from the inner wall 31A. The rear wall <NUM> is opposite from the front wall <NUM>. The bottom wall <NUM> is opposite from the top wall <NUM>. Each of the front wall <NUM>, the rear wall <NUM>, the top wall <NUM>, and the bottom wall <NUM> extends from the outer wall <NUM> to the mold surface 32A. As best shown in <FIG>, the rear wall <NUM> is wider than the front wall <NUM>. As best shown in <FIG>, the bottom wall <NUM> is wider than the top wall <NUM>. The front wall <NUM> has a surface area less than a surface area of the rear wall <NUM>. The top wall <NUM> has a surface area less than a surface area of the bottom wall <NUM>. For example, a projected surface area of the top wall <NUM> projected onto a plane P1 extending through the first removable mold tool 18A between the top wall <NUM> and the bottom wall <NUM> is less than a projected surface area of the bottom wall <NUM> projected onto the plane P1. Similarly, a projected surface area of the front wall <NUM> projected onto a plane P2 extending through the first removable mold tool 18A between the front wall <NUM> and the rear wall <NUM> is less than a projected surface area of the rear wall <NUM> projected onto the plane P2. Stated differently, the footprint of the top wall <NUM> is less than that of the bottom wall <NUM>, and the footprint of the front wall <NUM> is less than that of the rear wall <NUM>.

As best shown in <FIG>, both the front wall <NUM> and the rear wall <NUM> are non-planar. For example, at least a portion 40A of the front wall <NUM> is convex and at least a portion 42A of the rear wall <NUM> is convex. As shown in <FIG>, the surface 14A of the base <NUM> that will confront the portion 40A of the front wall <NUM> is concave (e.g., at interface <NUM>), and the surface 14B of the base <NUM> that will confront the portion 42A of the rear wall <NUM> is concave (e.g., at interface <NUM>). This allows the first removable mold tool 18A to be wedged into the first opening 22A in a direction toward the mold cavity 20A, easily providing a correct alignment of the mold surface 32A of the first removable mold tool 18A with the mold surface 30A of the base <NUM>. A length of the outer wall <NUM> is greater than a length of the inner wall 31A, as best shown in <FIG>, further contributing to the ability to wedge the first removable mold tool 18A into the first opening 22A to align the mold surface 32A of the first removable mold tool with the mold surface 30A of the base <NUM>. As shown in <FIG> and <FIG>, when properly aligned with the first removable mold tool 18A in the first opening 22A of the side wall 21A of the base <NUM>, the outer wall <NUM> of the first removable mold tool 18A is flush with the side wall 21A of the base.

Such relative dimensions and shape of the first removable mold tool 18A provides several advantages. First, the first removable mold tool 18A may be wedged into the first opening 22A in a direction toward the mold cavity 20A, easily providing a correct alignment of the mold surface 32A of the first removable mold tool 18A with the mold surface 30A of the base <NUM>. Additionally, the first removable mold tool 18A fits into the first opening 22A in only one orientation, as the surface 14A of the base <NUM> fits only to (e.g., can interface only with) the front wall <NUM>, and the surface 14B of the base <NUM> fits only to (e.g., can interface only with) the rear wall <NUM>. The second opening 22D is opposite from the first opening 22A and configured as a mirror image of the first opening 22A. The first removable mold tool 18A will not fit into the second opening 22D, preventing inadvertent misplacement of the first removable mold tool 18A during manufacturing. Additionally, the first removable mold tool 18A will not fit into the first opening 22A if placed upside down or backward.

Referring to <FIG>, the removable mold tool 18B may be referred to as a second removable mold tool and fits lengthwise in the second opening 22D with the mold surface 32B of the second removable mold tool 18B adjacent to the mold surface 30A of the base <NUM> and further defining the mold cavity 20A. The second removable mold tool 18B includes an outer wall <NUM> opposite from an inner wall 31B, a front wall <NUM> opposite from a rear wall <NUM>, a top wall <NUM>, and a bottom wall (not shown) opposite from the top wall <NUM>. The top wall <NUM>, the bottom wall, the front wall <NUM>, and the rear wall <NUM> of the second removable mold tool 18B are mirror images in shape and dimension of the top wall <NUM>, the bottom wall <NUM>, the front wall <NUM>, and the rear wall <NUM>, respectively, of the first removable mold tool 18A. Each of the front wall <NUM>, the rear wall <NUM>, the top wall <NUM>, and the bottom wall of the second removable mold tool 18B extend from the outer wall <NUM> to the mold surface 32B, with the rear wall <NUM> of the second removable mold tool 18B wider than the front wall <NUM> of the second removable mold tool 18B and the bottom wall of the second removable mold tool 18B wider than the top wall <NUM> of the second removable mold tool.

Because each mold tool <NUM>, 18A is separately inserted and removed from the base <NUM>, the topographies of the mold surfaces 32A, 32B of the removable mold tools 18A, 18B may be but need not be the same. For example, although shown as the same in <FIG>, the mold surface 32B of the second removable mold tool 18B may instead have a nonuniform topography different from the nonuniform topography of the first removable mold tool 18A. As shown in <FIG>, the mold surface 32A of the first removable mold tool 18A imparts the nonuniform topography to the outer surface 68A of a first outer side wall <NUM> of the bladder 64A thermoformed in the modular mold assembly <NUM>, and the mold surface 32B of the second removable mold tool 18B (shown in <FIG>) imparts a nonuniform topography to a second outer side wall of the bladder 64A. The second outer side wall is not shown but is opposite to the first outer side wall <NUM> in <FIG> and may be a mirror image thereof. For example, the nonuniform topologies may be at outer side walls at the medial and lateral side, respectively, of the bladder 64A for an article of footwear, as shown with respect to the medial side of footwear <NUM> in <FIG>.

<FIG> illustrates that at least some of the pyramidical cavities <NUM> at the mold surface 32A vary in size. For example, pyramidical cavities <NUM> near the center of the mold surface 32A may be larger in width and height than those nearer to the front or rear walls <NUM>, <NUM>, as indicated by pyramidical cavity 36A being wider than pyramidical cavity 36B and wider than pyramidical cavity 36C. The cavities 36A, 36B, 36C also may have the same or different depths (e.g., the distance that the cavity extends toward the outer wall <NUM>.

<FIG> shows the modular mold assembly <NUM> with polymeric material in the form of a first polymeric sheet <NUM> and a second polymeric sheet <NUM> placed between the mold portion <NUM> and the lower components of the modular mold assembly <NUM> (e.g., the removable mold tools 18A, 18B, the base <NUM> and the lower portion <NUM>. The polymeric sheets <NUM>, <NUM> are a polymeric material used to form the bladder 64A of <FIG>. In other embodiments, polymeric material may be blow molded in the mold cavities 20A-20C against the base <NUM> and the removable mold tools <NUM> or <NUM>.

The first and second polymeric sheets <NUM>, <NUM> can be a variety of polymeric materials that can resiliently retain a fluid such as nitrogen, air, or another gas. Examples of polymeric materials for the first and second polymeric sheets <NUM>, <NUM> include thermoplastic urethane, polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Moreover, the first and second polymeric sheets <NUM>, <NUM> can each be formed of layers of different materials including polymeric materials. In one embodiment, each of the first and second polymeric sheets <NUM>, <NUM> is formed from thin films having one or more thermoplastic polyurethane layers with one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to the pressurized fluid contained therein such as a flexible microlayer membrane that includes alternating layers of a gas barrier material and an elastomeric material, as disclosed in <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. Additional suitable materials for the first and second polymeric sheets <NUM>, <NUM> are disclosed in <CIT> and <CIT>. Further suitable materials for the first and second polymeric sheets <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 bladders disclosed herein, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. For example, the thicknesses of the first and second polymeric sheets <NUM>, <NUM> used to form the bladder can be selected to provide these characteristics.

Each removable mold tool 18A, 18B defines channels <NUM> (see, e.g., <FIG> and <FIG>) that extend through the removable mold tool 18A or 18B from the mold surface 32A or 32B to communicate with conduits 61A (shown in <FIG>) that extend to the bottom wall <NUM>. A channel <NUM> may open at the lowest point <NUM> of a cavity <NUM> (e.g., at the bottom of the cavity <NUM>) as shown in <FIG> and <FIG> or may instead or in addition open elsewhere on the mold surface <NUM>, such as at a high point of the mold between cavities <NUM>. The opening of the channel <NUM> at the mold surface <NUM> may be relatively small so as not to appear on the bladder formed at the mold surface <NUM>. For example, the width of the opening of each channel <NUM> at the mold surface <NUM> may be <NUM> millimeters. A vacuum source <NUM> may be connected with and applied to the channels <NUM> so that a vacuum is applied to the mold cavity 20A through the channels <NUM> during thermoforming to pull the second polymeric sheet <NUM> against the mold surface <NUM>. The vacuum helps to pull the polymeric sheet <NUM> fully into the cavities <NUM> against the mold surface <NUM> to fully impart the nonuniform topography of the mold tool 18A or 18B to the polymeric sheet <NUM> during thermoforming of the sheets <NUM>, <NUM> into a bladder 64A, shown in <FIG> and <FIG>. The base <NUM> may define at least one conduit 61B (shown in <FIG> and <FIG>) in fluid communication with the channels <NUM> and conduits 61A of the first removable mold tool 18A. The lower portion <NUM> may define openings at conduits 61C that communicate with the conduit(s) 61B and then extend through the lower portion <NUM> to the vacuum source <NUM>. For example, the channels in the lower portion <NUM> may extend horizontally from the conduits 61C to the sides of the lower portion <NUM> and connect to the vacuum source <NUM>.

<FIG> shows the thermoformed bladder 64A after removal from the modular mold assembly <NUM>, inflation, and sealing. The bladder 64A defines an interior cavity <NUM> that retains a fluid at a predetermined inflation pressure. As used herein, a "fluid" filling the interior cavity <NUM> may be a gas, such as air, nitrogen, another gas, or a combination thereof. For example, peripheral portions of the polymeric sheets <NUM>, <NUM> are sealed to one another during thermoforming around the interior cavity <NUM> at a peripheral flange <NUM>. The interior cavity <NUM> of the bladder 64A may be inflated through an inflation port <NUM> that is formed at the longitudinal passage 20F of the mold assembly <NUM> and is then plugged or otherwise sealed. The bladder 64A is shown trimmed around the peripheral flange <NUM> in <FIG>.

The bladder 64A has a side wall <NUM> with an outer surface 68A with a nonuniform topography imparted by the topography of the mold surface 32A of the removable mold tools 18A, 18B. The outer surface 68A shown is imparted by mold tool 18A. An identical outer surface on the other side of the bladder 64A (not shown in <FIG>) is imparted by removable mold tool 18B assuming removable mold tool 18B has a mold surface 32B that is a mirror image of mold surface 32A. The mold surface <NUM>, 30A of the base <NUM> imparts an outer surface <NUM> at front and rear walls of the bladder 64A that has a relatively smooth (e.g., more uniform) topography than the outer surface 68A of the side wall <NUM>. The outer surface <NUM> is adjacent to the outer surface 68A. The mold portion <NUM> imparts an outer surface <NUM> at the top of the bladder 64A that also has a smoother, more uniform topography than the outer surface 68A of the side wall <NUM>.

In other embodiments, the mold tool 18B could have a mold surface with a different nonuniform topography to impart a different nonuniform topography at the outer surface of the opposite side wall of the bladder 64A. The nonuniform topography of the outer surface 68A of the bladder 64A includes pyramidical shapes <NUM> corresponding with the pyramidical cavities <NUM> of the mold surface <NUM> of the removable mold tool 18A. As best shown in <FIG>, the pyramidical shapes <NUM> have peaks <NUM> extending outward from the bladder 64A and valleys <NUM> between the peaks <NUM>. The peaks <NUM> correspond with the depths of the cavities <NUM> (e.g., the lowest points <NUM>) and are sharply defined due to the vacuum applied through the channels <NUM>. The valleys <NUM> correspond with the ridges <NUM> of the mold surface <NUM> of the mold tool 18A. The outer surface 68A has inflections at the peaks <NUM> (protrusions) and at the valleys <NUM> (depressions) evidencing the nonuniform topography.

As can be seen in <FIG>, the original thickness T1 of the second polymeric sheet <NUM> is greater than the original thickness T2 of the first polymeric sheet <NUM>. The second polymeric sheet <NUM> is originally thicker as it stretched further to form both side walls and the bottom portion of the bladder 64A whereas the first polymeric sheet <NUM> only forms the top portion due to the displacement of the flange from the center of the bladder 64A nearer to the top wall formed by the first polymeric sheet <NUM>. For example, an original thickness T1 (see <FIG>) of the second polymeric sheet <NUM> prior to thermoforming is selected so that the minimum thickness T3 of the polymeric sheet <NUM> after thermoforming (e.g., the thickness at the depths of the valleys <NUM>, see <FIG>) is not less than a desired final thickness T3. Stated differently, the original thickness T1 is at least as great as the sum of the minimum thickness T3 and the depth D1. Accordingly, all portions of the first polymeric sheet <NUM> and the second polymeric sheet <NUM> forming the completed bladder 64A may have the same minimum thickness (at least minimum thickness T3) after thermoforming. The thickness of the side wall <NUM> of the bladder 64A at the outer surface 68A with the nonuniform topography may be equal to or greater than a thickness of the bladder 64A adjacent to the nonuniform topography.

<FIG> shows the removable mold tool 118C of <FIG>. The mold tool 18C has a mold surface 32C with a nonuniform topography that includes flat regions <NUM> each of which defines an irregular polygon. As best shown in <FIG>, at least some of the flat regions <NUM> are angled relative to one another. For example, flat regions 77A, 77B, 77C, 77D, and 77E are angled relative to one another. Vectors V1, V2, V3, V4, and V5 normal to the flat regions 77A, 77B, 77C, 77D, and 77E, respectively, extend at different angles to one another. The removable mold tool 18C has channels <NUM> (similar to channels <NUM> of the mold tool 18A) opening at intersections of the flat regions <NUM>. A vacuum may be applied to through the channels <NUM> to pull the polymeric sheet <NUM> against the flat regions <NUM>.

The removable mold tool 118C results in a bladder 64B shown in <FIG>. Stated differently, the mold surface 32C imparts an outer surface 68B at a side wall <NUM> of the bladder 64B. Referring to <FIG>, the outer surface 68B includes a plurality of flat regions <NUM> defining irregular polygons that correspond with (e.g., are the same shape and size as) the flat regions <NUM> of the mold surface 32C. For example, at least some flat regions 76A, 76B, 76C, 76D, and 76E of the plurality of the flat regions <NUM> are angled relative to one another so that vectors V6, V7, V8, V9, and V10 normal to the flat regions are angled relative to one another and extend at different angles to one another. The vectors V6, V7, V8, V9, and V10 correspond with vectors V1, V2, V3, V4, and V5, respectively, each corresponding pair extending <NUM> degrees apart from the other.

The polymeric sheets <NUM>, <NUM> used to form the bladder 64B may be the same sheets as used to form bladder 64A for example, if the bladders 64A, 64B are simultaneously thermoformed with the mold tools 18A, 18B, 118C, 118D arranged as in <FIG>. In other embodiments, the removable mold tools may be arranged differently, and different polymeric sheets may be used. Like the bladder 64A, the lower polymeric sheet <NUM> of the bladder 64B may have a thicker region that confronts the mold surface 32C so that the thickness of the bladder 64B at the outer surface 68B of the side wall <NUM> with the nonuniform topography is not less than a thickness of the bladder 64B at a region adjacent to the nonuniform topography of the outer surface 68B. Since the base <NUM> and the mold portion <NUM> are used in forming both bladders 64A, 64B, the surfaces <NUM> and <NUM> of bladder 64B have the same shape and relatively smooth topography as those of bladder 64A.

<FIG> show the removable mold tool 118E of <FIG>. The topography of the mold surface 32E of the removable mold tool 118E includes parallel grooves 80A extending in a direction from a front wall <NUM> of the removable mold tool 118E to a rear wall <NUM> of the removable mold tool 118E. Channels <NUM> extend through the removable mold tool 118E, and a vacuum may be applied through the channels <NUM> to pull the polymeric sheet <NUM> against the grooves 80A during thermoforming. As shown in <FIG> and <FIG>, the nonuniform topography 68C of the bladder 64C formed using the removable mold tool 118E includes parallel horizontal ribs 82A corresponding with the grooves 80A of the mold surface 32E. The ribs 82A protrude at the side wall <NUM> of the bladder 64C and extend lengthwise in a direction extending from the front wall <NUM> of the bladder 64C to the rear wall <NUM> of the bladder 64C (e.g., the ribs 82A extend horizontally lengthwise along the side wall <NUM> of the bladder 64C).

<FIG> shows another alternate removable mold tool <NUM> that can be used in place of any of the mold tools 18A-18F or 118C-118F in the mold assembly <NUM>. The topography of the mold surface <NUM> of the removable mold tool <NUM> includes parallel grooves 80B extending lengthwise in a direction from the top wall <NUM> of the removable mold tool <NUM> to the bottom wall <NUM> of the removable mold tool <NUM>. As shown in <FIG>, the nonuniform topography <NUM> of the bladder <NUM> formed using the removable mold tool 118E includes parallel vertical ribs 82B corresponding with the grooves 80B of the mold surface <NUM>. The ribs 82B protrude at the side wall <NUM> of the bladder <NUM> and extend lengthwise in a direction extending from the top wall of the bladder <NUM> to the bottom wall of the bladder <NUM> (e.g., the ribs 82B extend vertically lengthwise along the side wall <NUM> of the bladder <NUM>).

The nonuniform topographies of the outer surfaces of the side walls of the various bladders shown and described herein may entail various structural and/or functional advantages in comparison to bladders having side walls with smoother outer surfaces (e.g., more uniform topologies). For example, the pyramidical shapes <NUM>, the angled flat regions <NUM>, and the ribs 82A and 82B may each impart a greater stiffness of the side wall <NUM> under dynamic compressive loading (e.g., compression of the top wall toward the bottom wall) due in part to a stack up of these features of the nonuniform topography. For example, the vertical ribs 82B of the bladder <NUM> of <FIG> may act as compression-limiting posts at the side wall <NUM>, requiring greater force to compress the side wall <NUM> a given distance than if the side wall <NUM> were smooth (e.g., without a nonuniform topography or with a more uniform thickness). In contrast, the horizontal ribs 82A of the bladder 64C of <FIG> and <FIG> may not interfere with an initial amount of compression under dynamic loading (e.g., compression of the top wall of the bladder 64C toward the bottom wall) at the side wall <NUM> until the ribs 82A stack upon one another, at which point they increase the resistance of the side wall <NUM> to vertical compression. Under lateral compression (e.g., inward forces on the front and rear walls <NUM>, <NUM> of the bladder 64C), the side wall <NUM> having the horizontal ribs 82A will provide a greater resistance to compression than the side wall having the vertical ribs 82B. In some embodiments, ribs 82A or 82B of different sizes may be used at a medial side wall of a bladder than at a lateral side wall of the same bladder. For example, a tooling insert with thicker grooves 80A or 80B may be used at one side of a mold cavity <NUM> than at the opposite side of the mold cavity <NUM> so that the medial side wall of the resulting bladder will have a nonuniform topography with thicker ribs than the lateral side wall. When disposed in an article of footwear, the medial side wall may then provide greater compressive stiffness at the medial side of the article of footwear than at the lateral side.

Increased traction or grip may result from the nonuniform topologies of the sides wall <NUM>. For example, the bladder 64A with the side wall <NUM> having the pyramidical shapes <NUM> may provide traction or grip, as may either of the sets of ribs 82A, 82B. Similarly, the bladder 64B with the side wall <NUM> having the outer surface 68B of flat regions <NUM> of irregular polygons may have a greater coefficient of friction than would a relatively smooth outer surface. A variety of nonuniform topologies can be created at the outer surfaces of the bladders using various removable mold tools in the modular mold assembly <NUM> to provide these or other functional features and advantages.

<FIG> shows an article of footwear <NUM> with a sole structure <NUM> and an upper <NUM> secured to the sole structure <NUM>. The sole structure <NUM> defines an opening <NUM> in a side wall of a midsole <NUM>. The bladder 64A is shown disposed within the midsole <NUM> at the opening <NUM> so that the nonuniform topography (e.g., the pyramidical shapes <NUM>) of the outer surface 68A of the bladder 64A is aligned with the opening <NUM>. The pyramidical shapes <NUM> are thus exposed at the opening <NUM>, allowing their functional advantages to be accessed as well as allowing them to be viewed for aesthetic purposes. Stated differently, the outer surface 68A with the nonuniform topography is disposed at the opening <NUM> such that the nonuniform topography is viewable at an exterior of the article of footwear through the opening. The article of footwear <NUM> is just one example of a wearable article in which the bladder 64A may be incorporated. Bladders with outer surfaces having nonuniform topologies may be used in other wearable articles.

<FIG> shows that the second polymeric sheet <NUM> is a multi-layer sheet formed of thermoplastic polyurethane layers 58A alternating with barrier layers 58B of a copolymer of ethylene and vinyl alcohol (EVOH). As discussed with respect to <FIG>, the outermost layer 58AA is thicker at the outer surface 68A with the nonuniform topography than at adjacent regions of the outermost layer 58AA.

<FIG> shows another embodiment of a modular mold assembly <NUM> that is alike in all aspects to mold assembly <NUM> except that the mold assembly <NUM> has a base <NUM> that is wider than the base <NUM> at the cross-passages 20E (e.g., width W2 is greater than width W1). The base <NUM> to which the base <NUM> and removable mold tools 18A-18F secure is also wider than the lower portion <NUM>. Accordingly, the overall width W2 of a bladder 164A (see <FIG>) formed using the modular mold assembly <NUM> will be greater than the overall width W1 (see <FIG> and <FIG>) of a bladder 64A formed using the mold assembly <NUM>. Notably, the same removable mold tools 18A-18F and 118C-118F that secure to the base <NUM> may also secure to the base <NUM>. Accordingly, the nonuniform topography of the outer surface 168A of the side wall <NUM> of the bladder 164A is the same as that of the side wall <NUM> of the bladder 64A. The removable mold tools 18A-18F and 118C-118F can thus be used in different modular mold assemblies to manufacture bladders of different sizes, such as different widths, such as may be needed for different sizes or widths of footwear.

<FIG> is a perspective view of another embodiment of a bladder <NUM> thermoformed in a modular mold assembly using removable mold tools to impart a nonuniform topography at the outer surface of the bladder. The modular mold assembly used to thermoform the bladder <NUM> is not shown but includes tooling inserts with curved recesses of varying lengths and shapes and disposed in a relatively random orientation relative to one another (e.g., not in rows, columns, or regular groupings). Such tooling inserts impart the nonuniform topography of curved, elongated protrusions <NUM> at the outer surface of the bladder <NUM>. Some of the curved, elongated protrusions <NUM> are individually identified as protrusions 87A, 87B, and 87C. The bladder <NUM> is annular as an uninflated portion of the first and second polymeric sheets extending at the middle of the bladder <NUM> is trimmed to leave a central aperture <NUM>.

<FIG> is a perspective view of another embodiment of a bladder 64J thermoformed in a modular mold assembly using removable mold tools to impart a nonuniform topography at the outer surface of the bladder. The modular mold assembly is not shown but includes tooling inserts with waved nonoverlapping protrusions extending almost entirely around the perimeter of the mold cavity of the modular mold assembly used to form the bladder 64J. Such tooling inserts impart the nonuniform topography of waved, nonoverlapping protrusions <NUM> extending around the side walls and one end of the bladder 64J at the outer surface of the bladder 64J. Some of the waved, elongated protrusions <NUM> are individually identified as protrusions 88A, 88B, and 88C. The bladder 64J is annular as an uninflated portion of the first and second polymeric sheets extending at the middle of the bladder 64J is trimmed to leave a central aperture 89J.

The following Table <NUM> shows the steps of one implementation of a method <NUM> of manufacturing a wearable article such as an article of footwear <NUM> using the modular mold assembly <NUM> or <NUM> described herein. The method <NUM> may begin with step <NUM> in which a modular mold assembly <NUM> or <NUM> with one or more removable mold tools 18A-18F is provided. The entity carrying out the method <NUM> may manufacture the mold assembly <NUM> or <NUM> or may obtain it from another entity. Next, in step <NUM>, polymeric material (such as first and second polymeric sheets <NUM>, <NUM>) is disposed at the mold cavity 20A, 20B, 20C. In step <NUM>, a vacuum may be applied to pull the polymeric material against the mold surface, such as the vacuum applied through the channels <NUM> to pull the polymeric sheet <NUM> against the mold surface 32A. In step <NUM>, the first bladder, such as bladder 64A, is then thermoformed in the mold assembly <NUM> with the outer surface 68A having the nonuniform topography. The bladder 64A may then be inflated in step <NUM> and then sealed in step <NUM>. The completed bladder 64A may then be disposed in a wearable article in step <NUM>, such as an article of footwear <NUM> with the outer surface 68A aligned with an opening in the sole structure <NUM>.

The removable mold tools allow flexibility in use of the modular mold assembly <NUM> or <NUM> to manufacture bladders with different nonuniform topologies. For example, in step <NUM>, a first removable mold tool such as mold tool 18A may be removed, and in step <NUM> an alternate removable mold tool (e.g., a second removable mold tool) such as mold tool 18C may be inserted in its place in the mold assembly <NUM> or <NUM>. Additional polymeric material, such as different polymeric sheets, referred to herein as third and fourth polymeric sheets (configured the same as first and second polymeric sheets <NUM>, <NUM>) may then be disposed at the mold cavity 20B in step <NUM>, and then a second bladder 64B may be thermoformed in step <NUM>, with the second bladder 64B having an outer surface 68B with a different nonuniform topography as described herein due to the use of the second removable mold tool.

In addition to using different mold inserts in the same mold assembly, the method <NUM> may include using a mold insert in different mold assemblies, such as to manufacture bladders of different sizes but using the same removable mold tools to impart the same nonuniform topologies. For example, the method <NUM> may include step <NUM>, in which the first removable mold tool 18A (previously used in modular mold assembly <NUM>) is inserted into a different modular mold assembly <NUM>. Different polymeric material, such as additional polymeric sheets similar to polymeric sheets <NUM>, <NUM>, may then be disposed at the mold cavity of the modular mold assembly <NUM> in step <NUM>. In step <NUM>, another bladder with a different shape or volume, such as bladder 164A having a greater width and, due to the longer cross passages 20E, also a greater volume than bladder 64A. The bladder 164A has the same nonuniform topography (pyramidical protrusions <NUM>) at the outer surface 168A of the side wall <NUM> as the bladder 64A has at outer surface 68A of side wall <NUM>.

As used in the description and the accompanying claims, a value is considered to be "approximately" equal to a stated value if it is neither more than <NUM> percent greater than nor more than <NUM> percent less than the stated value.

The term "longitudinal" refers to a direction extending a length of a component. For example, a longitudinal direction of a shoe extends between a forefoot region and a heel region of the shoe. 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 a shoe extends between a lateral side and a medial side of the shoe. 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 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. 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 shoe 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 shoe in an assembled shoe. 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 modular mold assembly (<NUM>; <NUM>) comprising:
a base (<NUM>; <NUM>) having a mold surface (<NUM>, 30A, 30B, 30C) that partially defines a mold cavity (<NUM>, 20A, 20B, 20C) for thermoforming a polymeric bladder with a fluid-filled chamber; wherein the base (<NUM>; <NUM>) includes a side wall (21A) defining a first opening (22A, 22B, 22C) that opens into the mold cavity (<NUM>, 20A, 20B, 20C); and
a first removable mold tool (<NUM>, 18A, 18C, 18E) that has an inner wall (<NUM>, 31A, 31C, 31E) with a mold surface (<NUM>, 32A, 32C, 32E) having a topography different than a topography of the mold surface (<NUM>, 30A, 30B, 30C) of the base (<NUM>; <NUM>); wherein the first removable mold tool (<NUM>, 18A, 18C, 18E) fits in the first opening (22A, 22B, 22C) in the side wall (21A) of the base (<NUM>; <NUM>) with less than a predetermined clearance and with the mold surface (<NUM>, 32A, 32C, 32E) of the first removable mold tool (<NUM>, 18A, 18C, 18E) adjacent to the mold surface (<NUM>, 30A, 30B, 30C) of the base (<NUM>; <NUM>) and further defining the mold cavity (<NUM>, 20A, 20B, 20C); wherein the first removable mold tool (<NUM>, 18A, 18C, 18E) includes an outer wall (<NUM>) opposite the inner wall (<NUM>, 31A, 31C, 31E), a front wall (<NUM>), a rear wall (<NUM>) opposite the front wall (<NUM>), a top wall (<NUM>), and a bottom wall (<NUM>) opposite the top wall (<NUM>); wherein each of the front wall (<NUM>), the rear wall (<NUM>), the top wall (<NUM>), and the bottom wall (<NUM>) extends from the outer wall (<NUM>) to the mold surface (<NUM>, 32A, 32C, 32E); and wherein the rear wall (<NUM>) is wider than the front wall (<NUM>) and the bottom wall (<NUM>) is wider than the top wall (<NUM>),
wherein the first removable mold tool (<NUM>, 18A, 18C, 18E) defines channels (<NUM>) extending through the first removable mold tool (<NUM>, 18A, 18C, 18E) to the mold surface (<NUM>, 32A, 32C, 32E) of the first removable mold tool (<NUM>, 18A, 18C, 18E).