Article of footwear having first and second outsole components and method of making the same

Abstract

A sole structure (130, 3130, 3131, 3132) for an article of footwear (100, 3100) (131, 570) includes: a midsole including a polymer bladder element (3140, 3150) enclosing a fluid-filled interior cavity (3142); a first outsole component (3060, 3070) secured to a bottom (1064, 1237, 764) and a side surface (3078, 3079) of the polymer bladder element (3140, 3150); and a second outsole component (3062, 3070, 3072). The first outsole component (3060, 3070) includes a first base (3083, 4008) and a wall (3085, 3092, 4010) integral with the first base (3083, 4008). The second outsole member (3062, 3070, 3072) includes a second base (3090, 4012) fixed to the first base (3083, 4008) and a wall (3085, 3092, 4010) integral with the second base (3090, 4012) and fixed to an outer surface (3094, 4016, 4017) of a wall (3085, 3092, 4010) of the first outsole member (3060, 3070). The first base (3083, 4008) has a first portion (3082) having an integral tread element (3135, 3091). The second base (3090, 4012) is fixed to a second portion (3084, 620) of the first base (3083, 4008) without a tread element (3135, 3091). A method of manufacturing includes thermoforming a bladder member (3040, 3050, 3140, 3150) and a first outsole component (3060, 3070) and securing a second outsole component (3062, 3070, 3072) to the first outsole component (3060, 3070).

Description

[0001] This application is a divisional application of the invention application with application number 201780018504.8 and application date of March 13, 2017.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of priority to U.S. Application No. 15 / 070,082, filed on March 15, 2016, which is incorporated herein by reference in its entirety. Technical Field

[0004] The present teachings generally relate to articles of footwear including sole structures, and to methods of making the same. Background Art

[0005] Footwear generally includes a sole structure that is configured to be located under the wearer's foot to space the foot from the ground or floor surface. In particular, sports footwear sometimes uses polyurethane foam, rubber or other elastic materials in the sole structure to provide cushioning. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present invention can be better understood with reference to the following drawings and descriptions. The components in the drawings are not necessarily drawn to scale, but the emphasis is placed on illustrating the principles of the present invention. In addition, in the drawings, similar reference numerals refer to corresponding parts in all the different views.

[0007] Figure 1 is a cross-sectional view of an article of footwear including a co-molded article;

[0008] Figure 2 is a cross-sectional view of a co-molded article;

[0009] Figure 3 is a cross-sectional view of an open mold, illustrating the relationship of the various parts used to produce the article;

[0010] Figure 4 is a cross-sectional view of a closed mold, illustrating the Figure 3 the relationship of the parts of an object;

[0011] Figure 5 is a cross-sectional view of an open mold, illustrating the relationship of the various parts used to produce the article;

[0012] Figure 6 is a cross-sectional view of a closed mold, illustrating the Figure 5 the relationship of the parts of an object;

[0013] Figure 7is a cross-sectional view of an open mold illustrating the relationship of the various parts used to produce the articles of the present disclosure;

[0014] Figure 8 is a cross-sectional view of a portion of an open mold, illustrating the process used to produce Figure 7 the relationship of the parts of an object;

[0015] Fig. 9 is a cross-sectional view of a closed mold, illustrating the Figure 7 the relationship of the parts of an object;

[0016] Fig.10 is a cross-sectional view of an open mold illustrating the relationship of the various parts used to produce another article of the present disclosure;

[0017] Fig.11 is a cross-sectional view of a closed mold, illustrating the Fig.10 the relationship of the parts of an object;

[0018] Fig.12 is a cross-sectional view of an open mold illustrating the relationship of the various parts used to produce yet another article of the present disclosure;

[0019] Fig.13 is a cross-sectional view of a closed mold, illustrating the Fig.12 the relationship of the parts of an object;

[0020] Fig.14 is a bottom view of a sole structure for an article of footwear including a forefoot sole structure and a heel sole structure attached to an upper of the footwear;

[0021] Fig.15 is comprised of a shoe upper attached to the shoe Fig.14 a lateral side view of an article of footwear having a sole structure;

[0022] Fig.16 yes Fig.14 a perspective view of a lower surface of a forefoot bladder element of a sole structure;

[0023] Fig.17 yes Fig.14 a perspective view of a lower surface of a first outsole component of a forefoot sole structure;

[0024] Fig.18 yes Fig.17 a perspective view of an upper surface of a first outsole component;

[0025] Fig.19 is Fig.18 The line 19-19 in Fig.18 a cross-sectional perspective illustration of a first outsole component of;

[0026] Fig. 20 yes Fig.14 a perspective view of a lower surface of a heel bag element of a sole structure;

[0027] Fig.21 yes Fig.14 a perspective view of a lower surface of a first outsole component of a heel sole structure;

[0028] Fig. 22 yes Fig.21 a perspective view of an upper surface of a first outsole component;

[0029] Fig.23 is Fig.14 The line 23-23 in Fig.14 A cross-sectional view of a sole structure;

[0030] Fig.24 is Fig.14 The line 24-24 in Fig.14 A cross-sectional view of a sole structure;

[0031] Fig.25 is used for Fig.17 a cross-sectional view of an injection mold of a first outsole component;

[0032] Fig.26 is used for Fig. 22 a cross-sectional view of an injection mold of a first outsole component;

[0033] Fig. 27 is a cross-section and exploded view of an open thermoforming die, illustrating Fig.14 The relationship of some of the components of the sole structure; and

[0034] Fig.28 yes Fig. 27 A cross-sectional view of a mold and component with the mold in a closed position. DETAILED DESCRIPTION

[0035] A sole structure for an article of footwear includes a midsole, a first outsole component, and a second outsole component, the midsole having a polymer bladder element enclosing a fluid-filled interior cavity. The first outsole component is fixed to the bottom surface and the side surface of the polymer bladder element. The first outsole component includes a first base and a wall integral with the first base. The second outsole component includes a second base fixed to the first base and a wall integral with the second base and fixed to the outer surface of the wall of the first outsole component. The first base has an integral tread element protruding at a first portion of the bottom surface of the first base, but the second portion of the bottom surface is free of any tread element. The wall of the first outsole component has an outer surface adjacent to the second portion of the bottom surface. The second base of the second outsole component is fixed to the second portion of the bottom surface of the first base. Therefore, the first tread element does not interfere with the second base. In addition, the ground engaging surface of the sole structure includes the integral tread element of the first outsole component and includes the second outsole component.

[0036] In one or more embodiments, the bladder element has a curved tubular portion in the forefoot region of the sole structure. The side surface of the bladder element is at the inner curved wall of the bladder element at the curved tubular portion. In this configuration, the wall of the second outsole component supports and reinforces the inner curved wall of the bladder element, such as during dorsiflexion in the forefoot region.

[0037] In one or more embodiments, the first outsole component is a first material and the second outsole component is a second material different from the first material. For example, the first outsole component can be thermoplastic polyurethane and the second outsole component can be rubber. The second material can be selected to provide durability and enhanced support to the ground engaging surface to adjust the cushioning response of the first outsole component.

[0038] In one or more embodiments, the outer surface of the wall of the first outsole component has a recess adjacent to the second portion of the bottom surface of the first outsole component. The wall of the second outsole component can be fixed to the outer surface of the wall of the first outsole component in the recess. Therefore, the wall of the second outsole component is nested in the recess, which protects the wall of the second outsole component from forces that may cause delamination. In one embodiment, the wall of the second outsole component has a first thickness, the recess has a first depth, and the first thickness is greater than the first depth, so that the second outsole component protrudes outward from the first outsole component at the wall of the first outsole component.

[0039] In one or more embodiments, the wall of the first outsole component is an outer wall of the first outsole component, and the wall of the second outsole component is an outer wall of the second outsole component. The first outsole component has an inner wall that is integral with the first base, and the recess extends only halfway up along the outer wall of the first outsole component, extends along the bottom surface of the base, and extends upward along the inner wall of the first outsole component. The second outsole component has an inner wall that is integral with the second base and fixed to the outer surface of the inner wall of the first outsole component. The inner wall of the second outsole component extends further upward along the first outsole component than the outer wall of the second outsole component.

[0040] In one or more embodiments, the polymeric bladder element is configured such that at least a portion of the fluid-filled interior cavity has a U-shape having an arcuate portion at an outer perimeter of the sole structure. The first outsole component has a U-shape corresponding to the U-shape of the fluid-filled interior cavity, wherein a wall of the first outsole component is at the arcuate portion of the fluid-filled interior cavity.

[0041] The second outsole component may also have tread elements included in the ground engaging surface. In one or more embodiments, the second outsole component has a plurality of integral second tread elements protruding from the bottom surface of the second outsole component. The first tread elements and the second tread elements establish the ground engaging surface of the sole structure.

[0042] An article of footwear may include an upper. The midsole, the first outsole component, and the second outsole component may be configured as a forefoot sole structure secured to a forefoot region of the upper, and the sole structure may further include a heel sole structure secured to a heel region of the upper. The heel sole structure may include: a midsole having a polymeric bladder element enclosing a separate fluid-filled interior cavity isolated from a fluid-filled interior cavity of the polymeric bladder element of the forefoot sole structure; a first outsole component secured to a bottom surface of the bladder element of the heel sole structure; and a second outsole component secured to the first outsole component of the heel sole structure.

[0043] A method for manufacturing an article of footwear includes placing a preformed first outsole component into a thermoforming mold. The preformed first outsole component has a base having an integral tread element protruding from a first portion of a bottom surface of the base and having a second portion of the bottom surface without any tread element. The first outsole component also has a wall that is integral with the base and adjacent to the second portion of the bottom surface. The method includes placing a polymer material with the first outsole component in a thermoforming mold, and closing the thermoforming mold to encapsulate a first polymer sheet, a second polymer sheet, and the first outsole component in a mold cavity. A vacuum is applied to conform the first polymer sheet to a first mold surface of the thermoforming mold, and to conform the second polymer sheet to an upper surface of the first outsole component and to a second mold surface of the thermoforming mold, with an internal cavity between the first polymer sheet and the second polymer sheet.

[0044] The first portion of the polymer material may be a first polymer sheet, and the second portion of the polymer material may be a second polymer sheet. The method may also include: thermally bonding the first polymer sheet to the second polymer sheet to enclose an interior cavity, thermally bonding a lower surface of the second polymer sheet to an upper surface of the first sole component, and removing the thermally bonded upper and lower polymer sheets and the first outsole component as a unit from the thermoforming mold after a predetermined cooling period.

[0045] The second outsole component may be positioned on a second portion of the bottom surface of the first outsole component and bonded to the first outsole component. For example, the second outsole component may be positioned by nesting the second outsole component in a recess in the outer surface of a wall of the first outsole component. Nesting the second outsole component in the recess may include placing an upper edge of the second outsole component at an upper extent of the recess along a lip of the first outsole component. The wall may be an outer wall, the first outsole component may include an inner wall integral with the base, and the recess may extend along the bottom surface of the base, extend halfway up along the outer wall, and extend further up along the inner wall than the outer wall.

[0046] The method may include securing a footwear upper to an upper surface of a first polymer sheet. The first and second polymer sheets, the first outsole component, and the second outsole component may be configured as a forefoot sole structure and secured to a forefoot region of the footwear upper, and the method may include securing a heel sole structure to a heel region of the footwear upper, wherein a front edge of the heel sole structure is adjacent to a rear edge of the forefoot sole structure.

[0047] The second mold surface may have a positioning mark, and placing the first outsole component into the thermoforming mold may include placing a predetermined portion of the first outsole component at the positioning mark to orient the first outsole component at the predetermined position in the thermoforming mold.

[0048] The above features and advantages and other features and advantages of the present teachings are apparent from the following detailed description of modes for carrying out the present teachings when taken in conjunction with the accompanying drawings.

[0049] "A", "an", "the", "at least one" and "one or more" are used interchangeably to indicate that there is at least one of the items. Unless the context clearly indicates otherwise, there may be multiple such items. Unless otherwise explicitly or clearly indicated from the perspective of the context, all numerical values ​​of parameters (e.g., amounts or conditions) in this specification (including the appended claims) should be understood to be modified by the term "about" in all cases, regardless of whether "about" actually appears before the numerical value. "About" indicates that the numerical value described allows some slight imprecision (slightly close to the accuracy of the value; approximately or moderately close to the value; almost close to the value). If the imprecision provided by "about" cannot be understood in the art with this ordinary meaning unless otherwise, then the "about" used in this article at least indicates the changes that may be caused by the common methods of measuring parameters and using such parameters. In addition, the disclosure of a range should be understood to specifically disclose all values ​​and further divided ranges within the range. All references mentioned are incorporated herein in their entirety.

[0050] The terms "comprising", "including" and "having" are inclusive and therefore specify the presence of the stated features, steps, operations, elements or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements or parts. The order of steps, processes and operations may be changed when possible, and additional or alternative steps may be adopted. As used in this specification, the term "or" includes any and all combinations of the relevant listed items. The term "any of" should be understood to include any possible combination of the referenced items, including being understood as "any one of" the referenced items. The term "any of" should be understood to include any possible combination of the referenced claims of the appended claims, including being understood as "any one of" the referenced claims.

[0051] Those of ordinary skill in the art will recognize that terms such as "above," "below," "upwardly," "downwardly," "top," "bottom," etc. may be used descriptively with respect to the drawings and do not represent limitations on the scope of the invention as defined by the claims.

[0052] In an embodiment, the shaped article may be a cushioning layer or outsole for an article of footwear. Figure 1 Such an embodiment is illustrated. Figure 1 1 is a cross-sectional view of a footwear article including a co-molded article. Footwear article 100 includes an upper 120 and a sole structure 130. Upper 120 provides a comfortable and fixed cover for the wearer's foot. In this way, the foot can be positioned in upper 120 so that the foot is effectively fixed in footwear article 100 or otherwise the foot and footwear article 100 are integrated. Sole structure 130 is fixed to the lower area of ​​upper 120 and extends between the foot and the ground to, for example, attenuate ground reaction forces (i.e., cushion the foot), provide traction friction, enhance stability, and influence the movement of the foot. In fact, sole structure 130 is located under the foot and supports the foot.

[0053] The upper 120 is depicted as having a generally conventional configuration. Most of the upper 120 comprises a variety of material elements (e.g., textiles, foam, leather and synthetic leather), which are sewn or adhesively combined to produce an internal cavity for firmly and comfortably receiving the foot. The material element can be selected and positioned in the upper 120 to selectively impart performance such as durability, breathability, wear resistance, flexibility and comfort. The cavity in the upper 120 is shaped to accommodate the foot. Therefore, when the foot is positioned in the cavity, the upper 120 extends along the lateral side of the foot, along the medial side of the foot, above the foot, around the heel and below the foot. The shoelace 122 extends above the tongue 123. The shoelace 122 and the adjustability provided by the tongue 123 can be used in a conventional manner to modify the size of the internal cavity, thereby fixing the foot in the internal cavity and facilitating the foot to enter the internal cavity and move out of the internal cavity. Sockliner 125 may enhance the comfort of article of footwear 100 .

[0054] Further configurations of the upper 120 may also include one or more of the following: (a) a toe guard positioned in the forefoot region and formed of a wear-resistant material, (b) a heel counter positioned in the heel region for enhanced stability, and (c) one or more of a logo, a trademark, and a label with care instructions and material information. Given that aspects of the present discussion are primarily directed to the sole structure 130, the upper 120 may present the general configuration discussed above or the general configuration of virtually any other conventional or unconventional upper. Accordingly, the structure of the upper 120 may vary significantly.

[0055] Sole structure 130 includes an outsole 160 attached to fluid-filled chamber 140. Outsole 160 has ground engaging protrusions 135 associated therewith.

[0056] Figure 2 An alternative embodiment of a can-type article 200 is illustrated having a top 210 associated with a can 220. The can 220 is at least partially surrounded by a shell 230 having a protrusion 235 extending therefrom. Figure 2 , Figure 5 , Figure 6 , Fig.12 and Fig.13 and the accompanying description explain this alternative embodiment.

[0057] Figure 3 and Figure 4 The diagram shows the production of a sole structure (such as but not limited to Figure 1 The sole structure 130) is provided in a manner. Figure 3 and Figure 4 A cross section of a mold for co-molding a fluid-filled chamber 140 with an outsole 160 having protrusions 135 thereon is depicted. Outsole 160 can be produced from multiple preformed objects or elements assembled in a mold. In some embodiments, outsole 160 wraps around at least a portion of edge 143 on fluid-filled chamber 140. Molded structure 131 is an embodiment of an article having outsole 160 that wraps around a majority of the edge of fluid-filled chamber 140. Because these components are produced from thermoplastic materials, they can be softened to help create the shape in the mold.

[0058] Figure 3 and Figure 4 is a cross-sectional drawing of a mold 300 for structure 131. Figure 3 and Figure 4 As shown in , fluid-filled chamber 140 is co-molded with outsole 160 present in a mold. Adhesive may also be present on a suitable surface.

[0059] In general, a co-molded article can be produced in a two-piece mold with an upper mold portion and a lower mold portion by placing an outsole element into a lower mold portion and then placing a layer that will form a fluid-filled chamber 140 on top of the outsole element. The mold is then closed so that the upper mold portion and the lower mold portion are adjacent to each other. The mold is formed so that closing the mold causes the formation of the chamber. Then, the fluid under pressure is introduced into the chamber so that the filling of the chamber forces the upper surface of the chamber to be in a consistent relationship with the lower side of the upper mold portion, and also forces the lower portion of the chamber to be in a consistent relationship with the outer element below. Energy can be applied to the mold with heat, radio frequency, etc., so that the first element and the second element are co-molded together with the filled chamber, and the article is pushed against the mold surface and the outsole element. A second element part such as a polymer layer can be provided in the mold as a precursor for a finished product. This precursor can be formed in the mold as part of the co-molding process described herein, or can be provided as a fully preformed chamber ready for filling.

[0060] A variety of manufacturing processes may be used to produce sole structure 131. In some embodiments, mold 300 that may be utilized in a manufacturing process is depicted as including first mold portion 310 and second mold portion 320. Mold 300 is used to produce fluid-filled chamber 140 from first polymer layer 410 and second polymer layer 420, which are polymer layers that produce fluid-filled chamber upper surface 141 and fluid-filled chamber lower surface 142, respectively. More specifically, mold 300 facilitates the manufacturing process by (a) shaping first polymer layer 410 and second polymer layer 420 in areas corresponding to edge 143 of fluid-filled chamber 140, flange 146, and channels between chambers, and (b) joining first polymer layer 410 and second polymer layer 420 in areas corresponding to flange 146 and web area 1147.

[0061] Various surfaces or other areas of mold 300 will now be defined for use in discussing the manufacturing process.First mold portion 310 includes a first mold portion surface 350 that shapes a top surface of the co-molded article. Figure 31 and 2 are illustrated in the drawings of various portions of a first element, such as an outsole 160, and a second element, such as a fluid-filled chamber 140. A second mold portion 320 is shaped to receive a protrusion 135 that mates with a groove 325 in the second mold portion 320. The outsole 160 is then placed in the mold. The outsole 160 fits within the undercut 335. Then, when the article is molded, a second element precursor or first polymer layer 410 is put into place to become the top surface of the article, and a second element precursor or second polymer layer 420 creates the bottom surface or lower surface 142 of the second element, herein the fluid-filled chamber.

[0062] As first mold portion 310 and second mold portion 320 move toward each other, a variety of techniques may be used to draw first polymer layer 410 and second polymer layer 420 against the surfaces of first mold portion 310 and second mold portion 320, thereby initiating the process of shaping first polymer layer 410 and second polymer layer 420. For example, air may be partially exhausted from (a) the region between first mold portion 310 and first polymer layer 410 and (b) the region between second mold portion 320 and second polymer layer 420. More specifically, air may be drawn out through various vacuum ports in first mold portion 310 and second mold portion 320. By removing the air, first polymer layer 410 is drawn into contact with the surface of first mold portion 310, and second polymer layer 420 is drawn into contact with the surface of second mold portion 320. As another example, a fluid may be injected into the region between first polymer layer 410 and second polymer layer 420, thereby increasing the pressure between first polymer layer 410 and second polymer layer 420. During the preparatory stage of this process, an injection needle may be positioned between the first polymer layer 410 and the second polymer layer 420, and a fluid (such as a gas, liquid, gel, for example, or a mixture thereof) may then be ejected from the injection needle such that the first polymer layer 410 and the second polymer layer 420 engage the surface of the mold 300. Each of these techniques may be used together or independently.

[0063] As first mold portion 310 and second mold portion 320 continue to move toward each other, first polymer layer 410 and second polymer layer 420 are clamped between first mold portion 310 and second mold portion 320. More specifically, first polymer layer 410 and second polymer layer 420 are squeezed between clamping surface 330 and clamping edge 360. In addition to beginning the process of separating excess portions of first polymer layer 410 and second polymer layer 420 from the portion that forms fluid-filled chamber 140, the clamping of first polymer layer 410 and second polymer layer 420 begins the process of bonding or joining first polymer layer 410 and second polymer layer 420 in the area of ​​flange 146.

[0064] like Figure 4 146. As depicted in FIG. 147, after the first polymer layer 410 and the second polymer layer 420 are clamped, the first mold portion 310 and the second mold portion 320 continue to move toward each other and into a closed configuration. As the mold closes, the clamping surface 330 contacts and slides against a portion of the second seam forming surface 370. The contact between the clamping surface 330 and the second seam forming surface 370 effectively severs the excess portion of the first polymer layer 410 and the second polymer layer 420 from the portion that forms the fluid-filled chamber 140. The material forming the first polymer layer 410 and the second polymer layer 420 is compacted or otherwise gathered to form the flange 146. In addition to forming the flange 146, the first polymer layer 410 and the second polymer layer 420 are (a) shaped to create the fluid-filled chamber 140, and (b) pressed and joined to create the web area 1147.

[0065] When creation of fluid-filled chamber 140 is complete, mold 300 is opened. Fluid may then be injected into fluid-filled chamber 140 to pressurize the forefoot component fluid-filled chamber, thereby completing the manufacture of structure 131. As a final step in the process, structure 131 may be incorporated into the sole structure of article of footwear 100.

[0066] Co-molded articles can have many uses. Figure 5 A can or other container is shown. Figure 5 Depicted is the molding of a can-shaped article or other container. The mold 600 includes a first mold portion 610 having a mold surface 650. The second mold portion 620 includes a groove 625 to securely engage the protrusion 535 on the first element 560. The second polymer layer 520 and the first polymer layer 510 are in place in the open mold. After the first element 560 is inserted into the mold, the second polymer layer 520 will form the layer of the can-shaped article that contacts the first element 560. The first polymer layer 510 will form the upper surface of the can-shaped article.

[0067] Figure 6 The mold 600 is shown closed to form a can or article 570 within the mold. The surface 650 of the first mold portion 610 is the upper surface 572 of the top layer 506 of the article. The sealed can can be produced by fusing or bonding the polymer layers at the flange 546, which can extend around the periphery of the can. The protrusion 535 on the first element 560 fits tightly into the groove 625 in the second portion 620 of the mold.

[0068] Given that the previously described methods and molds form parts satisfactorily, skilled practitioners recognize that removing a co-molded article from a mold can be difficult. As long as the co-molded article is sufficiently flexible and resilient, the article can be slightly deformed to remove it from an undercut mold. However, protrusions formed on the outer surface of the co-molded article in grooves and other features that extend the article into the mold can make it very difficult to remove the article from the mold.

[0069] Therefore, the present disclosure relates to a co-molded article in a mold, which minimizes the contact between a protrusion on the article and the surface of the mold. The co-molded article may include a preformed article. In some embodiments, the preformed article can substantially maintain its shape. In such an embodiment, the first element may be a preformed element placed in the mold, wherein the inner surface is substantially not interrupted by grooves and other features in which the protrusion may be formed. On the contrary, in such an embodiment, the first element is placed in the mold, with minimal interference or contact between the protrusion and the mold. The element, when placed in the mold, substantially maintains its shape. In some embodiments, the base surface or end surface of the protrusion may contact the surface of the mold, but the side of the protrusion is substantially not in contact with the mold. In this way, the co-molded article can be easily removed from the mold.

[0070] In some embodiments, a sole structure for an article of footwear may be manufactured according to a method for co-molding a first element and a second element to produce a co-molded article. Figure 7 , Figure 8 and Fig. 9 Depicted are stages of this method for co-molding a sole structure for an article of footwear.Mold 700 may have a first mold portion 710 and a second mold portion 720. Shape 750 on first mold portion 710 may form a top surface 741 of the co-molded article.

[0071] The first element 760 can have a top surface 761, an edge surface 762, and a protrusion 735 having a base 737 opposite the top surface 761. The edge surface 762 can extend any distance away from the top surface 761. The first element 760 can also have a bottom surface 794. The second element 765 can have an edge 743, an upper surface 741, and a lower surface 764.

[0072] Any suitable polymer material may be used to create the first element, which will be Figure 7 . Although each feature is illustrated as a single layer in the figure, each such feature may include a single layer of material or a multilayer of material and may be thermoformed or otherwise formed. Examples of polymeric materials that may be used for such sole structures include any of polyurethane, urethane, polyester, polyester polyurethane, polyether, polyether polyurethane, latex, polycaprolactone, polyoxypropylene, polycarbonate macroglycol, and mixtures thereof. These and other polymeric materials, exemplary embodiments, and methods for making these materials may be found in U.S. Pat. No. 9,420,848 to Campos II et al., the entire contents of which are incorporated herein by reference.

[0073] The outsole can generally be made of any durable material. Typically, the outsole material is tough, durable, wear-resistant, flexible and non-slip. In some embodiments, the polyurethane material is durable enough for ground contact. Suitable thermoplastic polyurethane elastomer materials include Bayer PTFE sheets available from Bayer. 285. Available from BASF SP9339, SP9324 and C705 is also suitable. In some embodiments, polyurethane and other polymers that may not be durable enough for direct ground contact can be used to produce a part of the outsole. In such an embodiment, the rubber outsole can be bonded or adhered to the outsole. In an embodiment, the outsole material is transparent or translucent. In an embodiment, the ground engaging projection can be produced integrally as a part of the outsole, or can be produced and bonded to the outsole separately. The outsole can have a textured ground engaging surface to improve traction.

[0074] like Figure 7 , Figure 8 and Fig. 9 As depicted in , first element 760 can be an outsole. For such an embodiment, according to the method, outsole 760 is positioned in second mold portion 720, wherein base 737 of protrusion 735 contacts surface 780 of second mold portion 720. Surface 780 of second mold portion 720 is shaped so as not to contact most of protrusion 735 except base 737. Protrusion 735 can be considered as a ground engaging portion, wherein its end is base 737 that engages the ground. As shown in FIG. Figure 7 and Figure 8As particularly depicted in FIG. 7 , outsole 760 may have a slight arc or curve that causes edge 762 to not contact edge 862 of second mold portion 720. Not all of base 737 may contact surface 780 simultaneously prior to molding with the second element.

[0075] The precursor for the second element (fluid-filled chamber) is placed in the mold and the mold is closed. The first polymer layer 810 can form the top surface 741 of the second element 765. The second polymer layer 820 can form the edge 743 of the second element 765 and the lower surface or bottom 764 of the second element or fluid-filled chamber 765.

[0076] like Figure 7 , each of the first polymer layer 810 and the second polymer layer 820 is initially located between the first mold portion 710 and the second mold portion 720 in a spaced apart or open configuration. In this position, the first polymer layer 810 is located adjacent to or closer to the first mold portion 710, and the second polymer layer 820 is located adjacent to or closer to the second mold portion 720. A shuttle frame or other device can be used to appropriately position the first polymer layer 810 and the second polymer layer 820. As part of the manufacturing process, one or both of the first polymer layer 810 and the second polymer layer 820 are heated to a temperature that is conducive to forming and bonding. As an example, various radiant heaters or other devices can be used to heat the first polymer layer 810 and the second polymer layer 820, possibly before being located between the first mold portion 710 and the second mold portion 720. As another example, the mold 700 can be heated so that the contact between the mold 700 and the first polymer layer 810 and the second polymer layer 820 at a later portion of the manufacturing process raises the temperature to a level that is conducive to forming and bonding.

[0077] Once first polymer layer 810 and second polymer layer 820 are properly positioned, first mold portion 710 and second mold portion 720 are translated or otherwise moved toward each other and begin closing over first polymer layer 810 and second polymer layer 820. Fluid under pressure may be introduced into fluid-filled chamber 765 to conform upper surface 741 of fluid-filled chamber 765 to shape 750 of first mold portion 710, to conform lower surface 764 of fluid-filled chamber or second element 765 to shape of upper surface 761 of first element 760, and to conform edge 743 of fluid-filled chamber 765 to edge surface 762 of first element 760 or edge 862 of second mold portion 720.

[0078] As fluid is injected into fluid-filled chamber 765, second polymer layer 820 may be urged toward top surface 761 of outsole 760, edge 762 of outsole 760, and edge 862 of second mold portion 720. As pressure in fluid-filled chamber 765 increases, pressure on outsole top surface 761 may cause base 737 on protrusion 735 to urge toward surface 780 of second mold portion 720. Similarly, pressure in fluid-filled chamber 765 may cause edge 743 of fluid-filled chamber 765 to urge toward edge 762 of outsole 760, and may cause both to urge toward edge 862 of second mold portion. Edge 743 may also be urged into contact with edge 862 of second mold portion 720, wherein edge 762 of outsole 760 is not excluded from contact with edge 862 of second mold portion 720.

[0079] As in Figure 8 and Fig. 9 As can be particularly seen in FIG. 1 , bottom surface 794 of outsole 760 may generally not contact bottom surface 780 of second mold portion 720, even after the fluid-filled chamber is fully molded. Although outsole 760 remains in place, it is less likely to be formed than from a mold that applies force on such protrusions (such as Figure 3 and Figure 4 In the process of demoulding, the demoulding is performed with less force. After the sole structure is demoulded, the fluid pressure in the fluid-filled chamber 765 can be adjusted.

[0080] Fig.10 and Fig.11 Another embodiment of a co-molded article in a process of producing a sole structure for an article of footwear is illustrated, which can be manufactured according to a method for co-molding a first element and a second element to produce a co-molded article. Mold 1100 can have a first mold portion 1110 and a second mold portion 1120. Shape 1150 on first mold portion 1110 can produce a top surface 1041 of the co-molded article.

[0081] Outsole 1060 may have a top surface 1061, an edge surface 1062, and a protrusion 1035 having a base 1037 opposite top surface 1061. Second element 1065 may have an edge 1043, an upper surface 1041, and a lower surface 1064. Figure 7 , Figure 8 and Fig. 9 As described, any suitable polymer material may be used to create the sole structure.

[0082] In some embodiments, such as Fig.10 and Fig.11In the depicted embodiment, first element 1060 may be an outsole. For such an embodiment, according to the method, outsole 1060 is positioned in second mold portion 1120 with base 1037 of protrusion 1035 in contact with surface 1180 of second mold portion 1120. Surface 1180 of second mold portion 1120 is shaped so as not to contact a substantial portion of protrusion 1035 other than base 1037. Protrusion 1035 may be a ground engaging portion, with its end being a base 1037 that engages the ground. Fig.10 As particularly depicted in FIG. 1 , outsole 1060 may have a slight arc or curve that causes edge 1062 to not contact edge 1162 of second mold portion 1120. Outsole 1060 may include flange 1063 that may provide additional support to the sole structure.

[0083] The precursor for the second element (fluid-filled chamber) is placed in the mold and the mold is closed. The first polymer layer 1010 can produce the top surface 1041 of the second element 1065. The second polymer layer 1020 can form the edge 1043 and the lower surface or bottom 1064 of the second element or fluid-filled chamber 765.

[0084] like Fig.10 and Fig.11 As depicted in FIG. 1 , each of first polymer layer 1010 and second polymer layer 1020 is initially positioned between each of first mold portion 1110 and second mold portion 1120 in a spaced-apart or open configuration. Figure 7 , Figure 8 and Fig. 9 As described, a polymer layer is placed and heated.

[0085] Fluid under pressure can be introduced into the fluid-filled chamber 1065 as the fluid-filled chamber 1065 is formed so that the upper surface 1041 of the fluid-filled chamber 1065 conforms to the shape 1150 of the first mold portion, so that the lower surface 1064 of the fluid-filled chamber or second element 1065 conforms to the shape of the top surface 1061 of the first element or outsole 1060, and so that the edge 1043 of the fluid-filled chamber 1065 conforms to the edge surface 1062 of the outsole 1060 or the edge 1162 of the second mold portion 1120.

[0086] As fluid is injected into fluid-filled chamber 1065, second polymer layer 1020 may be urged toward top surface 1061 of outsole 1060, edge 1062 of outsole 1060, and edge 1162 of second mold portion 1120. As pressure in fluid-filled chamber 1065 increases, pressure on outsole top surface 1061 may cause base 1037 on protrusion 1035 to urge toward surface 1080 of second mold portion 1120. Similarly, pressure in fluid-filled chamber 1065 may cause edge 1043 of fluid-filled chamber 1065 to urge toward edge 1062 of outsole 1060, and may cause both to urge toward edge 1162 of second mold portion. Edge 1043 may also be urged into contact with edge 1162 of second mold portion 1120, wherein edge 1062 of outsole 1060 is not excluded from contact with edge 1162 of second mold portion 1120.

[0087] As in Fig.11 1060, bottom surface 1094 of outsole 1060 may not generally contact bottom surface 1180 of second mold portion 1120, even after fluid-filled chamber 1060 is fully molded. Although outsole 1060 is held in place during molding, demolding is performed with less force than from a mold that exerts force on such protrusions. After the sole structure is demolded, the fluid pressure in fluid-filled chamber 1065 may be adjusted. After the sole structure is demolded, the fluid pressure in fluid-filled chamber 1065 may be adjusted.

[0088] Embodiments of the present disclosure may be molded from any moldable sheet material, such as a thermoplastic polymer. Embodiments may also have any function, and may have any shape that may be molded. Embodiments accommodate pressurization of the mold after the bottom layer of the object is inserted into the mold, such that the pressure will push the layer to contact the fixed object, contact the edge of the fixed object or the mold, and push the fixed object toward the mold.

[0089] In some embodiments, the shape of the co-molded article can create a container. Fig.12 and Fig.13 A container with legs is depicted. The container may be a first element 1260, which may be characterized as a shell 1260. Fig.12As depicted in , first element or shell 1260 has been placed in second mold portion 1320. Shell 1260 may have feet or protrusions 1235, wherein the feet have bottoms 1237. Second mold portion 1320 may include bottom surface 1280. In some embodiments, bottom surface 1280 may not contact each bottom 1237 of feet 1235. Shell 1260 may have a shape that includes a slight arc. Therefore, whether each bottom 1237 of feet 1235 contacts bottom surface 1280 depends on the arrangement of feet 1235 and whether shell 1260 can have an arc when placed in second mold portion 1320. In such an embodiment, the arc may be manifested in object edge 1262. As shown in FIG. Fig.12 As depicted in , object edge 1262 shows such an arc such that object edge 1262 does not contact mold edge 1362.

[0090] like Fig.13 As depicted in FIG. 1 , before closing the mold, a first polymer web and a second polymer web are placed between the first mold portion 1310 and the second mold portion 1320 in the mold 1300 to contact with each other. Figure 7 , Figure 8 and Fig. 9 The described method is performed in essentially the same way.

[0091] In some embodiments, box top 1206 created from the first polymer layer may be bonded or otherwise attached to second polymer layer 1208, which forms the remainder of the box at flange 1246. The top surface of box top 1206 is shaped by surface 1350 to form box surface 1212.

[0092] Fluid can be injected into the volume formed by the second polymer layer 1208 and the box-shaped member top 1206. The fluid can be a gas, a liquid or a gel. Injecting the fluid into the box-shaped member 1265 can cause the second polymer layer 1208 to be pushed toward the top surface 1246 of the shell 1260, the edge 1262 of the shell 1260, and the edge 1362 of the second mold part 1320. As the pressure in the box-shaped member 1265 increases, the pressure on the first element bottom surface 1264 can cause the base 1237 on the protrusion 1235 to be pushed toward the surface 1280 of the second mold part 1320. Similarly, the pressure in the shell 1260 can cause the edge 1243 of the second polymer layer to be pushed toward the edge 1262 of the shell 1260, and can cause both to be pushed toward the edge 1362 of the second mold part 1320. Edge 1243 may also be advanced into contact with edge 1362 of second mold portion 1320 , wherein edge 1262 of shell 1260 is not excluded from contact with edge 1362 of second mold portion 1320 .

[0093] As in Fig.13 As can be particularly seen in FIG. 1 , the bottom surface 1294 of the shell 1260 may generally not contact the bottom surface 1390 of the second mold portion 1320, even after the shell is fully molded. Although the shell 1260 is held in place, demolding is performed with less force than from a mold that exerts force on such protrusions 1235. After the co-molded article is demolded, the fluid pressure in the box-shaped member 1265 can be adjusted.

[0094] Embodiments include articles manufactured according to the methods disclosed herein. Embodiments of these articles may be sole structures for articles of footwear, as described herein. Such sole structures may be attached to the uppers for articles of footwear to produce articles of footwear. The uppers for articles of footwear may be composed of any suitable material elements. For example, such material elements may include, for example, textiles, foams, leather, and synthetic leather. More than one material may be present in the uppers. The sole structures may be attached to the uppers by bonding, sewing or stitching or by any method known to technical practitioners.

[0095] Fig.14 An article of footwear 3100 is shown having a sole structure 3130 secured to an outer periphery of an upper 3120. Fig.15 Also shown in, or fixed to Figure 1 The upper 120 of the shoe. The sole structure 3130 can be fixed to the bottom surface of the upper 3120, or a strobel, a lasting board, or a foam layer can be fixed to the upper 3120, and the sole structure 3130 can be fixed to the bottom surface of the strobel, the lasting board, or the foam layer. The sole structure 3130 is located under the foot and supports the foot. The main elements of the sole structure 3130 are the forefoot sole structure 3131 and the heel sole structure 3132. The sole structure 3130 has a forefoot area 3134, a midsole area 3133, and a heel area 3136 and extends from the medial side 3137 to the lateral side 3138.

[0096] The forefoot sole structure 3131 includes a forefoot midsole, which in the illustrated embodiment is a polymer bladder element 3140 and is also referred to as a forefoot component, a forefoot bladder element, or a fluid-filled chamber. Fig.16 The polymer bladder element 3150 is best shown in FIG. Fig. 20 The bladder member 3140 surrounds Fig.15 and 163142. Similarly, the heel sole structure 3132 includes a heel midsole, which in the illustrated embodiment is a polymer bladder element 3150 and is also referred to as a heel component, heel bladder element, or fluid-filled chamber. The bladder element 3150 surrounds Fig.15 and Fig. 20 The fluid indicated in FIG. 1 fills the interior cavity 3152. The bladder members 3140, 3150 are Fig.14 Between the outsole member and the upper 3120 of the bottom view, as shown Fig.15 Best shown in .

[0097] The bladder members 3140 and 3150 are separated from each other and are not in fluid communication with each other. The bladder member 3140 has a plurality of tubular portions having an arcuate shape (e.g., a generally U-shaped shape), such that the fluid-filled interior cavity 3142 has corresponding tubular portions 3142A, 3142B, 3142C, 3142D, and 3142E interconnected and in fluid communication with each other via a channel 3143, as shown in FIG. Fig.16 The bladder member 3150 has a plurality of interconnected portions arranged in a U-shape such that the fluid filled interior cavity 3152 has a plurality of portions 3152A, 3152B, 3152C, 3152D and 3152E interconnected by passages 3153 and in fluid communication with each other, as shown in FIG. Fig. 20 The polymer bladder element 3140 is configured such that the curved portion of the fluid-filled interior cavity 3142 is at the outer periphery in the forefoot region 3134 of the sole structure 3131, as shown in FIG. Fig.15 The bladder member 3140 has an arcuate tubular portion 3149 in the forefoot region of the sole structure, as shown in FIG. Fig.16 3149. The arcuate tubular portion 3149 has an inner curved wall 3151 that has a tighter curvature than the outer wall of the arcuate tubular portion 3149. In other words, the inner curved wall 3151 is at the inner side of the U-shaped arcuate tubular portion 3149. The side surface 3079 of the bladder member 3140 is at the inner curved wall 3151 to which the first wall of the first outsole component is secured. Thus, during flexion of the forefoot region, the inner wall 3099 can support and reinforce both the second wall 3087 and the inner curved wall 3151 of the bladder member 3140 at the arcuate tubular portion. Such support and reinforcement should reduce stress on the second wall 3087 to prevent cracking of the second wall 3087.

[0098] The bladder members 3140, 3150 can each be formed from Fig.24 and 27The upper sheet 3144 and lower sheet 3146 shown in and described in this article are thermoformed (also referred to as the first sheet and the second sheet, the first layer and the second layer, or the upper layer and the lower layer), or in an alternative, can be blow molded. The sheet can have alternating TPU layers and gas barrier material layers. In any embodiment, each bladder element 3140, 3150 is configured to keep the fluid in the fluid-filled internal cavity 3142, 3152. As used herein, "fluid" includes gas, and the gas includes air, an inert gas (such as nitrogen) or another gas. Therefore, "fluid filling" includes "gas filling". The various materials used for bladder elements 3140, 3150 can be substantially transparent or can have a colored color. For example, bladder elements 3140, 3150 can be formed by any of the various polymer materials that can keep the fluid at a predetermined pressure, including a fluid that is a gas (such as air, nitrogen or another gas). For example, bladder members 3140, 3150 can be thermoplastic urethane (TPU) material, urethane, polyurethane, polyester, polyester polyurethane, and / or polyether polyurethane.

[0099] In addition, in one embodiment, the bladder member 3140, 3150 can be formed by one or more sheets having different material layers. The sheet can be a laminated film formed by a thin film having one or more first layers, the one or more first layers comprising a thermoplastic polyurethane layer and alternating with one or more second layers, also referred to herein as a barrier layer, a gas barrier polymer or a gas barrier layer. The second layer can include a copolymer of ethylene and vinyl alcohol (EVOH), which is impermeable to the pressurized fluid contained therein, as disclosed in U.S. Pat. No. 6,082,025 of Bonk et al., which is incorporated by reference in its entirety. The first layer can be arranged to form the outer surface of the polymer sheet. That is, the outermost first layer can be the outer surface of the bladder member 3140 or 3150. The bladder members 3140, 3150 may also be formed of a material comprising alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. Pat. Nos. 5,713,141 and 5,952,065 to Mitchell et al., which are incorporated by reference in their entirety. Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and regrind material of ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. Each sheet may also be a flexible microlayer film comprising alternating layers of a gas barrier polymer material (such as a second layer) and an elastomeric material (such as a first layer), as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk et al., which are incorporated by reference in their entirety. Additional suitable materials for the bladder members 3140, 3150 are disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy, which are incorporated by reference in their entirety. Other suitable materials for the bladder members 3140, 3150 include thermoplastic films containing crystalline materials, such as disclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy, and polyurethanes including polyester polyols, such as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk et al., which are incorporated by reference in their entireties. In selecting materials for the bladder members 3140, 3150, engineering properties such as tensile strength, stretch properties, fatigue properties, dynamic modulus, and loss factor may be considered. When the bladder members 3140 or 3150 are formed from a sheet, the thickness of the sheet used to form the bladder members 3140 or 3150 may be selected to provide these properties.

[0100] Forefoot bladder member 3140 and heel bladder member 3150 are formed of a polymer material surrounding a fluid, which may be a gas, liquid, or gel. For example, during walking and running, forefoot bladder member 3140 and heel bladder member 3150 may be compressed between the foot and the ground, thereby attenuating ground reaction forces. That is, after thermoforming, forefoot bladder member 3140 and heel bladder member 3150 are filled and typically pressurized with a fluid to cushion the foot. Fig.14 A sealed filling port 3155 is shown through which fluid is introduced into the internal chambers 3142, 3152 prior to sealing.

[0101] In some configurations, the sole structure 3130 may include a foam layer, for example, extending between the upper 3120 and one or both of the forefoot bag element 3140 and the heel bag element 3150, or the foam element may be located within a recess in a lower area of ​​the forefoot bag element 3140 and the heel bag element 3150. In other configurations, the forefoot sole structure 3131 may include a plate, adjuster, permanent element, or motion control member to further attenuate forces, enhance stability, or affect the movement of the foot. The heel sole structure 3132 may also include such a member for further attenuating forces, enhancing stability, or affecting the movement of the foot.

[0102] The forefoot sole structure 3131 also includes a first outsole component 3060 secured to the bag element 3140, and a plurality of second outsole components 3062 secured to the first outsole component 3060, as described herein. Fig.17 and Fig.18 In Fig.14 3062 is secured to the first outsole component. The heel sole structure 3132 includes a first outsole component 3070 and a second outsole component 3072 secured to the first outsole component 3070, as described herein. The first outsole component 3070 is secured to the first outsole component 3070. Fig.21 and Fig. 22 As shown in Fig.14 As shown in , the second outsole member 3072 is fixed to the first outsole member 3070. Fig.15 The first outsole components 3060, 3070 are shown secured to the bladder members 3140 and 3150 with the second outsole components 3062, 3072 removed.

[0103] In addition to providing a wear surface (i.e., ground engaging surface) for an article of footwear, the forefoot outsole component 3060 and the heel outsole component 3070 can enhance various properties and characteristics of the sole structure 3130. The properties and characteristics of the outsole (such as thickness, flexibility, properties and characteristics of the material used to make the outsole, and stretch) can be changed or selected to modify or otherwise adjust the cushioning response, compressibility, flexibility, and other properties and characteristics of the sole structure 3130. In the illustrated embodiment, the first outsole component is a first material and the second outsole component is a second material different from the first material. The first outsole components 3060 and 3070 are injection molded thermoplastic polyurethane (TPU) components that are preformed in their desired shape and configuration by an injection molding process before being thermally bonded to the corresponding bladder elements 3140, 3150 by the methods described herein. As described herein, the second outsole components 3062, 3072 are rubber and are preformed in their desired shape and then secured to the first outsole component 3060 or 3070. The first outsole component 3060 is a single integral one-piece component and the first outsole component 3070 is a single integral one-piece component. Each of the second outsole components 3062 and 3072 is also a single integral one-piece component.

[0104] The forefoot outsole component 3060 is fixed to the lower surface of the forefoot bag element 3140. In some embodiments, the forefoot sole structure 3131 can extend into the mid-shoe area. The forefoot outsole component 3060 can also be fixed to the lower area of ​​the forefoot bag element 3140 in the mid-shoe area. The heel outsole component 3070 is fixed to the lower area of ​​the heel bag element 3150. Both the heel bag element 3150 and the heel outsole component 3070 can extend into the mid-shoe area. The forefoot outsole component 3060 and the heel outsole component 3070 can be formed by wear-resistant materials. The wear-resistant material can be transparent or translucent to provide visually attractive effects. The wear-resistant material can be textured on the ground engagement surface to impart traction, such as imparting traction by including the integrated tread elements 3135, 3091 as described herein. Any or all components of the forefoot sole structure 3131 and the heel sole structure 3132 may be translucent or transparent and may be colored or patterned for an aesthetic appearance.

[0105] Fig.14 , 17 18 also illustrates the gas escape openings 2069 in the first outsole member 3060 of the forefoot sole structure 3131, and Fig.14 , 2122 illustrate gas escape openings 2079 in the first outsole component 3070 of the heel sole structure 3132, only some of which are indicated by reference numerals. These gas escape openings allow air or other gases trapped between the bladder element and the corresponding outsole component to escape during manufacturing. The medial surface of the outsole component can be shaped in a manner that can accumulate trapped gas and direct the trapped gas to the gas escape openings. For example, small interconnected grooves 2071 can be formed on the medial surface of the outsole component 3060 during injection molding, or can be provided in the surface by removing material after molding. Fig.19 As shown in , the gas escape opening 2069 is at the bottom of the groove 2071. Fig. 22 As shown in FIG. 1 , the first outsole member 3070 also has grooves 2071 on the inner surface, which guide the trapped gas to the gas escape openings 2079. The gas escape openings 2079 are in fluid communication with the grooves 3071.

[0106] The outsole reinforcements (e.g., including structural elements such as ribs), holes, the height of the outsole walls, the number and location of the outsole walls and overlapping bladder element walls (also referred to as bladder element edges), or other outsole features can be used to adjust the response of the sole structure. In particular, the overlap of the outsole element wall with the side wall of the forefoot bladder element or the heel bladder element or with the side wall of the underlying outsole element, such as at least at Figure 14-28 As described and illustrated in the accompanying drawings, the elastic response and cushioning response of the composite sole structure can be adjusted. Using the guidance provided herein, these and other properties and characteristics of the outsole in combination with the properties and characteristics of the fluid-filled bladder element can be selected and configured to provide the desired cushioning response.

[0107] exist Figures 14 to 28 as shown in and in accordance with Figure 25 to Figure 28 In the described embodiment of manufacture, the configuration of the first outsole components 3060 and 3070 supports the respective bladder elements 3140 and 3150 and allows the second outsole component 3062 or 3072 to be received and partially nested within the recess 4050 in the first outsole component 3060 or within the recess 4150 in the first outsole component 3070. The recesses 4050 and 4150 provide positioning guides during assembly and, as discussed herein, protect the second outsole components 3062 and 3072 from delamination during wear. In addition, both the first outsole components 3060, 3070 and the second outsole components 3062, 3072 have tread elements 3135, 3091, respectively, which establish the ground engaging surface of the sole structure (at Fig.24In the embodiment of the present invention, different traction properties can be provided at the locations of tread elements 3135, 3091 by using different shapes, sizes of tread elements 3135, 3091 and / or by using different materials for first outsole component 3060 and second outsole component 3062. Tread elements 3135, 3091 can be protrusions, ridges or ground engaging projections or sections that impart traction. Fig.14 As shown in FIG. 1 , tread element 3135 has different sizes and shapes, including rectangular and trapezoidal. Tread element 3091 is generally larger than tread element 3135. Depending on the material used for outsole components 3060, 3062, 3070, 3072, second outsole components 3062, 3072 can provide increased traction or reduced traction relative to first outsole components 3060, 3070.

[0108] like Fig.17 and 20 , tread element 3135 of first outsole component 3060, 3070 is an integral part of the first outsole component (i.e., tread element 3135 is formed with the base and walls by injection molding of the first outsole component), and tread element 3091 of second outsole component 3062 or 3072 is likewise an integral part of a one-piece, unitary second outsole component 3062 or 3072. The configuration of the outsole components in this manner simplifies manufacturing and reduces the likelihood of the tread element becoming separated from the base of the outsole components during wear.

[0109] Fig.17 and Fig.18 The first outsole member 3060 is shown prior to being attached to the second outsole member 3062. Fig.21 and Fig. 22 The first outsole member 3070 is shown prior to attachment of the second outsole member 3072. Fig.23 and Fig.24 A first outsole component 3060 is shown attached to a bottom surface 3080 of a bag member 3140 and to side surfaces 3078, 3079 of the bag member 3140. More specifically, the first outsole component 3060 has a first base 3083 attached to the bottom surface 3080 of the bag member 3140, a first wall 3085 integrally secured with the first base 3083 to the side surface 3078 of the bag member 3140, and a second wall 3087 integrally secured with the first base 3083 and to the side surface 3079 of the bag member 3140. As shown by Fig.14 In Fig.23 and Fig.24 The location of the cross section is indicated, and as Fig.18As shown in FIG, first wall 3085 and second wall 3087 are at an arcuate portion of the fluid-filled interior cavity 3142. Second wall 3092 of second outsole member 3062 is at an arcuate portion.

[0110] The first outsole member 3060 has an integrated tread element 3135 at a predetermined portion of the bottom surface 3081 of the first outsole member, while the other portions have no tread element. Fig.24 A base 3083 of a first outsole component 3060 is shown attached to a first bladder member 3140 and having an integral tread element 3135 at a first portion 3082 of a bottom surface 3081 of the base 3083. A second portion 3084 of the bottom surface 3081 of the base 3083 is free of any tread elements 3135. Another portion of the first outsole component 3060 shown attached to the bladder member 3140 also has a base 3083 and walls 3085, 3087 integral with the base 3083, wherein the first portion 3082 of the base 3083 has an integral tread element 3135 and the second portion 3084 is free of any tread elements. At least some of the tread-free portions are free of tread elements 3135, particularly because the second outsole component 3062 with its own integral tread element will be attached at the second portion 3084, as shown. Fig.14 In this way, no tread elements of the first outsole component 3060 will interfere with the attachment of the second outsole component 3062.

[0111] The second outsole member 3062 has a second base 3090 and optionally includes one or more integral tread elements 3091. The second base 3090 is secured to a second portion 3084 of the bottom surface 3081 of the first base 3083. The second outsole member 3062 has a second wall 3092 that is integral with the second base 3090. The second wall 3092 is secured to an outer surface 3094 of the first wall 3085 of the first outsole member 3060. The outer surface 3094 is adjacent to the second portion 3084 of the bottom surface 3081. With this configuration, the ground engaging surface 3098 of the sole structure 3131 includes the integral tread element 3135 of the first outsole member 3060 and the integral tread element 3091 of the second outsole member 3062.

[0112] Similarly, if Fig.21 and 224, the first outsole member 3070 of the heel sole structure 3132 has an integral tread element 3135 at a predetermined portion of the bottom surface 4002 of the first outsole member 3070, such as at a first area 4004, and has a second area 4006 without any tread elements. The first outsole member 3070 has a first base 4008 and an integral first wall 4010 extending from the first base adjacent to the second area 4006. The first wall 4010 is an outer wall. The first outsole member 3070 also has a second wall, referred to as an inner wall 4011, which is integral with the first base 4008.

[0113] The second outsole member 3072 has a second base 4012 fixed to the first base 4008. The second outsole member 3072 has a second wall 4014 (i.e., an outer wall) that is integral with the second base 4012 and fixed to an outer surface 4016 of the first wall 4010. Fig.14 , 15 As apparent in FIGS. 21 and 21 , the second outsole member 3072 has an inner wall 4015 that is integral with the second base 4012 and fixed to an outer surface 4017 of the second wall 4011 .

[0114] like Fig.23 3070, the first outsole component 3060 has an arcuate shape corresponding to the arcuate shape of the fluid-filled interior cavity 3142, wherein the first wall 3085 is at the outer periphery of the arcuate portion of the fluid-filled interior cavity 3142. The second wall 3092 of the second outsole component 3062 is also at the arcuate portion. Thus, the first wall 3085 and the second wall 3092 are outer walls. The second wall 3087 of the first outsole component 3060 is an inner wall located at the inner curve of the arcuate portion. The inner wall 3099 of the second outsole component 3062 is also at the inner curve of the arcuate portion. The tubular arcuate portion of the bladder member supported by the outer and inner walls of the outsole components 3060, 3070 provides support to act as a geometric constraint on the bladder member 3140 and provides stiffness to adjust the cushioning response of the bladder member 3140.

[0115] Reinforcements of the outsole components 3060, 3062, 3070, 3072 (e.g., comprising structural elements such as ribs), holes, the height of the walls 3085, 3087, 3092, 3099 of the outsole components 3060, 3062, 3070, 3072, the number and position of overlapping walls of the outsole components 3060, 3062, 3070, 3072 and overlapping walls of the bladder elements 3140, 3150 (also referred to as edges of the bladder elements), or other features of the outsole components 3060, 3062, 3070, 3072 may also be used to adjust the response of the sole structures 3131 and 3132. In particular, the overlap of the walls 3085, 3087, 4010, 4011 of the first outsole components 3060, 3070 away from the corresponding base portion 4008 and upward along the side surfaces 3078, 3079 of the forefoot bag element 3140 or upward along the side surface of the heel bag element 3150 and the overlap of the walls 3092, 3099, 4014 of the second outsole components 3062, 3072 away from the corresponding base portion and upward along the walls 3085, 3087, 4010, 4011 of the corresponding first outsole components 3060, 3070 (such as at least Figures 15 to 24 ) can be used to adjust the elastic response and cushioning response of the composite sole structures 3131, 3132. Using the guidance provided herein, these and other properties and characteristics of outsole components 3060, 3062, 3070, 3072 in combination with the properties and characteristics of fluid-filled bladder elements 3140, 3150 can be selected and constructed to provide a desired cushioning response.

[0116] The first outsole component 3060 and the second outsole component 3062 are cooperatively configured to fit together to help position the second outsole component 3062 on the first outsole component 3060 and reduce the likelihood that the second outsole component 3062 will separate from the first outsole component 3060 during wear. More specifically, and as Fig.24 As best shown in FIG. 1 , the outer surface 3094 of the first wall 3085 of the first outsole member 3060 has a recess 4050. When the forefoot sole structure 3131 is thermoformed, the recess 4050 is adjacent to the second portion 3084 of the bottom surface 3081 of the first outsole member 3060, such as Fig.24 As shown in . Fig.25 and Fig.26, the recess 4050 is provided by the shape of the injection mold 5010 that injection molds the first outsole component 3060. In an embodiment, the injection mold 5010 can have an upper mold 5012 and a lower mold 5014, each having mold surfaces 5016, 5018. While the first outsole component 3060 is molded to the contours of the mold surfaces 5016, 5018, the TPU material is injected through the port 5020. The protrusion 5022 in the lower mold 5014 causes the recess 4050 in the first wall 3085 of the medial side of the first outsole component 3060. Similar protrusions 5022 cause the recess 4050 in the first wall 3085 of the lateral side of the first outsole component 3060. The mold surface 5018 also has a recess 5026 that creates the tread element 3135. Additionally, the mold surfaces 5016, 5018 are formed such that the second wall 3087 (ie, inner wall) of the first outsole component 3060 has a greater height than the first wall 3085 (ie, outer wall) of the first outsole component 3060 and such that the upper ends 4070, 4072 of the walls 3085, 3087 taper.

[0117] The second wall 3092 of the second outsole component 3062 is configured so that it can fit within and be secured to the outer surface of the first wall 3085 of the first outsole component 3060 in the recess 4050. The first outsole component 3070 and the second outsole component 3072 of the heel sole structure 3132 are cooperatively configured in the same manner.

[0118] In addition, if Fig.24 4050, the second wall 3092 has a first thickness T1, and the recess 4050 has a first depth D1. The first thickness T1 is greater than the first depth D1, so that the second outsole component 3062 protrudes outward from the first outsole component 3060 at the first wall 3085. The upper edge 4060 of the second outsole component 3062 abuts on or just below the lip 4062 of the first outsole component 3060 in the recess 4050. The lip 4062 protects the upper edge 4060 from directly applied forces during use, thereby reducing the possibility of delamination or other misalignment of the second outsole component 3062.

[0119] like Fig.233090, the inner wall 3099 of the second outsole component 3062 extends upwardly from the second base 3090 of the second outsole component further than the second wall 3092 (i.e., the outer wall) of the second outsole component. Support of the bladder member 3040 at the inner wall 3099 is desirable to limit the inward movement of the bladder member 3040 during compression and deformation. The second outsole component 3062 of the bladder member 3050 can be similarly configured, wherein the inner wall extends upwardly along the inner wall of the first outsole component 3070 further than the outer wall.

[0120] In the illustrated embodiment, the recess 4050 extends through the bottom surface of the inner wall 3087 of the first outsole component 3060 and extends upward along the outer surface of the inner wall 3087 of the first outsole component 3060. Fig.23 3087 of the first outsole member 3060. Fig.18 ), to help prevent delamination of the first outsole component 3060 from the bladder element 3140. The first outsole component 3070 is similarly configured with a tapered upper end 4073 at the first wall 4010. Fig.14 and Fig. 22 As indicated in the figure, the upper end 4074 of the first outsole member 3070 continues upward along the inner wall of the tubular portion of the lower polymer sheet 3146 of the bladder member 3050 to the lower surface of the lower polymer sheet 3146 adjacent to the tubular portion to provide maximum support against the inner wall of the bladder member 3150.

[0121] A method of manufacturing an article of footwear including the sole structure 3131 and / or the sole structure 3132 as described above includes placing a preformed first outsole component 3160 into a thermoforming mold 6012, 6014. Fig. 27 In FIG. 6 , the thermoforming mold is schematically depicted as including an upper mold 6012 and a lower mold 6014. Fig.25 and Fig.26 Described and in Fig.17 and Fig.18, the first outsole component 3060 is preformed with a base 3083 having an integral tread element 3135 protruding from a first portion 3082 of a bottom surface 3081 of the base; a second portion 3084 of the bottom surface 3081 is preformed without any tread elements; and a wall 3085 is preformed that is integral with the base 3083 and adjacent to the second portion 3084 of the bottom surface. As used herein, "preformed" means that the first outsole component 3060 has certain features prior to the thermoforming process (i.e., prior to placement in the thermoforming molds 6012, 6014).

[0122] In an embodiment, the lower mold 6014 may have one or more positioning marks to orient the first outsole component 3060. Fig. 27 60, second mold surface 6018 has positioning mark 6024, and placing first outsole component 3060 into lower mold 6014 includes placing a predetermined portion of first outsole component 3060 at positioning mark 6024, thereby orienting first outsole component 3060 at a predetermined position in thermoforming mold 6014. Positioning mark 6024 is a cavity in second mold surface 6018, and the predetermined portion of first outsole component 3060 is one of tread elements 3135. Other alternative positioning marks may be used instead of or in addition to positioning mark 6024.

[0123] The method also includes placing a polymer material in a thermoforming mold 6012, 6014 along with the first outsole component 3060. The polymer material may be a first polymer sheet 3144 and a second polymer sheet 3146, also referred to as an upper polymer sheet and a lower polymer sheet due to their relative positions in the finished article of footwear. Alternatively, the polymer material may be a preform (e.g., a polymer material that is not in sheet form).

[0124] The thermoforming molds 6012, 6014 are then closed by placing the upper mold 6012 and the lower mold 6014 together, as shown. Fig.28, to encapsulate the polymer material (i.e., the encapsulated portion of the sheets 3144, 3146) and the first outsole component 3060 in a mold cavity 6028 defined between a mold surface 6026 of an upper mold 6012 and a mold surface 6018 of a lower mold 6014. The method then includes forming the sheets 3144, 3146 by a combined thermoforming and vacuum forming process that includes applying a vacuum to conform a first portion of the polymer material (i.e., the encapsulated portion of the first sheet 3144) to a first mold surface (i.e., surface 6026) of the thermoforming mold, and to conform a second portion of the polymer material (i.e., the bottom surface 3080 of the encapsulated portion of the second sheet 3146) to an upper surface 3088 of the first outsole component 3060 and to the second mold surface 6018, with an interior cavity 3142 between the first sheet 3144 and the second sheet 3146. Fig.28 6014, lip 4062 of first outsole component 3060 is not apparent because it is compressed against mold surface 6018. After the thermoforming process is complete (i.e., after bladder element 3140 and first outsole component 3060 are removed from thermoforming molds 6012, 6014), interior cavity 3142 may be filled. A gap may exist between the bottom surface of first outsole component 3060 and mold surface 6018 to facilitate removal of the outsole surface after thermoforming.

[0125] In an embodiment where the polymer material is a first polymer sheet 3144 and a second polymer sheet 3146, the method then includes thermally bonding the first polymer sheet 3144 to the second polymer sheet 3146 to enclose an internal cavity 3142, and thermally bonding the lower surface 3080 of the second polymer sheet 3146 to the upper surface 3088 of the first outsole component.

[0126] The first polymer sheet 3144 and the second polymer sheet 3146 are thermally bonded to each other around a peripheral flange 3148 formed between the clamping surface 6030 and the seam forming surface 6070 and at a web area 3147 between portions of the fluid filled interior cavity 3142. When the molds 6012, 6014 are closed, the clamping surface 6030 contacts and slides against a portion of the second seam forming surface 6070. The contact between the clamping surface 6030 and the second seam forming surface 6070 effectively severs excess portions 6810, 6820 of the first polymer sheet 3144 and the second polymer sheet 3146 from the portion forming the bladder member 3140. The materials forming the first polymer sheet 3144 and the second polymer sheet 3146 are compacted or otherwise gathered to form the flange 3148. In addition to forming flange 3148 , first polymer sheet 3144 and second polymer sheet 3146 are (a) shaped to create bladder member 3140 , and (b) compressed and joined to create web region 3147 .

[0127] The thermoformed sheets 3144, 3146 are allowed to cool, and the molds 6012, 6014 are then opened by separating the upper and lower molds 6012, 6014, and after a predetermined cooling period, the heat-bonded upper and lower polymer sheets 3144, 3146 and the first outsole component 3060 are removed from the molds 6012, 6014 as a unit. If the molds 6012, 6014 are configured to mold multiple sole structures 3131, 3132 simultaneously, additional trimming may be necessary around the flange 3148 or between adjacent sole structures. The bladder element 3140 with the attached first outsole component 3060 may be filled after thermoforming and before attaching the second outsole component 3062, or may be filled after attaching the second outsole component 3062.

[0128] After the first outsole component 3060 is attached to the bag member 3140, the second outsole component 3062 is positioned on the second portion 3084 of the bottom surface 3080 of the first outsole component 3060. The second outsole component 3062 is positioned by nesting the second outsole component 3062 in the recess 4050. The nesting includes abutting the upper edge 4060 of the second outsole component 3062 against the lip 4062 of the first outsole component 3060 at the upper extent of the recess 4050, as shown in FIG. Fig.15 As indicated in relation to one of the outsole components 3062. Fig.15 , 23 24, the upper edge 4060 of the second outsole member 3062 abuts against the lip 4062 of the first outsole member 3060 in the recess 4050. The second outsole member 3062 is bonded to the first outsole member 3060. Fig.15 As shown in , the footwear upper 3120 is then secured to the upper surface 4041 of the first polymer sheet 3144. Fig.15 , flange 3148 is shown at the lateral side of the sole structure 3130 and is bonded to the lower lateral side of the upper 3120.

[0129] The method has been described with respect to the forefoot sole structure 3131. The method may also include injection molding the first outsole component 3070, vacuum / thermoforming the bladder element 3150 and heat bonding the first outsole component 3070 to the bladder element 3150 in the thermoforming mold, attaching the second outsole component 3072 to the first outsole component 3070 as described, and then securing the heel sole structure 3132 to the heel area of ​​the upper 3120, wherein the front edge 3110 of the heel sole structure is adjacent to the rear edge 3112 of the forefoot sole structure, as described. Fig.14 and Fig.15 As shown in .

[0130] Although several modes for implementing many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize that various alternative aspects for practicing the present teachings are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting.

Claims

1. A sole structure for an article of footwear, the sole structure comprising: a polymeric bladder element surrounding a fluid-filled interior cavity, wherein the polymeric bladder element is configured with an arcuate portion that arcs inwardly from an outer perimeter of the sole structure, the arcuate portion having an outer curved wall at the outer perimeter and an inner curved wall inboard of the outer curved wall; a first outsole component including a first base secured to a bottom surface of the arcuate portion of the polymeric bladder element and a wall integral with the first base, the wall including an outer curved wall extending from the first base and secured to the outer curved wall of the arcuate portion of the polymeric bladder element and an inner curved wall extending from the first base and secured to the inner curved wall of the arcuate portion of the polymeric bladder element; and a second outsole member including a second base portion secured to the first base portion, an outer curved wall secured to the outer curved wall of the first outsole member, and an inner curved wall secured to the inner curved wall of the first outsole member; The first base has an integral tread element protruding at a first portion of a bottom surface of the first base; wherein a second portion of the bottom surface of the first base is free of any tread elements.

2. The sole structure according to claim 1, wherein: The arcuate portion of the polymer bladder element is one of a plurality of arcuate portions of the polymer bladder element, including a medial arcuate portion arcuate from the outer periphery inwardly at the medial side of the sole structure, and a lateral arcuate portion arcuate from the outer periphery inwardly and toward the medial arcuate portion at the lateral side of the sole structure; wherein the first outsole component is fixed to both the medial arc portion and the lateral arc portion; wherein the second outsole component is a medial second outsole component fixed to the first outsole component at the medial arcuate portion; and The sole structure also includes a lateral second outsole member secured to the first outsole member at the lateral arcuate portion.

3. The sole structure according to claim 2, wherein: The first outsole component is a single, unitary, one-piece component; and Each of the medial second outsole element and the lateral second outsole element is a unitary, unitary, one-piece component.

4. The sole structure according to claim 3, wherein: The medial second outsole component is a first medial second outsole component, and the lateral second outsole component is a first lateral second outsole component; The inner arc portion is a first inner arc portion, and the outer arc portion is a first outer arc portion; The multiple arcuate portions of the polymer bladder element also include a second medial arcuate portion that is arcuate from the outer periphery inwardly behind the first medial arcuate portion and on the inner side of the sole structure, and a second outer side arcuate portion that is arcuate from the outer periphery inwardly and toward the second medial arcuate portion behind the first outer side arcuate portion and on the outer side of the sole structure.

5. The sole structure according to claim 4, further comprising: a second medial second outsole member secured to the first outsole member at said second medial arcuate portion; and A second lateral second outsole member is secured to the first outsole member at the second lateral arcuate portion.

6. The sole structure according to any one of claims 1 to 5, wherein: The thickness of both the outer curved wall and the inner curved wall of the first outsole member tapers toward an upper end.

7. The sole structure according to any one of claims 1 to 5, wherein: The first outsole component is a first material and the second outsole component is a second material different than the first material.

8. The sole structure according to claim 7, wherein: The first outsole component is thermoplastic polyurethane and the second outsole component is rubber.

9. The sole structure according to any one of claims 1 to 5, wherein: The sole structure includes a forefoot sole structure configured for a forefoot region of the article of footwear.

10. The sole structure according to claim 9, further comprising: A heel sole structure configured for use in a heel region of an article of footwear, wherein the heel sole structure comprises: a midsole having a polymeric bladder element enclosing a separate fluid-filled interior cavity separate from the fluid-filled interior cavity of the polymeric bladder element of the forefoot sole structure; The first outsole component is secured to a bottom surface of a polymeric bladder element of a heel sole structure; and The second outsole component is secured to the first outsole component of the heel sole structure.

11. The sole structure according to any one of claims 1 to 5, wherein: The outer surface of the outer curved wall of the first outsole component has a recess; and The outer curved wall of the second outsole component is secured to an outer surface of the outer curved wall of the first outsole component within the recess.

12. The sole structure according to claim 11, wherein: The outer curved wall of the second outsole member has a first thickness; The recess has a first depth; and The first thickness is greater than the first depth such that the second outsole member protrudes outwardly from the first outsole member at an outer curved wall of the second outsole member.

13. The sole structure according to any one of claims 1 to 5, wherein: the arcuate portion of the polymeric bladder element having a U-shape with arms extending inwardly from an outer perimeter of the sole structure; the first outsole component having a U-shape corresponding to the U-shape of the curved portion of the fluid-filled interior cavity; and The second outsole component has a U-shape that corresponds to an exterior portion of the U-shape of the first outsole component and terminates at a location closer to an outer perimeter of the sole structure than the first outsole component.

14. The sole structure according to claim 13, wherein: A first portion of the bottom surface of the first base is further away from the outer perimeter of the sole structure than the second outsole component.

15. The sole structure according to any one of claims 1 to 5, wherein: The first outsole member includes an opening extending through the first outsole member; and The second outsole member is disposed over the opening.

16. The sole structure according to claim 1, wherein: The second outsole member has an integral tread element.

Images