Footwear strobells with bladders having grooved flanges and methods of manufacture

Abstract

The invention relates to a footwear strobel with a bladder having a fluted flange and a method of manufacture. A strobel for an article of footwear includes a polymeric bladder defining a lumen. The polymeric bladder is configured to retain a fluid in the lumen. The polymeric bladder has a peripheral flange extending around at least a portion of a perimeter of the lumen. The peripheral flange defines a groove extending along the peripheral flange. The polymeric bladder may include a first polymeric sheet bonded to a second polymeric sheet at a peripheral flange and joined to the second polymeric sheet at a plurality of internal welds, each of the plurality of internal welds extending only partially across the interior cavity. Methods of manufacturing a strobel and manufacturing footwear are included.

Description

[0001] This application is a divisional application of an application with an application date of May 31, 2019, application number 202210664166.8, and invention name “Footwear Strobel with a bladder having a groove flange and a manufacturing method”.

[0002] The application with the application date of May 31, 2019, the application number of 202210664166.8, and the invention name of “Footwear Strobel with a bladder with grooved flange and manufacturing method” is a divisional application of the application with the application date of May 31, 2019, the application number of 201980034600.0, and the invention name of “Footwear Strobel with a bladder with grooved flange and manufacturing method”.

[0003] CROSS-REFERENCE TO RELATED APPLICATIONS

[0004] This application claims the benefit of priority to U.S. Provisional Application No. 62 / 678,722, filed May 31, 2018, which is incorporated by reference in its entirety. Technical Field

[0005] The present teachings generally include strobels (midsole fabrics) for use in articles of footwear and methods of making footwear. background

[0007] Articles of footwear generally include two major elements: an upper and a sole structure. The sole structure is configured to be positioned under a wearer's foot to space the foot from the ground. One method of manufacturing an article of footwear involves the use of a lasting process. The upper is tightened around the last, thereby imparting the general shape of the foot to the cavity within the upper. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a schematic illustration of a bottom view of a Strobel for a first embodiment of an article of footwear.

[0009] Figure 2 The orientation of the internal weld is shown Figure 1 Schematic illustration of a partial bottom view of the Stronbel.

[0010] Figure 3 yes Figure 1 Schematic illustration of a top view of a Strobel.

[0011] Figure 4 is Figure 3 The line 4-4 in Figure 1 Schematic illustration of a cross-sectional view of a Strobel.

[0012] Figure 5 yes Figure 1 Schematic illustration of a partial cross-sectional view of a flange of a Strobel and an upper sewn to the flange in a first arrangement.

[0013] Figure 6 yes Figure 1 Schematic illustration of a partial cross-sectional view of a flange of a Strobel and an upper sewn to the flange in a second arrangement.

[0014] Figure 7 yes Figure 1 Schematic illustration of a partial cross-sectional view of a flange of a Strobel and an upper sewn to the flange in a third arrangement.

[0015] Figure 8 yes Figure 1 Schematic illustration of a partial cross-sectional view of a flange of a Strobel, a lasting component covering the Strobel, and an upper sewn to the flange and the lasting component.

[0016] Fig. 9 yes Figure 1 Schematic illustration of a partial cross-sectional view of a flange of a Strobel, an upper component covering the flange, and an upper sewn to the flange and the upper component.

[0017] Fig.10 yes Figure 1 Schematic illustration of a partial cross-sectional view of a flange of a Strobel, an upper component beneath the Strobel, and an upper sewn to the flange and the upper component.

[0018] Fig.11 yes Figure 1 Schematic illustration of a partial cross-sectional view of a flange of a Strobel, a first upper component covering the Strobel, a second upper component under the Strobel, and an upper sewn to the flange and the first and second upper components.

[0019] Fig.12 Yes Figure 1 Schematic illustration of a bottom view of a Strobel showing a polymer bladder and an upper component sewn to a peripheral flange of the polymer bladder.

[0020] Fig.13 yes Fig.12 Schematic illustration of a bottom view of a polymer capsule.

[0021] Fig.14 yes Fig.12 Schematic illustration of a bottom view of the upper part of the fabric.

[0022] Fig.15 is a schematic illustration of a bottom view of a Strobel including a polymer bladder and an last component sewn to the polymer bladder.

[0023] Fig.16 yes Fig.15 Schematic illustration of a bottom view of a polymer capsule.

[0024] Fig.17 yes Fig.15 Schematic illustration of a bottom view of the upper part of the fabric.

[0025] Fig.18 is a schematic illustration of a bottom view of a Strobel including a polymer bladder and an last component sewn to the polymer bladder.

[0026] Fig.19 yes Fig.18 Schematic illustration of a bottom view of a polymer capsule.

[0027] Fig. 20 yes Fig.18 Schematic illustration of a bottom view of the upper part of the fabric.

[0028] Fig.21 is a schematic illustration of a bottom view of a Strobel including a polymer bladder and an last component sewn to the polymer bladder.

[0029] Fig. 22 yes Fig.21 Schematic illustration of a bottom view of a polymer capsule.

[0030] Fig.23 yes Fig.21 Schematic illustration of a bottom view of the upper part of the fabric.

[0031] Fig.24 is a schematic illustration of a bottom view of a Strobel including a polymer bladder and an last component sewn to the polymer bladder.

[0032] Fig.25 is a schematic illustration of a bottom view of a Strobel including a polymer bladder and an last component sewn to the polymer bladder.

[0033] Fig.26 is a schematic illustration of a bottom view of a Strobel including a polymer bladder and an last component sewn to the polymer bladder.

[0034] Fig. 27 is a schematic illustration of a bottom view of a Strobel including a polymer bladder and an last component sewn to the polymer bladder.

[0035] Fig.28 is a schematic illustration of a bottom view of a Strobel including a polymer bladder and an last component sewn to the polymer bladder.

[0036] Fig.29is a schematic illustration of a bottom view of a Strobel including a polymer bladder and an last component sewn to the polymer bladder.

[0037] Fig.30 is Figure 3 The line 30-30 in Figure 3 Schematic illustration of a close up cross-sectional view of the flange of a Strobel.

[0038] Fig.31 is a schematic illustration of a close up cross-sectional view of a portion of an alternative embodiment of a Strobel for an alternative embodiment of an article of footwear.

[0039] Fig.32 is a schematic illustration of a bottom view of an alternative embodiment of a Strobel for an alternative embodiment of an article of footwear.

[0040] Fig.33 yes Figure 5 Schematic illustration of the upper and bottom view of the Strobel.

[0041] Fig.34 is a schematic cross-sectional view of an article of footwear comprising Fig.33 The upper and Stronbel of Fig.33 The line 34-34 in the Fig.33 Inverted and having a midsole secured thereto.

[0042] Fig.35 It is under dynamic compression loading Fig.34 Schematic cross-sectional view of the upper and the Strobel.

[0043] Fig.36 Includes an additional layer covering Stronbel Fig.34 Schematic cross-sectional view of an article of footwear.

[0044] Fig.37 is a schematic illustration of a bottom view of a polymer capsule.

[0045] Fig.38 is a schematic illustration of a bottom view of a polymer capsule.

[0046] Fig.39 yes Figure 1 Schematic illustration of a bottom view of a Strobel and a last with alignable positioning features.

[0047] Fig.40 yes Figure 1 Schematic illustration of a bottom view of a Strobel and a last having alternative alignable positioning features.

[0048] Fig.41yes Figure 1 Schematic illustration of an exploded view of a polymer sheet and tooling assembly of a Strobel.

[0049] Fig.42 yes Fig.41 A schematic perspective view of a portion of a tool assembly.

[0050] Fig.43 yes Fig.41 A schematic perspective view of another portion of the tool assembly.

[0051] Fig.44 is a schematic illustration of an exploded view of an alternative tool assembly.

[0052] Fig.45 yes Fig.44 Schematic illustration of a perspective view of a tool assembly in which the tool assembly is in an open position.

[0053] Fig.46 yes Figure 5 Schematic perspective view of a Strobel and an upper before the Strobel is sewn to the upper and an exploded view of the Strobel in an uninflated state.

[0054] Fig.47 yes Figure 5 Schematic perspective view of a Strobel and an upper, wherein the Strobel is sewn to the upper and the Strobel is in an uninflated state.

[0055] Fig.48 yes Fig.47 Schematic illustration of the Strobel and the upper during filling of the Strobel.

[0056] Fig.49 Moves towards the last of the footwear Fig.48 Schematic illustration of the Strobel and the upper.

[0057] Fig.50 It is on the shoe last. Fig.49 A schematic diagram of a Strobel and a shoe upper, and wherein Fig.34 The midsole is moved toward the Strobel for fixation to the Strobel and the upper.

[0058] Fig.51 is a flow chart of a method of manufacturing footwear.

[0059] describe

[0060] Some footwear include a stronbel fixed to the lower perimeter of the upper. Traditionally, a stronbel is a relatively inelastic textile material. The stronbel disclosed herein includes a capsule with a sealed fluid-filled chamber, and can provide greater comfort, resilience and energy return than the stronbel of traditional materials and structures. The stronbel constructed as a capsule can be a polymer material, which may feel a little slippery and / or may not be as flexible as traditional stronbel materials, making it more difficult to grip during the manufacturing process. Therefore, it may be difficult to accurately sew the stronbel to the upper in a sufficiently short period of time, and accurately sew the stronbel to the upper in a sufficiently short period of time may be required during mass production. In addition, the desired total height of the sole assembly is usually targeted at a predetermined height, and when stored before assembly or when heated during assembly, the fluid-filled capsules filled may tend to expand relative to their initial height, making the control of the height of the sole assembly more difficult.

[0061] The Strobel, article of footwear, and method of making footwear as disclosed and constructed herein address these issues while providing the benefits of a Strobel having a fluid-filled bladder.

[0062] More specifically, an article of footwear includes a Strobel that includes a polymer bladder that defines an interior cavity and is configured to retain a fluid in the interior cavity. The polymer bladder may have a peripheral flange that extends around at least a portion of the perimeter of the interior cavity. The peripheral flange may define a groove that extends along the peripheral flange. The groove may serve as a guide path for an operator or for a machine (including a robotic machine) to follow when sewing or otherwise securing the Strobel to a shoe upper.

[0063] In one or more embodiments, the polymer bladder may include a first polymer sheet and a second polymer sheet. The first polymer sheet may be bonded to the second polymer sheet at a peripheral flange. The first polymer sheet may be attached to the second polymer sheet at a plurality of internal welds, each of which only partially extends across the inner cavity. For example, the internal welds may be formed by a welding process such as radio frequency or ultrasonic welding using a tool that produces a weld by thermally bonding the sheets to each other. Alternatively, the internal welds may be formed by applying an anti-weld material to the contact surface (e.g., inner surface) of the first polymer sheet and the second polymer sheet in a pattern that produces an internal weld. For example, the anti-weld material may be screen printed on the sheet.

[0064] In one or more embodiments, the internal welds can be arranged in a pattern of rows and columns, wherein the rows are spaced apart in the longitudinal direction of the Stronbel and the columns are spaced apart in the transverse direction of the Stronbel. The internal welds of any two consecutive rows can be offset from each other and the internal welds of the alternating rows can be aligned with each other. In addition, the internal welds of any two consecutive columns can be offset from each other and the internal welds of the alternating columns can be aligned with each other. The internal welds can be arranged to define an equilateral triangle. More specifically, any two adjacent internal welds in a row in the row (and therefore in alternating columns) and the internal welds in a continuous row in the row and in a column between two adjacent internal welds can be positioned to define the corners of an equilateral triangle. In addition, at least most of the internal welds can be circular and can have equal diameters.

[0065] By placing the internal welds in offset rows and offset columns to define the described equilateral triangle, and by providing internal welds of equal size (e.g., equal diameter), the polymer bladder can more closely achieve the desired geometry when in an inflated state. For example, for a given diameter of the internal welds, this layout of the internal welds can achieve the lowest height of the inflated polymer bladder. In addition, the polymer bladder may be less likely to twist around the longitudinal axis or the transverse axis when inflated because the internal force of the fluid in the inner cavity on the inner surface of the polymer bladder can be more evenly distributed. In general, a larger number of smaller internal welds can provide better control of the height of the inflated Stronbel compared to a smaller number of larger internal welds.

[0066] In one or more embodiments, the peripheral flange has a first weld and a second weld spaced apart from the first weld. The first weld and the second weld extend lengthwise along the peripheral flange. The groove may extend lengthwise along the peripheral flange between the first weld and the second weld. The first weld may be on the inside of the groove. The second weld may be on the outside of the groove.

[0067] In some embodiments, the groove is on the side of the polymer bladder facing the foot (proximal side), in other embodiments, the groove is on the side of the polymer bladder facing the ground (distal side), and in other embodiments, both the side facing the foot and the side facing the ground have such grooves. This helps to achieve the use of the polymer bladder for footwear articles configured for the right foot, and alternatively, also for footwear articles configured for the left foot. In other words, the Strobel can be fixed to the upper configured for the right foot footwear article, or can be turned over for fixing to the upper configured for the left foot footwear article. In either case, one of the two grooves will be in the same position relative to the upper in both cases (e.g., set outward (away from the upper)) to serve as a guide for stitching. The polymer sheet can be transparent, in which case the groove will be visible at the distal side of the Strobel, and even in the embodiment where the groove is only arranged on the proximal side of the Strobel, it is also used as a guide path for stitching.

[0068] In one or more embodiments, the peripheral flange may include a first ridge protruding at the outer surface of the peripheral flange between the first weld and the groove. The peripheral flange may include a second ridge protruding at the outer surface of the peripheral flange between the second weld and the groove. These ridges may be caused by material of the polymer bladder displaced by the first weld and the second weld. These ridges help define the sides of the groove.

[0069] In one or more embodiments, the polymer bladder can have a locating feature that is at least one of a notch in the outer edge of the peripheral flange, a protrusion at the outer edge of the peripheral flange, a hole in the polymer bladder, or a marking on the polymer bladder. For example, a first hole can extend through one of the internal welds, and a second hole can extend through another of the internal welds. The locating feature or features can be used to precisely align with an upper and / or a footwear last, as described herein.

[0070] The article of footwear may also include an upper, and the strobel may be secured to the upper. In one example, the strobel may be secured to the upper by a series of stitches extending through the peripheral flange in the groove. The series of stitches may further extend around the outer edge of the peripheral flange.

[0071] Within the scope of the present disclosure, the article of footwear may also include an upper component disposed at the flange such that the series of stitches further extend through the upper component. In one or more embodiments, the polymer bladder and the upper component are each disposed in at least one different region of the forefoot region, the midfoot region, and the heel region of the article of footwear, the upper component is secured to the polymer bladder by a first series of stitches extending laterally across the polymer bladder and the upper component, and the upper component and the polymer bladder are secured to the upper by a second series of stitches extending through the upper component and through the polymer bladder in a groove of the polymer bladder.

[0072] In one or more embodiments, the lasting member is secured to the peripheral flange at the groove by a series of stitches extending through the lasting member and extending in the groove through the peripheral flange.

[0073] In one or more embodiments, the series of stitches is a first series of stitches, and the upper component is secured to the upper at a second series of stitches extending through the upper component and the upper. The second series of stitches may extend only through the upper and the upper component. Alternatively, the second series of stitches may further extend in the groove through the peripheral flange.

[0074] The midsole may be secured to at least one of the upper or the polymer bladder. For example, after a last is placed in the upper (e.g., an upper with a strobel secured thereto is placed on the last), the midsole may be secured to at least one of the upper or the polymer bladder, such as to a lower perimeter of the upper and a distal surface of the polymer bladder. In some embodiments, the article of footwear may include a protective covering covering the proximal surface of the polymer bladder and secured to the polymer bladder at the peripheral flange. The protective covering may protect the bladder from shear forces and sharp objects.

[0075] A method of manufacturing footwear may include forming a strobel by welding a first polymer sheet and a second polymer sheet to each other to define a polymer bladder having an interior cavity and configured to retain a fluid in the interior cavity. A peripheral flange may extend around at least a portion of a perimeter of the interior cavity. The welding may be performed at the peripheral flange, and the peripheral flange may define a groove extending along the peripheral flange.

[0076] Welding the first polymer sheet and the second polymer sheet to each other can include welding a plurality of internal welds, each of the plurality of internal welds extending only partially across the inner cavity. The internal welds can be arranged in a pattern of rows and columns as described above, can define an equilateral triangle as described, and can have equal diameters.

[0077] The Strobel manufactured according to the method may be a first Strobel corresponding to a first footwear size, and the method may also include manufacturing a second Strobel corresponding to a second footwear size greater than the first footwear size by welding the same or different sheets to each other to define a polymer bladder having an inner cavity and configured to retain a fluid in the inner cavity, and also having a peripheral flange extending around at least a portion of the perimeter of the inner cavity, the peripheral flange defining a groove extending along the peripheral flange. Welding the same or different sheets to each other may include welding an internal weld, the internal weld including a pattern of rows and columns identical to that on the first Strobel, and having at least one additional row and / or column. The additional row or column may include one or more internal welds.

[0078] The first polymer sheet and the second polymer sheet are welded to each other and can include welding a first weld and a second weld, which are spaced apart from each other and extend lengthwise along the peripheral flange, wherein the groove extends lengthwise along the peripheral flange between the first weld and the second weld. For example, the first weld and the second weld can be provided simultaneously via the same welding tool. Alternatively, the first weld and the second weld can be provided continuously by different tools. In other embodiments, the first weld and the second weld can be provided by applying a solder mask to the interfacing surfaces of the first sheet and the second sheet around the area where the first weld W1 and the second weld W2 will be formed, rather than at the area.

[0079] The manufacturing method may also include providing a locating feature on the Strobel, wherein the locating feature is at least one of a notch in the outer edge of the peripheral flange, a protrusion at the outer edge of the peripheral flange, a hole in the polymer bladder, or a marking on the polymer bladder.

[0080] A method of manufacturing footwear may include securing a strobel to an upper, such as by sewing the strobel to the upper along a groove in a peripheral flange of the strobel so that a series of stitches extend through the peripheral flange at the groove. The strobel may include a polymer bladder that defines an inner cavity and is configured to retain a fluid in the inner cavity, and the peripheral flange may extend around at least a portion of the perimeter of the inner cavity. In one or more embodiments, the method may include providing an upper component at the flange before sewing the strobel to the upper, and the series of stitches further extend through the upper component when the strobel is sewn to the upper.

[0081] In one or more embodiments, the method of making footwear begins with a strobel already formed. In other embodiments, the method of making footwear also includes forming the strobel by welding a first polymer sheet and a second polymer sheet to each other to define a peripheral flange having a groove and to define a plurality of internal welds, wherein each of the plurality of internal welds extends only partially across the interior cavity. The internal welds can be arranged in a pattern of rows and columns as described above to define an equilateral triangle and can have equal diameters.

[0082] The Strobel manufactured according to the manufacturing method can be a first Strobel corresponding to a first footwear size, and the method of manufacturing footwear can also include manufacturing a second Strobel corresponding to a second footwear size larger than the first footwear size by welding the same or different sheets to each other to define a polymer bladder having an inner cavity, the polymer bladder being configured to retain a fluid in the inner cavity, and the polymer bladder having a peripheral flange extending around at least a portion of the perimeter of the inner cavity, the peripheral flange defining a groove extending along the peripheral flange. Welding the same or different sheets to each other can include welding internal welds with at least one additional row and / or column in the same pattern of rows and columns as on the first Strobel. In other words, for the Strobel of the first footwear size and the Strobel of the second footwear size, most of the weld patterns are the same. For the Strobel of the larger second footwear size, additional internal welds are also included.

[0083] The method of manufacturing footwear may also include placing the upper with the strobel sewn thereto on a last (e.g., inserting the last into the upper). Placing the upper with the strobel sewn or otherwise secured thereto on the last may include aligning a locating feature on the strobel with a locating feature on the last. The locating feature on the strobel may be at least one of a notch in an outer edge of the peripheral flange, a protrusion from an outer edge of the peripheral flange, a hole in the polymer bladder (such as through one of the internal welds), or a marking on the polymer bladder. The method of manufacturing footwear may also include securing the midsole to at least one of the upper or the strobel while the upper and the strobel are on the last.

[0084] When the Strobel is sewn to the upper, the polymer bladder may be in an uninflated state, and the method of manufacturing the footwear may further include inflating the polymer bladder after the Strobel is sewn to the upper, and then sealing the inner cavity after the inner cavity is inflated. Placing the upper with the Strobel sewn thereto on the last may be after the polymer bladder is inflated and the inner cavity is sealed. In other embodiments, the Strobel may be inflated before the Strobel is sewn to the upper and / or before the upper with the Strobel sewn thereto is placed on the last.

[0085] The above features and advantages of the present teachings and other features and advantages will become apparent from the following detailed description of modes for carrying out the present teachings when taken in conjunction with the accompanying drawings.

[0086] Referring to the drawings, wherein like reference numerals refer to like parts throughout the several views, Figure 1-Figure 3 A strobel 10 is shown for use with an article of footwear 12 that includes an upper 14, such as in Fig.34 10. The strobel 10 includes a polymer bladder 16 that defines an interior cavity 18 and is configured to retain a fluid in the interior cavity. The polymer bladder 16 has a peripheral flange 20 that extends around at least a portion of a perimeter 21 of the interior cavity 18. In the illustrated embodiment, the peripheral flange 20 extends around the entire perimeter 21 (e.g., outwardly surrounding the interior cavity 18) generally in the XY plane of the strobel 10. The XY plane is a plane that passes through the width and length of the strobel 10, such as Figure 1 The Z plane is a plane passing through the height of the Strobel 10 from the proximal surface 24 of the Strobel 10 to the distal surface 26 of the Strobel 10, such as Figure 4 The strobel 10 is a full-length strobel having a forefoot region 25, a midfoot region 27, and a heel region 29. In other embodiments within the scope of the present disclosure, the strobel may extend in only one or two of these regions, such as only in the heel region 29, only in the forefoot region 25, in both the forefoot region 25 and the midfoot region 27 but not in any or all of the heel region 29, or in both the heel region 29 and the midfoot region 27 but not in any or all of the forefoot region 25. The peripheral flange 20 extends around the forefoot region 25, the midfoot region 27, and the heel region 29 of the strobel 10.

[0087] The peripheral flange 20 defines a groove 22 that extends along the peripheral flange 20. As discussed further herein, the groove 22 serves as a guide path for an operator or for a machine (including a robotic machine) to follow when sewing or otherwise securing the Strobel 10 to the upper 14. Fig.34 As shown in FIG. 1 , when the Strobel 10 is secured to the upper 14 at its peripheral flange 20, the Strobel 10 and the upper 14 together define a foot receiving cavity 39. Dynamic compressive loading of the sole structure 80 by the foot in the foot receiving cavity 39 (e.g., by the Fig.35 The force FC in FIG. 1 may create tension in the Strobel 10 in an outward direction around the peripheral flange 20 (as represented by the outward force FO), thereby creating a trampoline-like effect when the tension is subsequently released.

[0088] refer to Figure 4, the polymer bladder 16 includes a first polymer sheet 28 and a second polymer sheet 30. The first polymer sheet 28 is secured to the second polymer sheet 30 at the peripheral flange 20 to close the interior cavity 18. In other words, when the sheets 28, 30 are secured together at the peripheral flange 20 and the polymer bladder 16 is sealed, the first polymer sheet 28 and the second polymer sheet 30 retain the fluid in the interior cavity 18. As used herein, the "fluid" that fills the interior cavity 18 can be a gas, such as air, nitrogen, another gas, or a combination thereof.

[0089] The first polymer sheet 28 and the second polymer sheet 30 can be a variety of polymer materials that can resiliently retain fluids (such as nitrogen, air or other gases). Examples of polymer materials for the first polymer sheet 28 and the second polymer sheet 30 include thermoplastic urethane, polyurethane, polyester, polyester polyurethane and polyether polyurethane. In addition, the first polymer sheet 28 and the second polymer sheet 30 can each be formed by a layer of different materials including polymer materials. In one embodiment, each of the first polymer sheet 28 and the second polymer sheet 30 is formed by a film having one or more thermoplastic polyurethane layers, which has one or more barrier layers of ethylene and vinyl alcohol copolymer (EVOH) impermeable to the pressurized fluid contained therein, such as a flexible microlayer membrane (microlayer membrane) of alternating layers of gas barrier materials and elastomeric materials, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 of Bonk et al., which are incorporated by reference in their entirety. Alternatively, the layer may include ethylene-vinyl alcohol copolymers, thermoplastic polyurethanes, and regrind materials of ethylene-vinyl alcohol copolymers and thermoplastic polyurethanes. Additional suitable materials for the first polymer sheet 28 and the second polymer sheet 30 are disclosed in Rudy's U.S. Pat. Nos. 4,183,156 and 4,219,945, which are incorporated by reference in their entirety. Additional suitable materials for the first polymer sheet 28 and the second polymer sheet 30 include thermoplastic films containing crystalline materials (such as disclosed in Rudy's U.S. Pat. Nos. 4,936,029 and 5,042,176), and polyurethanes including polyester polyols (such as disclosed in Bonk et al. U.S. Pat. Nos. 6,013,340, 6,203,868, and 6,321,465), which are incorporated by reference in their entirety. Engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent may be considered when selecting materials for the strobel 10. For example, the thickness of the first polymer sheet 28 and the second polymer sheet 30 used to form the bladder may be selected to provide these properties.

[0090] refer to Figure 4 and Fig.30 , the peripheral flange 20 has a first weld W1 and a second weld W2 spaced apart from the first weld W1. The first polymer sheet 28 and the second polymer sheet 30 are bonded to each other at the interface 32 at the welds W1, W2. The sheets 28, 30 may or may not be bonded to each other at the portion of the interface 32 between the welds W1, W2. The welds W1 and W2 are bonded to each other at the interface 32 by using a method similar to Figure 42-Figure 43Tool components or Figure 44-Figure 45 The tool assembly is formed by a tool assembly. For example, the tool assembly may include a first mold portion 34A and a second mold portion 34B, such as Figure 42-Figure 43 The mold portions 34A, 34B are closed together over the polymer sheets 28, 30 and the polymer sheets 28, 30 may then be welded by radio frequency welding (also known as high frequency or dielectric welding) as the power supply 36 supplies energy to produce an alternating electric field that heats the polymer sheets 28, 30 at the locations where the mold portions 34A, 34B contact the polymer sheets 28, 30. Alternatively, the sheets 28, 30 may be secured to each other by additional thermal or adhesive bonding means.

[0091] The first weld seam W1 and the second weld seam W2 extend longitudinally along the peripheral flange 20. Figure 1 As best shown in FIG. 1 , the first weld W1 and the second weld W2 extend continuously along the entire peripheral flange 20 to completely surround (i.e., surround) the inner cavity 18. The groove 22 extends lengthwise along the peripheral flange 20 between the first weld W1 and the second weld W2. The first weld W1 is on the inside of the groove 22, and the second weld W2 is on the outside of the groove 22, wherein the inside (inward) is toward the center of the Strobel 10 and the outside (outward) is away from the center of the Strobel 10.

[0092] The heating and pressure of the tool assembly at the welds W1 and W2 may displace some material of the second polymer sheet 30 so that the peripheral flange 20 may include a first ridge 38 protruding at an outer surface (e.g., distal surface 26) of the peripheral flange 20 between the first weld W1 and the groove 22, and a second ridge 40 protruding at the distal surface 26 of the peripheral flange 20 between the second weld W2 and the groove 22. The ridges 38, 40 help define the sides of the groove 22.

[0093] In some embodiments, such as Fig.30 In the embodiment of the present invention, the groove 22 is located in the distal surface 26, which is the side of the polymer bladder 16 facing the ground when the Strobel 10 is secured to the upper 14. In other embodiments, the groove 22 can be located on the proximal side (proximal surface 24), which is the side of the polymer bladder 16 facing the foot when the Strobel 10 is secured to the upper 14. Because the polymer sheets 28, 30 can be transparent, in embodiments where the grooves 22 are only provided on the proximal side, the grooves 22 will be visible through the peripheral flange 20 at the distal side. In addition, if used as a Strobel for an article of footwear configured for the left foot, Figure 1 The Strobel 10 has a groove 22 on the proximal side and, if used as a Strobel for an article of footwear configured for a right foot, Figure 1The Strobel 10 has a groove on the distal side. In other embodiments, both the distal surface 26 and the proximal surface 24 have such grooves 22, such as Fig.31 . The provision of grooves 22 on both sides of the peripheral flange 20A helps to achieve the use of the polymer bladder 16 for a footwear article configured for the right foot, and alternatively, also for a footwear article configured for the left foot. In other words, the Strobel 10 with the peripheral flange 20A can be fixed to the upper 14 configured for the right foot footwear article, or can be turned over for fixing to the upper 14 configured for the left foot footwear article. In either case, one of the two grooves 22 will be in the same position relative to the upper in both cases (e.g., set outward (away from the upper)) to serve as a guide for stitching. In an embodiment with grooves 22 only on one of the sides of the peripheral flange 20, because the polymer sheets 28, 30 can be transparent, the grooves 22 are visible at the far side even in an embodiment where the grooves 22 are only set on the near side.

[0094] refer to Figure 4 , the inner surface 52 of the first polymer sheet 28 is joined to the inner surface 54 of the second polymer sheet 30 at a plurality of internal welds 60, each of the plurality of internal welds 60 being interior to the perimeter 21 of the inner cavity 18 and extending only partially across the inner cavity 18. For example, the internal welds 60 may be formed by a welding process such as radio frequency or ultrasonic welding using a tool that creates the weld by thermal bonding of the polymer bladder 16. Figure 42-Figure 43 , each internal weld 60 is produced by a corresponding pair of protrusions, the pair of protrusions including one of the protrusions 72A of the mold portion 34A or its mold insert 34C, and one of the protrusions 72B of the mold portion 34B or its mold insert 34D. The protrusions 72A, 72B may also be referred to as weld posts. The mold inserts 34C, 34D may also be referred to as shims. The use of mold inserts 34C, 34D including protrusions 72A, 72B enables the insert to be converted to an insert with a different protrusion pattern when a different pattern of internal welds is required. Alternatively, the protrusions 72A, 72B may be integral with the mold portions 34A, 34B, respectively, rather than being provided on a removable mold insert.

[0095] During welding, the polymer sheets 28, 30 contact each other between each pair of protrusions 72A, 72B and create an internal weld 60 where they contact. Prior to placing the polymer sheets 28, 30 between the mold portions 34A, 34B and between the mold inserts 34C, 34D, a weld resist material may be placed on all portions of the interior surfaces 52, 54 where welds are not desired to ensure that the desired weld pattern is achieved.

[0096] In some embodiments, tool assemblies or radio frequency welding are not used to produce welds W1 and W2 at the peripheral flange and at the internal weld (e.g., no mold portion is used) because the use of only solder mask material is sufficient to achieve the pattern of welds W1 and W2 and the desired internal weld 60. For example, solder mask material (also known as blocker ink) can be printed or otherwise provided on one or both of the inner surface of the first polymer sheet 28 and the inner surface of the second polymer sheet 30. The sheets 28, 30 can then be placed in a uniform press and bonded to each other at all portions of the interface surface (e.g., the inner surface) where solder mask material is not provided.

[0097] The internal weld 60 limits the separation of the first polymer sheet 28 and the second polymer sheet 30 to Figure 4 The separation position shown in Figure 4 A strobel 10 is depicted having an interior cavity 18 that is inflated and sealed at a given inflation pressure of the gas in the interior cavity 18, such that the strobel 10 is in an inflated state. However, it should be understood that in some embodiments of the method 200 for manufacturing the strobel 10 (or any other strobel described herein), the strobel 10 (e.g., the bladder 16) is not inflated and sealed until after it is secured to the upper 14. In other embodiments of the method 200, the strobel 10 may be inflated and sealed before it is secured to the upper 14. Due to the pressurized gas in the interior cavity 18, the outward force on the inner surface 52 of the first polymer sheet 28 and the inner surface 54 of the second polymer sheet 30 exerts tension on the polymer sheets 28, 30 around the inner weld 60, and the inner weld 60 prevents the polymer sheets 28, 30 from moving further outward away from each other. When pressure is exerted on the strobel 10 (such as due to the compressive force FC of the wearer's dynamic load when the footwear 12 impacts the ground during running or other movement), the strobel 10 is compressed. Fig.35 As shown in FIG. 1 , the Strobel 10 is compressed and the polymer sheets 28 , 30 move closer together in proportion to the load on the first polymer sheet 28 and the second polymer sheet 30 .

[0098] Protrusions 72A and 72B are arranged in patterns that mirror each other so that when protrusions 72A contact first polymer sheet 28 and protrusions 72B contact second polymer sheet 30 during portion 200A of manufacturing method 200 disclosed herein, the groups of protrusions 72A, 72B are aligned, thereby pressing polymer sheets 28, 30 together therebetween. Fig.42 and Fig.43 To produce Figure 1-Figure 3 The pattern of the bonding pattern of the internal weld 60 shown in FIG. 1 schematically depicts representative protrusions 72A, 72B.

[0099] When the inner cavity 18 is filled, the internal weld 60 creates a dimple 61 at the proximal surface 24 (ie, the outer surface) of the first polymer sheet 28 and at the distal surface 26 (ie, the outer surface) of the second polymer sheet 30, such as Figure 4 In other words, the proximal surface 24 of the first polymer sheet 28 is non-planar at any of the internal welds 60, and the distal surface 26 of the second polymer sheet 30 is non-planar at any of the internal welds. For example, Figure 1 , Figure 3 and Fig.32 The dashed lines around each of the internal welds 60 in the figure represent dimples 61 where the respective polymer sheets 28, 30 are bent inwardly along a generally annular surface relative to the internal welds 60. In the figures, only some of the internal welds 60 and some of the dimples 61 are labeled with reference numerals.

[0100] The gas in the inner cavity 18 can be fluidly connected around each internal weld 60. In other words, the internal weld 60 does not create a sub-chamber in the inner cavity 18. When the compressive force FC is applied to the Strobel 10, such as in Fig.35 This allows the gas to shift around the inner weld 60 in the inner cavity 18 during impact of the article of footwear 12 with the ground G. For example, during a footstrike, as the foot rolls forward from heel to toe, the gas can shift from the rear portion of the Strobel 10 to a more forward portion of the Strobel 10. Thus, the supportive cushioning provided by the fluid in the inner cavity 18 can be provided in the areas where it is most needed during use of the Strobel 10.

[0101] like Figure 1 The best shown in Figure 42-Figure 4372A, 72B shown in the figure, each of the internal welds 60 has a circular diameter D. The energy imparted by the welding process is delivered to the polymer sheets 28, 30 over the circular area of ​​the contact surface 63, thereby producing a circular weld 60. In an embodiment where only a solder mask material is used without a tool assembly having a protrusion, the solder mask material is printed to leave an uncovered circular area, thereby producing a circular weld. As shown, the diameter D of each of the internal welds 60 is equal. In other embodiments, at least a majority (i.e., greater than or equal to half) of the circular welds 60 have an equal diameter D. In other embodiments, the internal welds 60 may have a shape other than a circle, such as an ellipse, a square, etc.

[0102] refer to Figure 1 , the internal welds 60 are arranged in a pattern of rows and columns. In the illustrated embodiment of Stron Bell 10, there are twenty-two rows marked as R1, R2, R3, R4, R5, R6, R7, R8, R9, R10, R11, R12, R13, R14, R15, R16, R17, R18, R19, R20, R21 and R22. The center C of each of the internal welds 60 in a row falls along the common line representing the position of the row. These rows are all parallel to each other. There are eleven columns marked as C1, C2, C3, C4, C5, C6, C7, C8, C9, C10 and C11. These columns are all parallel to each other. The center of each of the internal welds 60 in a column falls along the common line representing the position of the column. These rows are spaced apart from the first row R1 to the twenty-second row R22 in the longitudinal direction of Stron Bell 10. The longitudinal direction is the direction from the rearmost extension 37 of the Strobel 10 to the frontmost extension 35 of the Strobel 10. The columns are spaced apart from the first column C1 to the eleventh column C11 in the transverse direction of the Strobel 10. The transverse direction of the column spacing is the direction from the outer side 33 to the inner side 31.

[0103] The pattern of the internal welds 60 is such that the internal welds 60 of any two consecutive rows in the rows are offset from each other and the internal welds of alternating rows in the rows are aligned with each other. For example, the internal welds 60 of the odd rows R1, R3, R5, R7, R9, R11, R13, R15, R17, R19 and R21 are aligned with each other. The internal welds 60 of the even rows R2, R4, R6, R8, R10, R12 and R14 are aligned with each other. However, the internal welds 60 of the odd rows are offset from the internal welds 60 of the even rows.

[0104] In addition, the pattern of the internal welds 60 is such that any two consecutive columns of internal welds 60 are offset from each other and the internal welds 60 of alternating columns are aligned with each other. For example, the internal welds 60 of odd columns C1, C3, C5, C7, C9, and C11 are aligned with each other. The internal welds 60 of even columns C2, C4, C6, C8, and C10 are aligned with each other. However, the internal welds 60 of odd columns are offset from the internal welds 60 of even columns.

[0105] Utilizing this pattern of offset rows and columns, the internal welds 60 may be circular, have equal diameters D, and be arranged to define an equilateral triangle. Figure 2 As illustrated in , the centers C of any two adjacent internal welds in one of the rows (as depicted by the internal welds 60 in row R3, which are in alternating columns C1, C3) and the centers C of the internal welds 60 in a consecutive row R2 in the rows and in column C2 between two adjacent internal welds in row R3 are positioned to define the corners of an equilateral triangle.

[0106] By placing the internal welds 60 in offset rows and offset columns to define the described equilateral triangle, and by providing internal welds of equal diameter D, a minimum height of the inflated polymer bladder in the Z direction can be achieved for a given diameter D and number of internal welds 60. In addition, when inflated, the polymer bladder 16 may be less likely to twist about a longitudinal axis or a transverse axis through the bladder 16 because the internal forces of the fluid in the lumen 18 on the inner surface of the polymer bladder 16 can be more evenly distributed. In general, a greater number of smaller internal welds can provide better control over the height of the inflated strobel than a smaller number of larger internal welds.

[0107] The diameter of the internal welds 60 and the distance D1 between the centers C of the internal welds 60 determine the diameter D2 of the space between the internal welds 60 forming an equilateral triangle, which in turn is proportional to the maximum height between the outer surfaces 24 and 26 in the Z direction. Figure 42-Figure 43 The area of ​​the contact surface 63 of each protrusion 72A, 72B in the embodiment is equal to the area of ​​each internal weld 60. For the circular contact surface 63 shown, the diameter of the contact surface 63 is equal to the diameter of the internal weld 60. In one example, each protrusion 72A or 72B (or Fig.45The diameter of the contact surface 63 of each protrusion 172A or 172B) and the diameter of each internal weld 60 can be from about 0.1 inches (in.) (2.54 millimeters (mm)) to about 0.3 in. (7.6 mm), or can be from about 0.14 in. (3.56 mm) to about 0.23 in. (5.84 mm). For example, each internal weld 60 can have a diameter of 0.1875 in. (4.762 mm). In another example, each internal weld 60 can have a diameter of about 0.2500 in.

[0108] In one example, if Figure 2 As shown in FIG. 1 , the distance D1 between the centers of any internal weld 60 forming an equilateral triangle can be from about 0.4 in. (10.1 mm) to about 0.8 in. (20.3 mm), or can be from about 0.46 in. (11.68 mm) to about 0.77 in. (19.56 mm). In one example, the distance D1 can be 0.6125 in. (15.557 mm). In another example, the distance D1 can be 0.667 inches. Therefore, the centers of two adjacent protrusions 72A or 72B forming a weld 60 are spaced a corresponding distance apart.

[0109] In one example, if Figure 2 As shown in , the circular space between the three internal welds 60 forming an equilateral triangle (i.e., a circle tangent to each of the three internal welds 60) can have a diameter D2 from about 0.3 in. (7.62 mm) to about 0.7 in. (17.8 mm), and can be from about 0.39 in. (9.91 mm) to about 0.65 in. (16.51 mm). In one example, the diameter D2 can be 0.520 in. (13.20 mm). In an example, each internal weld 60 can have a diameter of 0.1875 in., the distance D1 between the centers C can be 0.6125 in., and the diameter D2 can be 0.520 in.. In another example, each internal weld 60 can have a diameter of 0.2500 in., the distance D1 between the centers C can be 0.667 in., and the diameter D2 can be 0.520 in. Therefore, a circle between and tangent to any three adjacent protrusions of the protrusions 72A or 72B arranged to form an equilateral triangle (or any three adjacent protrusions of the protrusions 172A, 172B arranged to form an equilateral triangle) has a corresponding diameter D2.

[0110] The filled polymer bladder 16 can be maintained along the plane P1 (at Figure 4). Plane P1 extends perpendicular to the cross-section shown. By spacing the internal welds 60 in the pattern described, when filled, the Strobel 10 is less likely to move away from the horizontal or longitudinal direction. Figure 4 The plane P1 of the contact surface 24 or the distal surface 26 is curled so that the plane P1 becomes a curved surface instead and the Strobel 10 appears slightly concave or slightly convex when viewed as a whole at the proximal surface 24 or the distal surface 26. Providing an internal weld 60 having a diameter D (e.g., by providing a protrusion 72A, 72B or 172A, 172B having a contact surface diameter D, or by printing a blocker ink around a circle of diameter D) and a distance D1 between the centers C within the range set forth helps prevent such curling.

[0111] Strobel 10 may be a first Strobel corresponding to a first footwear size. The first footwear size may be indicated by a first length L1 from forward-most extension 35 to rearward-most extension 37 and / or a first width Y1 from medial side 31 to lateral side 33 at, for example, sixteenth row R16, which may generally correspond to one of the widest areas of Strobel 10 configured to correspond to the metatarsal joints of a wearer's foot. Fig.32 The second Strobel 110 shown in FIG. 1 can be manufactured according to the same method 200. Thus, portion 200A of the method 200 discussed herein can include manufacturing a second Strobel 110 corresponding to a second footwear size greater than the first footwear size by welding the same or different sheets 28, 30 to each other in a pattern including the rows and columns in the first Strobel and having at least one additional row and / or column to form a polymer bladder 116 that is otherwise identical to the polymer bladder 16.

[0112] For example, the Strobel 110 has a second footwear size indicated by a second length L2 from the front-most extension 35 to the rear-most extension 37 and / or a second width Y2 from the medial side 31 to the lateral side 33, wherein the second length L2 is greater than the first length L1, and the second width Y2 is greater than the first width Y1 when measured at the same row (e.g., the sixteenth row R16) of each Strobel 10, 110. The internal welds 60 of the Strobel 110 include all twenty-two rows and eleven columns of the first Strobel 10, including the same pattern of internal welds 60 of these rows and columns, and also include additional internal welds 60 (designated by reference numeral 60A for clarity) in each of the twentieth row R20 and the twenty-second row R22, and an additional row (the twenty-third row R23) having three internal welds (designated by reference numeral 60B for clarity). The additional internal welds 60A, 60B maintain the pattern of offset rows and columns and have the same relative spacing as the internal welds 60 of the Strobel 10 while maintaining the same overall maximum height in the Z direction when filled as the Strobel 10.

[0113] refer to Figure 5-Figure 11 and Fig.33 Although securing the strobel 10 to the upper 14 is not limited to stitching, the strobel 10 may be secured to the upper 14 by a series of stitches 82 (only some of the stitches 82 are indicated by reference numerals) extending through the peripheral flange 20 in the groove 22. Stitching may occur prior to placing the last 84 in the opening 86 formed by the upper 14 ( Fig.46 and Fig.49 In other words, the upper 14 is not placed on the last 84 until after it has been secured to the strobel 10. For manufacturing efficiency, it is desirable that the securing of the strobel 10 to the upper 14 be accomplished accurately and relatively quickly. The grooves 22 in the peripheral flange 20 help speed up the stitching process by serving as a visual path for an operator and / or machine (including a robotic machine) to follow during the stitching process.

[0114] exist Figure 5-Figure 11 , various ways of sewing the Strobel 10 to the upper 14 are shown. Although described with respect to the Strobel 10, the various arrangements are also applicable to the Strobel 110 and any other Strobel shown and described herein. Figure 5, the edge 88 of the upper 14 abuts against the peripheral flange 20, and the stitch 82 extends through the peripheral flange 20 at the groove 22 (i.e., through both of the polymer sheets 28, 30 at the peripheral flange 20) and around the outer edge 90 through the upper 14 and around the peripheral flange 20. The strobel 10 is moved relative to the suture needle, or vice versa, so that the needle moves along the groove 22 while the stitch 82 advances along the groove 22 and around the polymer bladder 16.

[0115] Figure 6 Another stitching arrangement is shown in which the upper 14 is stacked on the peripheral flange 20 on the side of the peripheral flange 20 opposite the groove 22 (i.e., on the proximal surface 24), and the stitch 82 extends through the upper 14 and through both of the polymer sheets 28, 30 at the groove 22 and advances along the peripheral flange 20 in the groove 22. Figure 7 Another stitching arrangement is shown in which the upper 14 is stacked on the peripheral flange 20 on the same side of the flange 20 as the groove 22 (i.e., on the distal surface 26), and the stitch 82 extends through the upper 14 and through both of the polymer sheets 28, 30 at the groove 22 and advances along the peripheral flange 20 in the groove 22.

[0116] Figure 8-Figure 29 An additional arrangement is shown for securing the Strobel to the upper 14 by including one or more lasting components, which may be a substantially inelastic material, such as that used in conventional Strobels. In other words, Figure 8-Figure 19 The Strobel not only includes a polymer bladder with a flange 20 as described herein, but also includes an upper component. More specifically, in a non-limiting example, the upper component can be one or more of a woven or non-woven textile, an elastomer, or a foam backed with a textile layer. The upper component is thinner than the height of the polymer bladder (i.e., not as high) and can be substantially easier to grip than the bladder during sewing of the Strobel to the footwear upper 14. By adding one or more upper components, stress on the bladder (such as caused by stitches 82) can be minimized. Figure 8 In the embodiment of the present invention, the lasting member 17J covers the entire bladder 16 (including the flange 20 at the proximal surface 24). The upper 14 is sewn to the flange 20 in the groove 22 and to the lasting member 17J by a series of stitches 82.

[0117] exist Fig. 9 In the embodiment, the lasting member 17K covers only the flange 20, rather than covering the entire bag 16. For example, the lasting member 17K may be as follows: Figure 3The shoe upper 14 is an elongated strip in the shape of the flange 20 that appears in the groove 22 and can wrap around the inner cavity 18 outside the inner cavity 18. Alternatively, the lasting member 17K can be below the flange 20. The upper 14 is sewn to the flange 20 and to the lasting member 17K in the groove 22 by a series of stitches 82.

[0118] exist Fig.10 In the embodiment, the lasting member 17L is below the entire bladder 16 at the distal surface 26, and the upper 14 is stitched to the flange 20 and to the lasting member 17L in the groove 22 by a series of stitches 82. Fig.11 In, similar to Figure 8 The first lasting member 17L of the lasting member covers the entire bag 16 including the flange 20, and is similar to Fig.10 The second lasting member 17L of the lasting member is below the entire bladder 16 including the flange 20. The upper 14 is sewn to the flange 20 in the groove 22 and to the first lasting member 17L and the second lasting member 17L by a series of stitches 82.

[0119] Figure 12-Figure 29 Various embodiments of the Strobel 10, 10A, 10B, 10C, 10D, 10E, 10F, 10G, 10H, 10I within the scope of the present teachings are shown. The Strobel each includes a polymer bladder 16, 16A, 16B, 16D, 16E, 16F, 16G, 16H or 16I configured to have a flange 20 with a groove 22, as shown in reference Figure 1-Figure 4 The Strobels also each include an upper component secured to the polymer bladder. The polymer bladder and the upper component secured to the polymer bladder together form a formed Strobel that is subsequently secured to the upper as described herein.

[0120] refer to Figure 12-14 , StronBell 10 includes Figure 1-Figure 4 The polymer bladder 16 and the lasting member 17 fixed to the peripheral flange 20. Fig.14 As shown in FIG. 1 , the lasting member 17 has a hole 19. The size of the hole 19 is set so that the polymer bladder 16 partially extends through the hole 19, and the peripheral flange 20 abuts the lasting member 17 around the hole 19. For example, as Fig.12 (which is a bottom view), the lasting member 17 overlies and abuts the flange 20, and a portion of the second polymer sheet 30 at the inflated portion of the polymer bladder 16 extends through the hole 19. The outer edge 90 of the flange 20 extends laterally outside the hole 19, and the outer edge 91 of the lasting member 17 extends laterally outside the outer edge 90 of the flange 20. The outer edge 90 extends along Fig.14In other words, the polymer bladder 16 is wider than the hole 19, and the lasting member 17 is wider than the polymer bladder 16. Fig. 9 The lasting member 17K is similar to the lasting member 17 in all respects, except that it has the same width as the polymer bladder 16 so that its outer edge 91 is aligned with the outer edge 90 of the polymer bladder 16.

[0121] The lasting member 17 is configured to be formed around the perimeter 21 of the inner cavity 18 of the bladder 16 (at Figure 1 Indicated in the figure) extends around the peripheral flange 20. Figure 12-14 In the embodiment of the present invention, the upper part 17 has a Figure 3 The forefoot region 25, midfoot region 27 and heel region 29 of the polymer bladder 16 are indicated in FIG. Aperture 19 and polymer bladder 16 extend in each of the forefoot region 25, midfoot region 27 and heel region 29.

[0122] The lasting member 17 has locating features 93G, which may be holes or marks in the lasting member 17, or notches in the outer edge of the lasting member 17 or protrusions at the outer edge of the lasting member 17, which are spaced apart from each other at the same relative spacing as the notches 93A or other locating features of the polymeric bladder 16. When the polymeric bladder 16 is placed at the hole 19, the locating features 93A align with the locating features 93G. This properly positions the flange 20 relative to the lasting member 17 for subsequent suturing through the flange 20. Alternatively, instead of or in addition to the notches 93A, the locating features on the polymeric bladder 16 may be one or more holes 93D punched or otherwise provided through the bladder 16, such as Fig.33 As shown in .

[0123] The lasting member 17 is sewn or otherwise secured to the polymer bladder 16 with stitches 81 that extend through the flange 20 at the grooves 22. The grooves 22 serve as a guide path for an operator or for a machine (including a robotic machine) to follow when sewing or otherwise securing the lasting member 17 to the polymer bladder 16. Fig.12As shown in FIG. 1 , a first series of stitches 81 extends through the upper member 17 and in the groove 22 through the peripheral flange 20, securing the upper member 17 to the polymer bladder 16. Both the first series of stitches 81 and the groove 22 extend completely around and outside the perimeter 21 of the inner cavity 18 of the polymer bladder 16. Only some of the stitches 81 are indicated by reference numbers. The Strobel 10 having the polymer bladder 16 secured to the upper member 17 can then be secured by a second series of stitches extending through the upper member 17 and through the upper 14 but not through the polymer bladder 16 (e.g., the upper member 17 can extend through the outside of the flange 20) or by a second series of stitches extending through both the flange 20 and the upper member 17 (e.g., the second series of stitches extending through the flange 20) Fig. 9 The stitch 82) is fixed to the upper 14.

[0124] Figure 15-17 Another embodiment of a Strobel 10A is shown, which includes a polymer bladder 16A and a lasting member 17A secured to a peripheral flange 20 of the polymer bladder 16A by a first series of stitches 81 extending through the peripheral flange 20 and the lasting member 17A. Both the first series of stitches 81 and the grooves 22 extend completely around and outside the perimeter 21 of the inner cavity 18.

[0125] like Fig.17 As shown in FIG. 1 , the lasting member 17A has an aperture 19A. The aperture 19A is sized so that the polymer bladder 16A partially extends through the aperture 19A, and the peripheral flange 20 abuts the lasting member 17A around the aperture 19A. The outer edge 90 of the flange 20 extends laterally outside the aperture 19A, and the outer edge 91 of the lasting member 17A extends laterally outside the outer edge 90 of the flange 20.

[0126] The lasting member 17A is configured to extend along a peripheral flange 20 around the perimeter 21 of the interior cavity 18 of the bladder 16A. Figure 15-17 In the embodiment of the present invention, the upper member 17A has a forefoot region 25, a midfoot region 27, and a heel region 29. The aperture 19A extends in the forefoot region 25 and may extend partially in the midfoot region 27. The polymer bladder 16A is configured to extend in the forefoot region 25 and partially in the midfoot region 27 with the aperture extending into the midfoot region 27 but not in the heel region 29.

[0127] The lasting member 17A has a locating feature 93G, which can be a hole in the lasting member 17A or a mark on the lasting member 17A, or a notch in the inner peripheral edge of the lasting member 17A that defines the hole 19A or a protrusion at the inner peripheral edge of the lasting member 17A that defines the hole 19A, which are spaced from each other at the same relative spacing as the notch 93A or other locating features of the polymer bladder 16A. When the polymer bladder 16A is placed at the hole 19A, the locating feature 93A is aligned with the locating feature 93G. Similar to the lasting member 17, the lasting member 17A is sewn or otherwise secured to the polymer bladder 16A with a first series of stitches 81 extending through the flange 20 at the groove 22. Both the first series of stitches 81 and the groove 22 extend completely around and outside the perimeter 21 of the inner cavity 18 of the polymer bladder 16A. Similar to the Strobel 10, the Strobel 10A having the polymer bladder 16A secured to the last component 17A may be secured to the upper 14 by a second series of stitches 82 extending through the last component 17A and the upper 14 but not through the polymer bladder 16A.

[0128] Figure 18-Figure 20 Another embodiment of a Strobel 10B is shown, which includes a polymer bladder 16B and a lasting member 17B secured to a peripheral flange 20 of the polymer bladder 16B by a first series of stitches 81 extending through the peripheral flange 20 and the lasting member 17B. Both the first series of stitches 81 and the grooves 22 extend completely around and outside the perimeter 21 of the inner cavity 18.

[0129] like Fig. 20 As shown in FIG. 1 , the lasting member 17B has an aperture 19B. The aperture 19B is sized so that the polymer bladder 16B partially extends through the aperture 19B, and the peripheral flange 20 abuts the lasting member 17B around the aperture 19B, similar to Fig.25 The lasting member 17 and the flange 20 are shown in FIG. The outer edge 90 of the flange 20 extends laterally outside the hole 19B, and the outer edge 91 of the lasting member 17B extends laterally outside the outer edge 90 of the flange 20.

[0130] The lasting member 17B is configured to extend along a peripheral flange 20 around the perimeter 21 of the inner cavity 18. Figure 18-Figure 20 In the embodiment of FIG. 1 , the upper member 17B has a forefoot region 25, a midfoot region 27, and a heel region 29. The aperture 19B extends in the heel region 29. The polymer bladder 16B is configured to extend in the heel region 29, but not in the midfoot region 27 or the forefoot region 25.

[0131] The lasting member 17B has a locating feature 93G, which can be a hole in the lasting member 17B or a mark on the lasting member 17B, or a notch in the inner peripheral edge of the lasting member 17B that defines the hole 19B or a protrusion at the inner peripheral edge of the lasting member 17B that defines the hole 19B, which are spaced apart from each other at the same relative spacing as the notch 93A or other locating features of the polymer bladder 16B. When the polymer bladder 16B is placed at the hole 19B, the locating feature 93A is aligned with the locating feature 93G. Both the first series of stitches 81 and the grooves 22 extend completely around and outside the perimeter 21 of the inner cavity 18 of the polymer bladder 16B. Similar to the Strobel 10, the Strobel 10B having the polymer bladder 16B fixed to the lasting member 17B can be fixed to the upper 14 by a second series of stitches 82 extending through the lasting member 17B and through the upper 14 but not through the polymer bladder 16B.

[0132] Figure 21-23 Another embodiment of a Strobel 10C is shown, which includes a polymer bladder 16 and a lasting member 17C secured to a peripheral flange 20 of the polymer bladder 16 by a first series of stitches 81 extending through the peripheral flange 20 and the lasting member 17C. Both the first series of stitches 81 and the grooves 22 extend completely around and outside the perimeter 21 of the inner cavity 18.

[0133] like Fig.21 As shown in FIG. 1 , the dimensions of the lasting member 17C are set so that the peripheral flange 20 abuts the surface of the lasting member 17C and the lasting member 17C covers the polymer bladder 16 between the inner side of the polymer bladder 16 and the outer side of the polymer bladder 16 and extends across the polymer bladder 16. Fig.21 As best shown in , the outer edge 90 of the flange 20 is aligned with the outer edge 91 of the lasting member 17C because the polymeric bladder 16 and the lasting member 17C have the same width. The lasting member 17C is configured to extend along the peripheral flange 20 around the perimeter 21 of the inner cavity 18 and on one side of the bladder 16 (e.g., on the top of the bladder 16 or under the bottom of the bladder 16 depending on the side of the bladder on which the lasting member 17C is disposed). Figure 21-23 In an embodiment of the present invention, both the lasting member 17C and the polymeric bladder 16 have a forefoot region 25, a midfoot region 27, and a heel region 29, and the lasting member 17C does not have a hole through which the polymeric bladder 16 extends.

[0134] The lasting component 17C has locating features 93G, which are holes or notches in the outer periphery of the lasting component 17C or protrusions at the outer periphery of the lasting component 17C, and these locating features 93G are spaced from each other at the same relative spacing as the notches 93A or other locating features of the polymer bladder 16. When the lasting component 17C is placed against the polymer bladder 16, the locating features 93A are aligned with the locating features 93G, and the lasting component 17C is sewn to the polymer bladder 16 using a first series of stitches 81 extending through the flange 20 and the lasting component 17C at the groove 22. Both the first series of stitches 81 and the groove 22 extend completely around and outside the perimeter 21 of the interior cavity 18 of the polymer bladder 16. The Strobel 10C is secured to the polymer bladder 16 by a second series of stitches (similar to those in FIG. 1 ) extending through the lasting component 17C and through the upper 14 and also extending through the flange 20 of the polymer bladder 16 in the groove 22. Figure 8 The first series of stitches 81 and the second series of stitches 82 are both fixed to the upper 14. Both the first series of stitches 81 and the second series of stitches 82 extend through the polymer bladder 16 in the groove 22.

[0135] In some embodiments, both the lasting member and the polymer bladder extend the entire width of the strobel, but neither extends the entire length, and the lasting member and the polymer bladder are arranged longitudinally along the strobel. Figure 24-Figure 29 In an embodiment, the polymer bladder and the upper component are each disposed in at least one different area of ​​the forefoot area, the midfoot area, and the heel area of ​​the Strobel, and the upper component is secured to the polymer bladder by a first series of stitches extending laterally across the polymer bladder and the upper component.

[0136] refer to Fig.24 , the polymer bladder 16D is disposed in the forefoot region 25 and may extend slightly into the midfoot region 27. The lasting member 17D extends in the heel region 29 and the midfoot region 27, wherein the front lateral edge 23 of the lasting member 17D abuts or slightly overlaps the rear lateral edge 90D of the polymer bladder 16D. The groove 22 does not extend across the polymer bladder 16D (e.g., from the medial side to the lateral side) at the rear lateral edge 90D. The polymer bladder 16D may be formed by cutting the polymer bladder 16 and adding a transversely extending weld W3 to seal the inner cavity 18 at the cut. The first series of stitches 81 extend transversely across the Strobel 10D through the polymer bladder 16D behind the weld W3 to secure the lasting member 17D to the polymer bladder 16D. A subsequent second series of stitches securing the Strobel 10D to the upper 14 will extend around the polymer bladder 16D in the groove 22 through the polymer bladder 16D to the rear lateral edge 90D and will continue around the perimeter of the lasting member 17D near the outer edge 91 behind the series of stitches 81.

[0137] The positioning features (e.g., notch 93A) of polymer bladder 16D and positioning features 93G of lasting component 17D are used to align Strobel 10D with upper 14 when Strobel 10D is secured to upper 14. Outer edge 90 of polymer bladder 16D forms the outer edge of Strobel 10D in forefoot region 25 and in the front portion of midfoot region 27, and outer edge 91 of lasting component 17D forms the outer edge of Strobel 10D in the rear portion of midfoot region 27 and in heel region 29. In forefoot region 25, Strobel 10D includes only polymer bladder 16D. In the heel region, Strobel 10D includes only lasting component 17D. The article of footwear may include a sole structure, such as Fig.50 The midsole 83 is fixed to the distal side of the polymer bladder 16D and to the lower extension of the upper 14 at the polymer bladder 16D, and is fixed to the distal side of the lasting member 17D and to the lower extension of the upper 14 at the lasting member 17D.

[0138] Fig.25 A Strobel 10E is shown which is constructed the same as described with respect to Strobel 10D, except that polymer bladder 16D is replaced by polymer bladder 16E having flange 20 with groove 22 extending completely around polymer bladder 16E, including at rear transverse edge 90D. In other words, polymer bladder 16E is formed to the dimensions shown, rather than being cut from a longer polymer bladder 16 and then welded at weld seam W3. A first series of stitches 81 that secures last component 17D at rear transverse edge 90D extends through flange 20 at groove 22.

[0139] Fig.26A Strobel 10F is shown with a polymer bladder 16F cut from the polymer bladder 16 at the rear lateral edge 90D and also at the front lateral edge 90F. The polymer bladder 16F is welded at the weld W3 and also at the weld W4 to seal the inner cavity 18. The first series of stitches includes stitch 81A extending transversely across the Strobel 10F through the polymer bladder 16F behind the weld W3 to secure the rear lasting component 17F2 to the polymer bladder 16F. The first series of stitches also includes stitch 81B extending transversely across the Strobel 10F through the polymer bladder 16F in front of the weld W4 to secure the front lasting component 17F1 to the polymer bladder 16F. A subsequent second series of stitches securing the Strobel 10F to the upper 14 will extend through the polymer bladder 16F in the groove 22 at the medial and lateral sides of the polymer bladder 16F and will continue around the rear lasting component 17F2 near the outer edge 91 behind the series of stitches 81A and around the lasting component 17F1 in front of the stitches 81B. The outer edges 91 of the lasting components 17F1 and 17F2 and the outer edge 90 of the polymer bladder 16F form the outer edge of the Strobel 10F. The lasting components 17F1, 17F2 each have at least one locating feature 93G, which is a hole or notch (or protrusion or mark) that can be aligned with similarly spaced locating features on the upper 14 when the Strobel 10F is stitched to the upper 14, just as the notches 93A or other locating features in the polymer bladder 16F can be aligned.

[0140] Fig. 27 A Strobel 10G is shown which is constructed the same as described with respect to Strobel 10F, except that polymer bladder 16F is replaced by polymer bladder 16G having flange 20 with groove 22 extending completely around polymer bladder 16G, including at rear lateral edge 90D and front lateral edge 90F. In other words, polymer bladder 16G is formed to the dimensions shown, rather than being cut from a longer polymer bladder 16 and then welded at welds W3 and W4. A first series of stitches 81A, 81B that secure the lasting components 17F2, 17F1 at rear lateral edge 90D and front lateral edge 90F, respectively, extend through flange 20 at groove 22.

[0141] Fig.28A Strobel 10H is shown that is constructed similarly to Strobel 10D, except that a polymer bladder 16H is located in the rear portion of the heel region 29 and the midfoot region 27, and an upper component 17H is located in the front portion of the forefoot region 25 and the midfoot region 27. The polymer bladder 16H can be cut from the polymer bladder 16 and welded at a transverse weld seam W5 to seal the interior cavity 18, and the upper component 17H is then sewn to the polymer bladder 16H at a forward transverse edge 90G of the polymer bladder 16H using a first series of stitches 81 that extend transversely across the Strobel 10H from the medial side to the lateral side of the polymer bladder 16H and in front of the weld seam W5.

[0142] Fig.29 A Strobel 10I is shown which is constructed the same as described with respect to Strobel 10H, except that polymer bladder 16H is replaced by polymer bladder 16I having flange 20 with groove 22 extending completely around polymer bladder 16I, including at front lateral edge 90G. In other words, polymer bladder 16I is formed to the dimensions shown, rather than being cut from a longer polymer bladder 16 and then welded at weld W5. A first series of stitches 81 securing lasting component 17H to polymer bladder 16I extends through flange 20 at groove 22 near front lateral edge 90G.

[0143] In the articles of footwear described herein, the polymer bladder may be secured directly to upper 14 via stitches, such as stitch 82, extending through flange 20 at groove 22. These configurations will tend to constrain the polymer bladder in the XY plane to a greater degree during dynamic compression than configurations in which the polymer bladder is not secured directly to upper 14 but is instead secured to an upper component via a first series of stitches, such as stitch 81, and the upper component is then secured to the upper via a second series of stitches, such as stitch 82, extending only through the upper component and upper 14.

[0144] In each of the embodiments described herein, Fig.49 , the strobel may be secured to the upper 14 as described before the last 84 is placed in the opening 86 formed by the upper 14. In other words, the upper 14 is not placed on the last 84 until it has been secured to the strobel. For manufacturing efficiency, it is desirable to accomplish the securing of the strobel to the upper 14 accurately and relatively quickly. During this process, the strobel is moved relative to the suture needle, or vice versa, such that the needle moves along the lasting member and / or the groove 22 and the stitch 82 advances along the lasting member and / or the groove 22 (depending on the embodiment, as described herein).

[0145] Fig.36An embodiment of footwear 12A is shown in which a protective covering layer 85 is fixed to the proximal side of the Strobel 10. Thus, the protective covering layer 85 will be disposed within the foot receiving cavity 39. The protective covering layer 85 may be a wear-resistant material to protect the capsule 16 from shear forces and / or sharp objects. The protective covering layer may be formed, for example, of a polymer sheet, a fabric layer, or other protective layer that, in addition to protecting the capsule 16 from sharp objects, can protect the capsule 16 from shear forces (e.g., by minimizing (or maintaining sufficiently low) the coefficient of friction between the wear-resistant material of the protective covering layer 85 and the capsule 16). The protective covering layer 85 may be fixed to the capsule 16 only at the flange 20 by stitching or otherwise. In an embodiment having an upper part surrounding the capsule, the covering layer 85 may be fixed to the upper part instead. The same stitch used to fix the covering layer 85 to the capsule and / or the upper part (in an embodiment including an upper part) may also extend through the Strobel with the covering layer and fix the Strobel with the covering layer to the upper 14. Alternatively, the cover layer 85 may first be secured to the bladder and / or the lasting component (in embodiments that include a lasting component) and then the Strobel with the cover layer 85 secured thereto may be secured to the upper.

[0146] Fig.37 A capsule 16J is shown within the scope of the present disclosure, which may be formed by, for example, the Fig.44 The bladder 16J has a circular internal weld 60, as shown in FIG. Figure 2 As discussed, these circular internal welds 60 are arranged in an equilateral triangle. The bladder 16J also has a locating feature 93H, which is a protrusion at the outer peripheral edge 90 of the bladder 16J. The protrusion 93H is triangular in shape and can be aligned with similarly spaced locating features on the last component, on the upper 14, or on the last 84.

[0147] Fig.44 and Fig.45 A tool 134 is shown for radio frequency welding polymer sheets 28, 30 to form bladder 16J. An upper mold portion 134A and a lower mold portion 134B are shown. A mold insert 134C can be secured to mold portion 134A, and a mold insert 134D can be secured to mold portion 134B. Mold inserts 134C, 134D can be mirror images of each other. Fig.44A second pair of mold inserts 134C, 134D are shown fixed to mold portions 134A and 134B in alignment with each other so that two bladders 16J can be formed simultaneously. Each mold insert 134C, 134D includes protrusions and ridges 94, 96. Protrusions 172A of mold insert 134C are identical in geometry and arrangement to protrusions 172B of mold insert 134D. For example, they can be configured to form circular welds 60 arranged in an equilateral triangle. Protrusions 172B of mold insert 134D (only some of which are in Fig.45 134C) and ridges 94, 96 are aligned with those of the mold insert 134C. In some embodiments, the mold inserts 134C, 134D can be integrally formed with the respective mold portions 134A, 134B as a one-piece component. The welding can be radio frequency welding, which is accomplished when the mold portions 134A, 134B (and mold inserts 134C, 134D) are closed together on the polymer sheets 28, 30 and the power supply 36 supplies energy to generate an alternating electric field that heats the polymer sheets 28, 30, thereby generating welds W1, W2 and internal welds 60 at locations where the mold portions 134A, 134B and / or mold inserts 34C, 34D are applied to the polymer sheets 28, 30.

[0148] As shown, each bladder 16J is produced by compression of the first polymer sheet 28 and the second polymer sheet 30 disposed between mold inserts 134C, 134D. Each mold insert 134C, 134D includes six triangular protrusions 98A at the outer periphery of the ridge 96, which results in triangular protrusions 93H of the bladder 16J. In other embodiments, there may be fewer or more protrusions 98A of the mold insert and protrusions 93H produced on the bladder 16J, and they may have different shapes.

[0149] Fig.38 Another embodiment of a bladder 16K is shown having all of the features described with respect to bladder 16 except having a different arrangement of locating features, which are holes 93D (e.g., through holes) extending through one or more of the internal welds 60 and thus through both of the polymer sheets 28, 30. For example, two are shown in the forefoot region 25, one is shown in the midfoot region 27, and one is shown in the heel region 29. Providing locating features in each of these regions may enable more precise positioning of the bladder 16K relative to the lasting component, upper, or last. It should be appreciated that in the embodiment of the present invention, the locating features may be used to locate the bladder 16K in the shoe. Fig.38In the embodiment of and in many other embodiments shown herein, some internal welds are shown as being partially disposed on the flange 20. This may occur in certain tools or when a solder resist material (e.g., blocker ink) is provided to provide internal welds positioned in such a manner. When the same number of internal welds are used for different grades of footwear, some internal welds may partially fall on the flange 20 for certain grades.

[0150] To further improve the efficiency of sewing the upper 14 to the Strobel 10 (or any other Strobel discussed herein), the Strobel 10 can be in an uninflated state when sewing occurs. When in an uninflated state, the Strobel 10 is more flexible, making it easier to manipulate the Strobel 10 relative to a sewing machine that provides the stitches 82. After the upper 14 is secured to the Strobel 10 by a series of stitches 82, the Strobel 10 is inflated to a predetermined pressure, or maintained at ambient pressure without inflation, and then the interior cavity 18 is sealed, such as by plugging the port 97 of the polymer bladder 16 or the filling tube is sealed. The port 97 is, for example, Figure 1 Although port 97 is shown as being partially disposed in flange 20, port 97 may be disposed elsewhere on strombell 10. Inflation and sealing occurs prior to placing the upper 14 with strombell 10 sewn thereto on last 84 because, in its inflated state, strombell 10 and upper 14 are more representative of their final relative configurations and thus are more representative of their final relative configurations when midsole 83 of sole structure 80 is subsequently secured to distal surface 26 of strombell 10 and / or the lower perimeter of upper 14 (such as at lower perimeter edge 88 of upper 14 (see FIG. Fig.46 ) at), the Strobel 10 and the upper 14 can be more accurately placed on the last 84. In other embodiments, before the bladder 16 is fixed to the upper 14, a polymer bladder (such as bladder 16) can be inflated and sealed.

[0151] To increase the speed and accuracy with which the Strobel 10 (or any other Strobel described herein) and the upper 14 are positioned on the last 84, the Strobel 10 can be configured with positioning features, as discussed. Figure 1 As shown in FIG. 1 , the Strobel 10 has recesses 93A spaced around the outer edge 90 of the peripheral flange 20. The recesses 93A in the bladder 16 may be formed by the mold portions 34A, 34B or the mold inserts 34C, 34D, or may be provided in other ways. Fig.43, mold portion 34B has continuous inner ridges 94 and outer ridges 96 that are spaced apart from one another and together form welds W1 and W2, with groove 22 between welds W1, W2. Outer ridge 96 has a notch 98 that at least partially forms notch 93A of Strobel 10. In general, the various locating features described herein can be provided, for example, by welding, cutting, stamping, printing, dyeing, etc. Alternatively or in addition to notch 93A, Strobel 10 can have a locating feature that is a hole 93D extending through one or more of the inner welds 60 and thus through both polymer sheets 28, 30, such as Figure 1 and Figure 4 In other embodiments, the positioning features of a bladder (such as bladder 16) or a positioning feature of an upper component (such as upper component 17) can be protrusions, holes, printed marks, etc. In some embodiments, a combination of notches and protrusions or other marks can be used.

[0152] Still further, a laser may be used to align features of a Strobel, such as Strobel 10, with last 84. A separate fixture may be used to align Strobel 10 with the perimeter of upper 14. In some embodiments, the center of the heel (e.g., at the outer edge of the peripheral flange) may be aligned with features on the last. Additionally, in some embodiments, a pattern may be printed on the Strobel, which pattern may then be aligned with a pattern on last 84. For example, the far side of Strobel 10 may have an alignment pattern printed on it, because this side will be adhered to midsole 83 so that the printed pattern will not be visible in the finished article of footwear.

[0153] The upper 14 may have locating features, which are spaced apart markings, notches, protrusions, or holes along the lower periphery of the upper near the location where the upper is stitched to the Strobel 10. The locating features of the upper 14 have the same relative spacing as the relative spacing of the locating features (e.g., notches 93A and / or holes 93D) of the Strobel 10. The locating features of the upper 14 may be aligned with the locating features of the Strobel 10 prior to stitching so that when stitching along the groove 22, the upper 14 and the Strobel 10 are properly aligned with each other. Fig.46 , upper 14 is shown as having a locating feature (eg, a marking or hole 93B) that can be aligned with a locating feature (eg, notch 93A) of Strobel 10 for this purpose.

[0154] Alternatively, or in addition, last 84 may be configured with locating features having the same relative spacing as the locating features of Strobel 10. Fig.39 , Fig.40 and Fig.49As shown in FIG. 1 , the positioning features 93C or 93E may be, for example, marks on the shoe last 84 or holes in the shoe last 84 that align with the positioning features 93A or 93C of the Strobel 10. Fig.39 and Fig.40 In the figure, for the sake of clarity, the upper 14 is not shown. Fig.39 In the embodiment of the last 84, the last 84 has positioning features 93D, which are marks or holes spaced relative to each other at the same relative spacing as the positioning features 93A. Fig.40 and Fig.49 In the embodiment of the present invention, the shoe last 84 has a locating feature 93E, which is a mark or hole spaced at the same relative spacing as the locating feature 93D. It should be understood that when the Strobel 10 is in the uninflated state, the locating features on the Strobel 10 have a slightly different relative spacing than when the Strobel 10 is in the inflated state. Therefore, if the Strobel 10 is secured to the upper 14 when in the uninflated state and is placed on the shoe last 84 when in the inflated state, the locating features on the Strobel 10 can have the same relative spacing as the relative spacing of the locating features on the shoe last 84 in the inflated state, as described herein.

[0155] exist Fig.51 The steps of a method 200 for manufacturing footwear, including any of the strobels and articles of footwear described herein, are shown in a flowchart of . Part 200A of method 200 includes step 206 of providing a strobel (such as strobel 10, etc.). Providing a strobel may include forming a strobel. In other embodiments of method 200, when provided in step 206, the strobel may already be in a formed state (e.g., at step 206, the strobel may be obtained in a formed state). Therefore, the entity that provides the strobel may both form the strobel and assemble it in the footwear, or a separate entity may form the strobel and the entity that performs method 200 may obtain the formed strobel to perform method 200. Therefore, providing step 206 may or may not include forming a strobel.

[0156] In an embodiment including forming a strobel, step 206 may include a sub-step in which the first polymer sheet 28 and the second polymer sheet 30 are welded together at the first weld W1 and the second weld W2 in the peripheral flange 20 to form the polymer bladder 16 having the inner cavity 18, and because the welds W1, W2 create the ridges 38, 40, the grooves 22 are formed in the peripheral flange 20. As previously described, the welding may be radio frequency welding, which is accomplished when mold portions, such as mold portions 34A, 34B and mold insert 34C (or mold portions 134A, 134B and mold inserts 134C, 134D) are closed together on the polymer sheets 28, 30 and the power supply 36 supplies energy to generate an alternating electric field that heats the polymer sheets 28, 30 to create a weld at the location where the mold insert 34C (or 134C, 134D) is applied to the polymer sheets 28, 30.

[0157] Separately or simultaneously with the sub-step of welding the first weld W1 and the second weld W2, step 206 may include the sub-step of welding the internal weld 60 by radio frequency welding through the protrusions 72A, 72B. For example, if the portion of the tool assembly having the ridges 94, 96 (e.g., the mold portions 34A, 34B or 134C, 134D) and the portion having the protrusions 72A, 72B (e.g., the mold inserts 34C, 34D) or the portion having the protrusions 172A, 172B (e.g., the mold inserts 134C, 134D) are simultaneously applied to the sheets 28, 30, the internal weld 60 will be provided simultaneously with the welds W1, W2.

[0158] Part 200A of method 200 may include a step in which one or more locating features, such as notches 93A, protrusions 93H, or markings or holes (both indicated as locating features 93D) are provided on the Strobel 10. In some embodiments, the locating features may be provided during the radio frequency welding included in step 202 of providing the Strobel as described. Alternatively, the notches 93A, protrusions 93H or holes 93D or markings may be cut, stamped, printed or otherwise formed in a separate subsequent step.

[0159] For some Strobels, portion 200A of method 200 may include the step of cutting holes in the lasting component, such as cutting holes 19, 19A, 19B in lasting components 17, 17A, 17B, respectively. Portion 200A of method 200 may include the step of placing a polymer bladder at the hole, such as placing polymer bladders 16, 16A, 16B at holes 19, 19A, 19B, respectively. Portion 200A of method 200 may include step 216 of aligning the polymer bladder with the lasting component, such as by aligning one or more locating features 93A of polymer bladder 16, 16A, 16B, etc. with one or more locating features 93G of lasting component 17, 17A, 17B, etc.

[0160] Portion 200A of method 200 includes step 218 of securing the lasting component to the bladder along the grooves in the peripheral flange. For example, once the polymer bladder and the lasting component are aligned in step 216, portion 200A of method 200 can proceed to step 218 and the lasting component can be secured to the polymer bladder, such as at the peripheral flange 20 or at the edges 90D, 90F, 90G, as described with respect to various embodiments, such as by sewing a first series of stitches 81 through the lasting component and the polymer bladder.

[0161] The Strobel 10 manufactured according to portion 200A of method 200 may be a first Strobel corresponding to a first footwear size, such as Strobel 10. Portion 200A of method 200 may be repeated to manufacture a second Strobel (e.g., Fig.32 The second Strobel 110 corresponds to a second shoe size that is larger than the first shoe size and has an internal weld 60 including the same pattern of rows and columns as on the first Strobel and at least one additional column or row of internal welds 60A, as referred to herein Fig.32 As described. The second strobel can be formed from the same polymer sheets 28, 30, for example, at a different location on the polymer sheets 28, 30 than the first footwear strobel. Alternatively, a different set of polymer sheets can be used, including a first sheet and a second sheet, such as the first polymer sheet 28 and the second polymer sheet 30. For the first footwear size, the same pattern of internal welds 60 as on the smaller strobel is repeated, and only the internal welds 60A are added to one or more of the existing rows or columns of internal welds 60, or additional rows of internal welds 60A and / or additional columns of internal welds 60A are added, while maintaining the same spacing between adjacent internal welds, as described with reference to Figure 2 This provides consistent cushioning characteristics across different shoe sizes.

[0162] Fig.51The method 200 of manufacturing footwear depicted in the flowchart may include forming a Strobel 10 according to portion 200A of the method 200 of manufacturing a Strobel 10 (i.e., may include steps 206-218 and any or all of the sub-steps described with reference thereto), and then proceeding to portion 200B of the method 200 of manufacturing an article of footwear, or may include only portion 200B of the method 200 of manufacturing an article of footwear by starting with a pre-formed Strobel (i.e., starting at step 220).

[0163] refer to Fig.46 , the positioning features of the strobel 10 (e.g., notches 93A) can be aligned with the positioning features of the upper 14 (e.g., holes or markings 93B). Then in step 220, the strobel 10 can be secured to the upper 14, such as by a series of stitches 82 extending through the bladder 16 at the groove 22 (and / or through the upper component in embodiments where the upper 14 is secured to the upper component). In other words, in some embodiments, the stitches 82 (referred to as the second series of stitches) can extend only through the bladder and the upper 14, while in other embodiments, the stitches 82 can also extend through the bladder, the upper, and the upper component, and in still other embodiments, the stitches 82 can extend only through the upper component because the bladder is secured to the upper component with a separate series of stitches.

[0164] like Fig.36 As shown in FIG. 2 , prior to or concurrently with step 220, a protective cover 85 may be secured to the strobel 10, such as by sewing. In an exemplary embodiment, the protective cover 85 may overlie the strobel and may be secured to the strobel 10 only at the flange 20, for example, by sewing at or near the seam 82. The sewing may be computer sewing, or may be hand sewing.

[0165] Next, portion 200B of method 200 may proceed to a filling step in which, as described with reference to Fig.48200B, the polymer bladder is filled, such as by a source 99 of pressurized fluid, which may be nitrogen, air or another gas. Method 200B may then proceed to a sealing step in which the inner chamber 18 is sealed by sealing a filling port or other opening in the polymer bladder to keep the fluid in the inner chamber 18. Alternatively, if the polymer bladder 16 is expected to be under ambient pressure when assembling the footwear, part 200B of method 200 may skip the filling step. The environmental polymer bladder 16 may even be sealed by welding of step 206, in which case part 200B of method 200 may also skip the sealing step. In other embodiments, before part 200B of method 200 begins, the bladder 16 may have been filled (e.g., when provided under step 206, the bladder 16 may have been filled and sealed).

[0166] The upper 14 with the strobel 10 (or other strobel described herein) sewn thereto can then be placed on the last 84. This can be accomplished by placing the last 84 into the opening 86 of the upper 14 or by moving the upper 14 onto the last 84 so that the last 84 is located in the opening 86, as by Fig.49 , wherein the upper 14 and the Strobel 10 are moved in the direction of arrow A. In step 228, which may occur simultaneously with placing the Strobel 10 on the shoe last 84 or may occur after adjusting the Strobel 10 on the shoe last 84, one or more locating features of the Strobel (e.g., notches 93A, protrusions 93H, markings or holes 93D) are aligned with corresponding one or more locating features (e.g., markings or holes 93C, 93E) of the shoe last 84. The locating features on the shoe last 84 may have some predetermined tolerance range, such as by making the locating features on the shoe last 84 larger than the locating features on the Strobel 10 (or any other Strobel described herein), so that as long as the locating features of the Strobel overlap to some extent with the locating features of the shoe last 84, the parts are considered to be aligned accurately enough. However, if the locating features of the Strobel and the locating features of the last 84 are not sufficiently aligned, the upper 14 with the Strobel can be removed and then placed again on the last 84 to see if better alignment can be achieved. If better alignment cannot be achieved, the Strobel and the upper 14 are considered to be out of assembly tolerance and can be recycled.

[0167] If step 228 is completed with the locating features of the Strobel 10 and the locating features of the last 84 successfully aligned, then portion 200B of method 200 may proceed to step 230 and the midsole 83 may be secured to the upper 14 and / or the Strobel (such as the Strobel 10) while the upper 14 and the Strobel 10 are positioned on the last 84. Fig.5010 and the upper 14. The method 200 is described by the midsole 83 moving toward the strobel 10 and the upper 14 in the direction of arrow B. Where the strobel 10 and the upper 14 meet the midsole 83, an adhesive may be applied to the midsole 83 and / or the strobel 10 and the upper 14 to secure the midsole 83 to the upper 14, and / or the midsole 83 may be placed in a heated state, which causes it to be thermally bonded to the strobel 10 and the upper 14. In some embodiments, the assembled parts may then be heated by placing the assembled parts in a heater to activate the adhesive. Any other parts of the outsole or sole structure 80 (not shown) may also be secured to the midsole 83 or the upper 14, and then the method 200 is completed.

[0168] The following clauses provide exemplary configurations of the Strobel, articles of footwear, and methods of manufacture disclosed herein.

[0169] Item 1: An article of footwear comprising: a Strobel, the Strobel comprising: a polymer bladder defining an interior cavity and configured to retain a fluid in the interior cavity, the polymer bladder having a peripheral flange extending around at least a portion of a perimeter of the interior cavity; and wherein the peripheral flange defines a groove extending along the peripheral flange.

[0170] Clause 2: The article of footwear of Clause 1, further comprising: an upper; wherein the Strobel is secured to the upper.

[0171] Clause 3: The article of footwear as recited in Clause 2, wherein the strobel is secured to the upper by a series of stitches extending in the groove through the peripheral flange.

[0172] Clause 4: The article of footwear as recited in any of Clauses 2-3, further comprising: a midsole secured to at least one of the upper or the polymer bladder.

[0173] Clause 5: The article of footwear as recited in any of Clauses 3-4, further comprising: an upper component disposed at the flange; wherein the series of stitches further extends through the upper component.

[0174] Clause 6: An article of footwear as described in any of clauses 1-5, wherein: the polymer bladder includes a first polymer sheet and a second polymer sheet; the first polymer sheet is joined to the second polymer sheet at the peripheral flange; and the first polymer sheet is connected to the second polymer sheet at a plurality of internal welds, each of the plurality of internal welds extending only partially across the inner cavity.

[0175] Clause 7: The article of footwear as described in Clause 6, wherein: the internal welds are arranged in a pattern of rows and columns, wherein the rows are spaced apart in the longitudinal direction of the Strobel and the columns are spaced apart in the lateral direction of the Strobel; the internal welds of any two consecutive rows are offset from each other and the internal welds of alternating rows are aligned with each other; and the internal welds of any two consecutive columns are offset from each other and the internal welds of alternating columns are aligned with each other.

[0176] Clause 8: The article of footwear of Clause 7, wherein any two adjacent interior welds in one of the rows and interior welds in a column in a consecutive one of the rows and between the two adjacent interior welds are positioned to define corners of an equilateral triangle.

[0177] Clause 9: The article of footwear as recited in any of Clauses 6-8, wherein at least a majority of the interior welds are circular and have equal diameters.

[0178] Clause 10: An article of footwear as described in any of clauses 1-9, wherein: the peripheral flange has a first weld and a second weld spaced apart from the first weld; the first weld and the second weld extend longitudinally along the peripheral flange; the groove extends longitudinally along the peripheral flange between the first weld and the second weld; the first weld is on the inner side of the groove; and the second weld is on the outer side of the groove.

[0179] Clause 11: The article of footwear as described in any of clauses 1-10, wherein the polymer bladder has a locating feature, the locating feature being at least one of a notch in the outer edge of the peripheral flange, a protrusion at the outer edge of the peripheral flange, a hole in the polymer bladder, or a marking on the polymer bladder.

[0180] Item 12: A method of manufacturing footwear, comprising: securing a Strobel to a shoe upper along a groove in a peripheral flange of the Strobel; wherein the Strobel includes a polymer bladder defining an interior cavity and configured to retain a fluid in the interior cavity, the peripheral flange extending around at least a portion of the perimeter of the interior cavity.

[0181] Clause 13: The method of Clause 12, wherein securing the strobel to the upper is accomplished by sewing the strobel to the upper such that a series of stitches extend through the peripheral flange at the groove.

[0182] Clause 14: The method of Clause 12, further comprising: forming the strobel by welding a first polymer sheet and a second polymer sheet to one another to define the peripheral flange having the groove and to define a plurality of internal welds, each of the plurality of internal welds extending only partially across the interior cavity.

[0183] Clause 15: A method as described in Clause 14, wherein: the internal welds are arranged in a pattern of rows and columns, wherein the rows are spaced apart in the longitudinal direction of the Strobel and the columns are spaced apart in the transverse direction of the Strobel; the internal welds of any two consecutive rows are offset from each other and the internal welds of alternating rows are aligned with each other; the internal welds of any two consecutive columns are offset from each other and the internal welds of alternating columns are aligned with each other; and wherein any two adjacent internal welds in one row in the row and the internal welds in a column in a consecutive row in the row and between the two adjacent internal welds are positioned to define the corners of an equilateral triangle.

[0184] Clause 16: A method as described in any of clauses 14-15, wherein the Strobel is a first Strobel corresponding to a first shoe size, and the method further includes: manufacturing a second Strobel corresponding to a second shoe size larger than the first shoe size by welding the same or different sheets to each other to define a polymer bladder, the polymer bladder having: an inner cavity, the polymer bladder being configured to retain a fluid in the inner cavity; and a peripheral flange, the peripheral flange extending around at least a portion of the perimeter of the inner cavity, the peripheral flange defining a groove extending along the peripheral flange; wherein welding the same or different sheets to each other includes welding internal welds in a pattern of rows and columns as on the first Strobel with at least one additional row or column.

[0185] Clause 17: The method as described in any of Clauses 12-16 also includes: placing the upper with the Strobel fixed to the upper on a shoe last; wherein placing the upper with the Strobel sewn to the upper on the shoe last includes aligning a positioning feature on the Strobel with the shoe last; and wherein the positioning feature on the Strobel is at least one of a recess in the outer edge of the peripheral flange, a protrusion at the outer edge of the peripheral flange, a hole in the polymer bladder, or a mark on the polymer bladder.

[0186] Clause 18: The method of Clause 17, further comprising: securing a midsole to at least one of the upper or the strobel while the upper and the strobel are on the last.

[0187] Clause 19: A method as described in any of Clauses 12-18, wherein the polymer bladder is in an uninflated state when the Strobel is fixed to the upper, and the method further comprises: inflating the polymer bladder after the Strobel is fixed to the upper; and sealing the inner cavity after the inner cavity is inflated; wherein the upper with the Strobel fixed to the upper is placed on the last after the polymer bladder is inflated and the inner cavity is sealed.

[0188] Clause 20: The method of any one of Clauses 12-19, further comprising: providing a lasting component at the flange before securing the Strobel to the upper.

[0189] Item 21: A Strobel for an article of footwear, the Strobel comprising: a polymer bladder defining an interior cavity and configured to retain a fluid in the interior cavity, the polymer bladder having a peripheral flange extending around at least a portion of a perimeter of the interior cavity; and wherein the peripheral flange defines a groove extending along the peripheral flange.

[0190] Clause 22: A Stronbel as described in Clause 21, wherein: the polymer bladder comprises a first polymer sheet and a second polymer sheet; the first polymer sheet is joined to the second polymer sheet at the peripheral flange; and the first polymer sheet is connected to the second polymer sheet at a plurality of internal welds, each of the plurality of internal welds extending only partially across the inner cavity.

[0191] Clause 23: A Strobel as described in Clause 22, wherein: the internal welds are arranged in a pattern of rows and columns, wherein the rows are spaced apart along the longitudinal direction of the Strobel and the columns are spaced apart along the transverse direction of the Strobel; the internal welds of any two consecutive rows are offset from each other and the internal welds of alternating rows are aligned with each other; and the internal welds of any two consecutive columns are offset from each other and the internal welds of alternating columns are aligned with each other.

[0192] Clause 24: The Strobel of Clause 23, wherein any two adjacent internal welds in one of the rows and the internal welds in a column between the two adjacent internal welds in a consecutive one of the rows are positioned to define corners of an equilateral triangle.

[0193] Clause 25: The Stronbel of any of Clauses 22-24, wherein at least a majority of the internal welds are circular and have equal diameters.

[0194] Clause 26: A Stronbel as described in any of Clauses 21-25, wherein: the peripheral flange has a first weld and a second weld spaced apart from the first weld; the first weld and the second weld extend longitudinally along the peripheral flange; the groove extends longitudinally along the peripheral flange between the first weld and the second weld; the first weld is on the inner side of the groove; and the second weld is on the outer side of the groove.

[0195] Clause 27: The Stronbel as described in Clause 26, wherein: the peripheral flange includes a first ridge protruding at the outer surface of the peripheral flange between the first weld and the groove; and the peripheral flange includes a second ridge protruding at the outer surface of the peripheral flange between the second weld and the groove.

[0196] Clause 28: The Stronbel of any of Clauses 21-27, wherein the polymer bladder has a locating feature, the locating feature being at least one of a notch in the outer edge of the peripheral flange, a hole in the polymer bladder, or a marking on the polymer bladder.

[0197] Item 29: An article of footwear comprising: an upper; a strobel, the strobel comprising: a polymer bladder defining an interior cavity and configured to retain a fluid in the interior cavity, the polymer bladder having a peripheral flange extending around at least a portion of a perimeter of the interior cavity; wherein the peripheral flange defines a groove extending along the peripheral flange; and wherein the strobel is secured to the upper by a series of stitches extending in the groove through the peripheral flange.

[0198] Item 30: An article of footwear as described in Item 29, wherein: the polymer bladder includes a first polymer sheet and a second polymer sheet; the first polymer sheet is joined to the second polymer sheet at the peripheral flange; and the first polymer sheet is connected to the second polymer sheet at a plurality of internal welds, each of the plurality of internal welds extending only partially across the inner cavity.

[0199] Item 31: An article of footwear as described in Item 30, wherein: the internal welds are arranged in a pattern of rows and columns, wherein the rows are spaced apart in the longitudinal direction of the Strobel and the columns are spaced apart in the lateral direction of the Strobel; the internal welds of any two consecutive rows are offset from each other and the internal welds of alternating rows are aligned with each other; and the internal welds of any two consecutive columns are offset from each other and the internal welds of alternating columns are aligned with each other.

[0200] Clause 32: The article of footwear of Clause 31, wherein any two adjacent interior welds in one of the rows and interior welds in a column in a consecutive one of the rows and between the two adjacent interior welds are positioned to define corners of an equilateral triangle.

[0201] Clause 33: The article of footwear as recited in any of Clauses 30-32, wherein at least a majority of the interior welds are circular and have equal diameters.

[0202] Clause 34: An article of footwear as described in any of clauses 29-33, wherein: the peripheral flange has a first weld and a second weld spaced apart from the first weld; the first weld and the second weld extend longitudinally along the peripheral flange; the groove extends longitudinally along the peripheral flange between the first weld and the second weld; the first weld is on the inner side of the groove; and the second weld is on the outer side of the groove.

[0203] Clause 35: The article of footwear as described in Clause 34, wherein: the peripheral flange includes a first ridge protruding at the outer surface of the peripheral flange between the first weld and the groove; and the peripheral flange includes a second ridge protruding at the outer surface of the peripheral flange between the second weld and the groove.

[0204] Clause 36: The article of footwear as recited in any of clauses 29-35, wherein the polymeric bladder has a locating feature that is at least one of a notch in an outer edge of the peripheral flange, a hole in the polymeric bladder, or a marking on the polymeric bladder.

[0205] Clause 37: The article of footwear as recited in any of Clauses 29-36, further comprising: a midsole secured to at least one of the upper or the polymer bladder.

[0206] Clause 38: The article of footwear as recited in any of Clauses 29-37, further comprising: an upper component disposed at the flange; wherein the series of stitches further extends through the upper component.

[0207] Item 39: A method of manufacturing footwear, comprising: forming a Strobel by the following steps: welding a first polymer sheet and a second polymer sheet to each other to define a polymer bladder, the polymer bladder having: an inner cavity, the polymer bladder being configured to retain a fluid in the inner cavity; a peripheral flange, the peripheral flange extending around at least a portion of the perimeter of the inner cavity; and wherein the welding is at the peripheral flange, and the peripheral flange defines a groove extending along the peripheral flange.

[0208] Clause 40: The method of Clause 39, wherein welding the first polymer sheet and the second polymer sheet to one another comprises welding a plurality of internal welds, each of the plurality of internal welds extending only partially across the inner cavity.

[0209] Clause 41: A method as described in Clause 40, wherein: the internal welds are arranged in a pattern of rows and columns, wherein the rows are spaced apart along the longitudinal direction of the Strobel and the columns are spaced apart along the transverse direction of the Strobel; the internal welds of any two consecutive rows are offset from each other and the internal welds of alternating rows are aligned with each other; and the internal welds of any two consecutive columns are offset from each other and the internal welds of alternating columns are aligned with each other.

[0210] Item 42: A method as described in Item 41, wherein the Strobel is a first Strobel corresponding to a first shoe size, and the method further includes: manufacturing a second Strobel corresponding to a second shoe size larger than the first shoe size by welding the same or different sheets to each other to define a polymer bladder, the polymer bladder having: an inner cavity, the polymer bladder being configured to retain a fluid in the inner cavity; a peripheral flange, the peripheral flange extending around at least a portion of the perimeter of the inner cavity, the peripheral flange defining a groove extending along the peripheral flange; and wherein welding the same or different sheets to each other includes welding internal welds in a pattern of rows and columns as on the first Strobel with at least one additional row or column.

[0211] Clause 43: A method as described in any of clauses 29-42, wherein welding the first polymer sheet and the second polymer sheet to each other includes welding a first weld and a second weld, the first weld and the second weld are spaced apart from each other and extend longitudinally along the peripheral flange, wherein the groove extends longitudinally along the peripheral flange between the first weld and the second weld.

[0212] Clause 44: The method of any one of clauses 29-43, further comprising: providing a positioning feature on the Strobel; wherein the positioning feature is at least one of a notch in the outer edge of the peripheral flange, a hole in the polymer bladder, or a mark on the polymer bladder.

[0213] Item 45: A method of manufacturing footwear, comprising: stitching a Strobel to a shoe upper along a groove in a peripheral flange of the Strobel such that a series of stitches extend through the peripheral flange at the groove; wherein the Strobel includes a polymer bladder defining an interior cavity and configured to retain a fluid in the interior cavity, and the peripheral flange extends around at least a portion of the perimeter of the interior cavity.

[0214] Clause 46: The method of Clause 45, further comprising: forming the strobel by welding a first polymer sheet and a second polymer sheet to one another to define the peripheral flange having the groove and to define a plurality of internal welds, each of the plurality of internal welds extending only partially across the interior cavity.

[0215] Clause 47: A method as described in Clause 46, wherein: the internal welds are arranged in a pattern of rows and columns, wherein the rows are spaced apart along the longitudinal direction of the Strobel and the columns are spaced apart along the transverse direction of the Strobel; the internal welds of any two consecutive rows are offset from each other and the internal welds of alternating rows are aligned with each other; and the internal welds of any two consecutive columns are offset from each other and the internal welds of alternating columns are aligned with each other.

[0216] Item 48: A method as described in Item 47, wherein the Strobel is a first Strobel corresponding to a first shoe size, and the method further includes: manufacturing a second Strobel corresponding to a second shoe size larger than the first shoe size by welding the same or different sheets to each other to define a polymer bladder, the polymer bladder having: an inner cavity, the polymer bladder being configured to retain a fluid in the inner cavity; a peripheral flange, the peripheral flange extending around at least a portion of the perimeter of the inner cavity, the peripheral flange defining a groove extending along the peripheral flange; wherein welding the same or different sheets to each other includes welding internal welds in a pattern of rows and columns as on the first Strobel with at least one additional row or column.

[0217] Clause 49: The method of any of Clauses 45-47, further comprising: placing the upper with the strobel stitched thereto on a last.

[0218] Clause 50: The method of Clause 49, wherein placing the upper with the strobel stitched thereto on the last comprises aligning locating features on the strobel with locating features on the last.

[0219] Clause 51: The method of Clause 50, wherein the locating feature on the Strobel is at least one of a notch in the outer edge of the peripheral flange, a hole in the polymer bladder, or a marking on the polymer bladder.

[0220] Clause 52: The method of any of Clauses 49-51, further comprising: securing a midsole to at least one of the upper or the strobel while the upper and the strobel are on the last.

[0221] Clause 53: A method as described in any of Clauses 49-52, wherein the polymer bladder is in an uninflated state when the Strobel is sewn to the upper, and the method further comprises: inflating the polymer bladder after the Strobel is sewn to the upper; and sealing the inner cavity after the inner cavity is inflated; wherein after the polymer bladder is inflated and the inner cavity is sealed, the upper with the Strobel sewn to the upper is placed on the shoe last.

[0222] Clause 54: The method of any one of Clauses 45-53, further comprising: providing an upper component at the flange before sewing the Strobel to the upper; wherein when the Strobel is sewn to the upper, the series of stitches further extend through the upper component.

[0223] To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including claims). In addition, all references mentioned are incorporated herein in their entirety.

[0224] "Articles of footwear," "articles of footwear," and "footwear" may be considered both as machines and manufactured articles. Assembled, ready-to-wear articles of footwear (e.g., shoes, sandals, boots, etc.) and individual components of articles of footwear (e.g., midsoles, outsoles, upper components, etc.) prior to final assembly into ready-to-wear articles of footwear are considered and may be referred to interchangeably as "articles of footwear" or "footwear" in the singular or plural.

[0225] "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 in view 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 "approximately" in all cases, regardless of whether "approximately" actually appears before the numerical value. "Approximately" indicates that the numerical value described allows some slight imprecision (some approach to the accuracy of the value; approximately or moderately close to the value; almost). If the imprecision provided by "approximately" is not otherwise understood in this ordinary meaning in the art, then "approximately" as used herein at least indicates the changes that may be caused by the ordinary methods of measuring and using these parameters. In addition, the disclosure of a range should be understood to specifically disclose all values ​​within the range and further divided ranges.

[0226] The terms "comprising", "including" and "having" are inclusive and therefore specify the presence of the stated features, steps, operations, elements or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements or components. 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" is understood to include any possible combination of the referenced items, including "any" of the referenced items. The term "any" is understood to include any possible combination of the referenced claims of the appended claims, including "any" of the referenced claims.

[0227] For consistency and convenience, directional adjectives may be used throughout this detailed description corresponding to the illustrated embodiments. One 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.

[0228] The term "longitudinal" refers to a direction extending along the length of a component. For example, the longitudinal direction of an article of footwear extends between the forefoot region and the heel region of the article of footwear. The terms "forward" or "anterior" are used to refer to the general direction from the heel region toward the forefoot region, and the terms "rearward" or "posterior" are 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 by a longitudinal axis and a forward longitudinal direction and a rearward longitudinal direction along the axis. The longitudinal direction or longitudinal axis may also be referred to as a front-rearward direction or a front-rearward axis.

[0229] The term "lateral" refers to a direction extending along the width of a component. For example, the lateral direction of an article of footwear extends between the lateral side and the medial side of the article of footwear. The lateral direction or lateral axis may also be referred to as the lateral direction or lateral axis or the medial direction or medial axis.

[0230] The term "vertical" refers to a direction that is generally perpendicular to both the lateral direction and the longitudinal direction. For example, in the case where the sole structure is placed flat on a ground surface, the vertical direction may extend upward from the ground surface. It will be understood that each of these directional adjectives may be applied to a separate component of the sole structure. The term "upward" or "upwards" refers to a vertical direction pointing to the top of a component, which may include the instep, fastening area, and / or throat of an upper. The term "downward" or "downwards" refers to a vertical direction that is opposite to the upward direction, pointing to the bottom of a component, and may generally point to the bottom of the sole structure of an article of footwear.

[0231] The "interior" of an article of footwear (such as a shoe) refers to the portion of the space occupied by the wearer's foot when the article of footwear is worn. The "inner side" of a component refers to the side or surface of the component that is oriented toward (or will be oriented toward) the interior of the component or article of footwear in the assembled article of footwear. The "outer side" or "exterior" of a component refers to the side or surface of the component that is oriented away from (or will be oriented away from) the interior of the article of footwear in the assembled article of footwear. In some cases, other components may be located between the inner side of the component and the interior in the assembled article of footwear. Similarly, other components may be located between the outer side of the component and the space outside the assembled article of footwear. In addition, the terms "inward" and "inwardly" refer to the direction toward the interior of a component or article of footwear (such as a shoe), while the terms "outward" and "outwardly" refer to the direction toward the exterior of a component or article of footwear (such as a shoe). In addition, the term "proximal" refers to a direction closer to the center of the footwear component or closer to the foot when the foot is inserted into the footwear article when the footwear article is worn by the user. Similarly, the term "distal" refers to a relative position further away from the center of the footwear component or further away from the foot when the foot is inserted into the footwear article when the footwear article is worn by the user. Therefore, the terms proximal and distal can be understood to provide generally opposite terms to describe relative spatial positions.

[0232] Although various embodiments have been described, this description is intended to be exemplary rather than restrictive, and it will be apparent to those of ordinary skill in the art that more embodiments and implementations within the scope of the embodiments are possible. Any feature of any embodiment may be used in combination with or in place of any other feature or element in any other embodiment, unless specifically limited. Therefore, the embodiments are not limited except in accordance with the appended claims and their equivalents. Moreover, various modifications and variations may be made within the scope of the appended claims.

[0233] Although several modes for implementing many aspects of the present teachings have been described in detail, those skilled in the art to which these teachings relate will recognize a variety of alternative aspects of implementing the present teachings within the scope of the appended claims. It is intended that all content contained in the above description or shown in the accompanying drawings should be interpreted as an illustration and example of the entire range of alternative embodiments that will be recognized by ordinary technicians, such as implied by the included content, structurally and / or functionally equivalent to the included content, or otherwise obvious based on the included content, and not limited to only those explicitly depicted and / or described embodiments.

Claims

1. An article of footwear, include: Stronbel, said Stronbel includes: a polymeric bladder defining an interior cavity and configured to retain a fluid within the interior cavity, the polymeric bladder having a peripheral flange extending around at least a portion of a perimeter of the interior cavity; and an upper component, the upper component being sewn to the polymer bladder; in: The peripheral flange defines a groove extending along the peripheral flange; The upper part has a hole; The polymeric bladder extends partially through the aperture; The peripheral flange has a first weld and a second weld spaced apart from the first weld; The first weld and the second weld extend lengthwise along the peripheral flange; The groove extends lengthwise along the peripheral flange between the first weld and the second weld; The first weld is inside the groove; and The second weld is outside the groove.

2. The article of footwear according to claim 1, wherein the lasting member is stitched to the peripheral flange using a stitch extending through the peripheral flange at the groove.

3. The article of footwear according to claim 1, further comprising: include: vamp; The Strobel is fixed to the shoe upper.

4. The article of footwear according to claim 1, in: The polymer bladder and the upper component both have a forefoot region, a midfoot region, and a heel region; and The apertures extend in the forefoot region, the midfoot region, and the heel region.

5. The article of footwear according to claim 1, in: The upper component has a forefoot region, a midshoe region and a heel region; the aperture is in the forefoot region and does not extend in the heel region; and The polymer bladder extends in the forefoot area and not in the heel area.

6. The article of footwear according to claim 1, in: The upper component has a forefoot region, a midshoe region and a heel region; The aperture extends in the heel region; and The polymer bladder extends in the heel region but not in the midfoot region or the forefoot region.

7. The article of footwear according to claim 1, further comprising: include: A covering layer covers the proximal side of the polymer bladder and is sewn to the polymer bladder at the peripheral flange, or to the lasting component.

8. The article of footwear according to claim 1, further comprising: include: A cover layer covers the foot-facing surface of the polymer bladder and is stitched to the polymer bladder at the peripheral flange.

9. The article of footwear according to claim 1, in: The peripheral flange includes a first ridge protruding at an outer surface of the peripheral flange between the first weld and the groove; and The peripheral flange includes a second ridge protruding at the outer surface of the peripheral flange between the second weld and the groove.

10. The article of footwear according to claim 9, in: The groove, the first weld and the second weld are located on a distal surface of the peripheral flange; The peripheral flange defines an additional groove extending along a proximal surface of the peripheral flange; the peripheral flange having an additional first weld on the proximal surface of the peripheral flange and an additional second weld spaced apart from the additional first weld; The additional first weld and the additional second weld extend lengthwise along the peripheral flange, and the additional groove extends lengthwise along the peripheral flange between the additional first weld and the additional second weld; The additional first weld is inside the additional groove; and The additional second weld is outside the additional groove.

11. The article of footwear according to claim 1, in: The polymer capsule includes a first polymer sheet and a second polymer sheet; the first polymer sheet is bonded to the second polymer sheet at the perimeter flange; and The first polymer sheet is joined to the second polymer sheet at a plurality of internal welds, each of the plurality of internal welds extending only partially laterally across the interior cavity.

12. The article of footwear according to claim 1, in: The internal welds are arranged in a pattern of rows and columns, wherein the rows are spaced apart in a longitudinal direction of the strobel and the columns are spaced apart in a transverse direction of the strobel; Any two consecutive rows of said internal welds are offset from each other and alternating rows of said internal welds are aligned with each other; and The internal welds of any two consecutive columns are offset from each other and the internal welds of alternating columns are aligned with each other.

13. The article of footwear according to claim 12, wherein any two adjacent interior welds in one of the rows and interior welds in a column in a consecutive one of the rows and between the two adjacent interior welds are positioned to define corners of an equilateral triangle.

14. The article of footwear according to claim 11, wherein at least a majority of the interior welds are circular and have equal diameters.

15. The article of footwear according to claim 1, wherein the Strobel has a positioning feature, the positioning feature being at least one of: a notch in the outer edge of the peripheral flange or a notch in the outer edge of the upper component, a hole in the polymer bladder or a hole in the upper component, a printed pattern on the polymer bladder, or a mark on the polymer bladder or a mark on the upper component.

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