Cushioning member for wearable article

Abstract

A cushioning component for a wearable article includes a bladder including a first barrier sheet and a second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, and sealing from each other along the peripheral bond to enclose the interior cavity and retain the gas in the interior cavity. The core includes at least one polymeric sheet disposed within the interior cavity, entirely inside the peripheral bond, and traversing the interior cavity between the opposing inner surfaces of the first and second barrier sheets, and bonding directly to opposite inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonding portions to secure the first barrier sheet to the second barrier sheet. The at least one polymeric sheet does not create any sealed chamber within the bladder that is not in fluid communication with the interior cavity.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 435,377, filed on December 27, 2022, which is incorporated by reference in its entirety. Technical Field

[0003] The present disclosure generally relates to a cushioning component for a wearable article that includes a bladder and a core of at least one polymer sheet disposed in the bladder. Background Art

[0004] Wearable articles, such as footwear, often include cushioning components. Some cushioning components are configured as fluid-filled bladders that enclose an interior cavity to retain gas within the interior cavity to provide cushioning when loaded. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The drawings described herein are for illustration purposes only, are schematic in nature, and are intended to be exemplary rather than limiting the scope of the present disclosure.

[0006] Figure 1 is a perspective view of a polymer sheet showing one side of the polymer sheet with a barrier ink disposed on the side.

[0007] Figure 2 yes Figure 1 A perspective view of the opposite side of a polymer sheet wherein the barrier ink is applied to the Figure 1 A different pattern than that shown on one side is provided on the opposite side.

[0008] Figure 3 Yes Figure 2 A cross-sectional view of a cushioning component of a core and a bladder having a first barrier sheet and a second barrier sheet, wherein the cushioning component is in an unexpanded state.

[0009] Figure 4 yes Figure 3 The buffer component is in an expanded state along Figure 6 A cross-sectional view taken along line 4-4 in FIG.

[0010] Figure 5 is along Figure 4 The line 5-5 in Figure 4 A cross-sectional view of a buffer component.

[0011] Figure 6 yes Figure 4 A perspective view of one side of a cushioning component.

[0012] Figure 7is a side view of an alternative embodiment of a cushioning component including a bladder and a core having a single polymer sheet disposed in the bladder.

[0013] Figure 8 yes Figure 7 A perspective view of a cushioning component.

[0014] Fig. 9 yes Figure 7 A plan view of a single polymer sheet of a core showing one side of the polymer sheet with the barrier ink disposed thereon.

[0015] Fig.10 yes Fig. 9 A plan view of the opposite side of a single polymer sheet wherein the barrier ink is in the form of Fig. 9 A different pattern than that shown on one side is provided on the opposite side.

[0016] Fig.11 is a perspective view of a first side of a first polymeric sheet for use in a multi-sheet core showing barrier ink disposed thereon in a first pattern and an opposing second side without any barrier ink disposed thereon.

[0017] Fig.12 Is in a multi-sheet core with Fig.11 20 is a perspective view of a second side of a second polymer sheet used in conjunction with a first polymer sheet of FIG. 10 , showing barrier ink disposed on the second side in a pattern consistent with the first pattern of the first sheet.

[0018] Fig.13 yes Fig.12 The second polymer sheet relative to Fig.12 0026] A perspective view of the device 100 is flipped in position to show a first side of a second polymer sheet with the barrier ink disposed thereon in a pattern that deviates from the first pattern of the first sheet.

[0019] Fig.14 It forms the core Fig.11 a first polymer sheet and Fig.13 A perspective view of a second polymer sheet.

[0020] Fig.15 Yes Fig.14 A cross-sectional view of a cushioning component of a core, wherein the cushioning component is in an unexpanded state.

[0021] Fig.16 yes Fig.15 A cross-sectional view of a cushioning component in a first expanded state.

[0022] Fig.17 yes Fig.16A cross-sectional view of a cushioning component in a second expanded state that is more expanded than the first expanded state.

[0023] Fig.18 is a perspective view showing the top and outside of a cushioning component having a core having a plurality of polymer sheets and Fig.17 The bonding pattern of the core is similar to the bonding pattern of .

[0024] Fig.19 is along Fig.18 The line 19-19 in Fig.18 A cross-sectional view of a buffer component.

[0025] Fig. 20 It shows Fig.18 A perspective view of the inside of the cushioning component.

[0026] Fig.21 is a perspective view from the rear, showing Fig.18 The rear and top of the cushioning component.

[0027] Fig. 22 Yes Fig.18 A lateral view of an article of footwear having a cushioning component.

[0028] Fig.23 is a lateral view of a sole structure for an article of footwear, the sole structure including a heel cushioning component having a core having a plurality of polymer sheets and Fig.17 The bonding pattern of the is similar to the bonding pattern of the and includes a foam midsole layer covering the heel cushioning component.

[0029] Fig.24 Yes Fig.23 A lateral view of an article of footwear with a sole structure.

[0030] Fig.25 is a plan view of an alternative embodiment of a cushioning component including a bladder, a forefoot wick having at least one polymer sheet disposed in the bladder, and a separate heel wick having at least one polymer sheet disposed in the bladder.

[0031] Fig.26 is a plan view of another alternative embodiment of a cushioning component including a bladder, a forefoot wick having at least one polymer sheet disposed in the bladder, and a separate heel wick having at least one polymer sheet disposed in the bladder.

[0032] Fig. 27 is a plan view of an alternative embodiment of a cushioning component including a bladder, a forefoot wick having at least one polymer sheet disposed in the bladder, and a separate heel wick having at least one polymer sheet disposed in the bladder. DETAILED DESCRIPTION

[0033] The present disclosure generally relates to a wearable article including a cushioning component having a bladder and a core disposed in the bladder, the core including at least one polymer sheet bonded to the inside of a barrier sheet of the bladder to act as a stretch component. Providing a stretch component within the bladder can be used to constrain the bladder when it is expanded, preventing it from adopting a spherical shape. A stretch component such as a core according to the present disclosure enables bonding of at least one polymer sheet to the barrier sheet at a bonding portion having a pattern, which patterns produce technical advantages in terms of the performance of the cushioning component and the ease of manufacturing of the cushioning component.

[0034] More specifically, a cushioning component for a wearable article includes a bladder, which includes a first barrier sheet and a second barrier sheet. The first barrier sheet and the second barrier sheet define an internal cavity between the relative inner surfaces of the first barrier sheet and the second barrier sheet, and are sealed to each other along a peripheral bonding portion to close the internal cavity and retain gas in the internal cavity. The cushioning component includes a core arranged in the internal cavity so that the core is completely spaced inward from the peripheral bonding portion. The core includes at least one polymer sheet, which crosses the internal cavity between the relative inner surfaces of the first barrier sheet and the second barrier sheet, and is directly bonded to the relative inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonding portions to fasten the first barrier sheet to the second barrier sheet. The at least one polymer sheet is displaced from the relative inner surface by gas at the unbonded area of ​​the at least one polymer sheet. The plurality of bonding portions are arranged so that the gas in the internal cavity is fluidly connected around the at least one polymer sheet without the at least one polymer sheet producing any sealed chamber in the bladder that is not fluidly connected to the internal cavity. In other words, the at least one polymer sheet does not subdivide the interior cavity into separate sealed sub-chambers.

[0035] In some embodiments, the at least one polymer sheet is a single polymer sheet and is bonded to both inner surfaces of the barrier sheet. In other embodiments, there are multiple polymer sheets that make up the core. By utilizing a barrier ink disposed on at least one polymer sheet, the pattern of the bond of the core to the inner surface of the barrier sheet (and the bond of adjacent polymer sheets in embodiments where the core includes more than one polymer sheet) is controlled to determine the final geometry of the complete cushioning component, including height differences in different areas of the footwear article, toe kick, etc.

[0036] Furthermore, utilizing barrier inks allows for ease of manufacturing since the barrier ink patterns can be relatively easily digitally achieved compared to other tensile component formations that require specific molds or mold inserts to control the bonding of the barrier sheet to an internally positioned polymer sheet.

[0037] In some embodiments, the core includes only a single polymer sheet bonded to opposing inner surfaces of the first barrier sheet and the second barrier sheet. In one example, the barrier ink pattern can be linear rows that create a pattern of bonds that provide a zigzag arrangement of the single polymer sheet between the barrier sheets. In yet other embodiments, the barrier ink pattern creates a pattern of bonds that extend outward from a central area in the array.

[0038] In other embodiments, the core comprises a plurality of polymer sheets, some of which have adjacent edges bonded to one another.The barrier ink pattern may produce a pattern of bonds providing a honeycomb arrangement of the polymer sheets of the core within the interior cavity.

[0039] By arranging the barrier ink so that it extends to the outer periphery of the core at the inner surface of the barrier sheet, and by ensuring that the outer periphery of the core is completely inside the peripheral bond of the barrier sheet, the pattern of the core's bond does not create any sealed chambers within the bladder that are not in fluid communication with the interior cavity. In this way, the core itself controls the final geometry of the expanded cushioning component, but does not affect the cushioning response of the cushioning component under dynamic loads. Additionally, by utilizing the barrier ink, the cushioning component can be relatively flat prior to expansion.

[0040] The above features and advantages and other features and advantages of the teachings of the present disclosure will be apparent from the following detailed description of the modes for carrying out the teachings of the present disclosure when considered in conjunction with the accompanying drawings. It should be understood that although embodiments may be described separately in the following drawings, their individual features may be combined into additional embodiments.

[0041] Figure 1 is included in Figures 3 to 6 A perspective view of a polymer sheet 10 in a core 12 of a cushioning component 14 is shown. The core 12 is bonded to a first barrier sheet 16 and a second barrier sheet 18 that form a bladder 20 that defines an interior cavity 21 between opposing interior surfaces of the first barrier sheet 16 and the second barrier sheet 18 (e.g., between an interior surface 17 of the first barrier sheet 16 and an interior surface 19 of the second barrier sheet 18). The polymer sheet 10 is a single polymer sheet and is the only polymer sheet included in the core 12. Although the polymer sheet 10 is a single polymer sheet, in some examples, it may include multiple layers of material, as discussed herein.

[0042] Figure 1One side 22 of the polymer sheet 10 is shown. The side 22 is referred to herein as the second side. The barrier ink 24 is disposed on the second side 22 of the polymer sheet 10 in a pattern of linear and parallel rows, including rows A, rows B, rows C, and rows D. The barrier ink 24 may be disposed on the sheet 10 via one or more print heads (not shown) controlled by a computer according to a stored algorithm representing a predetermined print pattern. The print pattern of rows A through D is referred to herein as the second predetermined pattern.

[0043] As used herein, the barrier ink may also be referred to as an anti-welding ink or anti-welding material and may be printed at all selected locations where the bonds of the polymer sheet 10 and the barrier sheets 16, 18 described herein are not desired according to different predetermined programmed patterns on each side 22, 26 of the polymer sheet 10. When bonded to each other, such as by heat treatment, the stacked flat polymer sheets 10 and barrier sheets 16, 18 produce bonds between adjacent sheets on all adjacent sheet surfaces except where the barrier ink is disposed. Thus, the pattern of the barrier ink determines the corresponding pattern of the resulting bonds in the finished cushioning component 14.

[0044] Figure 2 The barrier ink 24 is shown disposed on an opposite side 26 (referred to herein as the first side 26 ) in a different predetermined pattern (referred to as the first predetermined pattern) than on the second side 22 . Specifically, Figure 2 The first predetermined pattern shown is a pattern of linear and parallel rows, the rows including row E, row F, and row G.

[0045] from Figure 1 and Figure 2 As is apparent from the figure, the rows A, B, C, and D of the second predetermined pattern on the second side 22 are at least partially offset from and overlap the rows E, F, and G of the first predetermined pattern on the first side 26. In this arrangement, the area 26A between the rows E and F on the first side 26 is directly opposite (directly overlaying) the row C of the blocker ink 24 on the second side 22. The area 26B between the rows F and G on the first side 26 is directly opposite (directly overlaying) the row B of the blocker ink 24 on the second side 22. Similarly, the area 22A between the rows A and B on the second side 22 is directly opposite (directly below) the row G of the blocker ink 24 on the first side 26. The area 22B between the rows B and C on the second side 22 is directly opposite (directly below) the row F of the blocker ink 24 on the first side 26. The area 22C between the rows C and D on the second side 22 is directly opposite (directly below) the row E of the blocker ink 24 on the first side 26. The areas of the first side 26 and the second side 22 on which the barrier ink 24 is disposed (e.g., the areas at rows A, B, C, D, E, F, and G) will become Figure 8The only unbonded areas of the core 12 in the core 12 (eg, the only areas of the inner surfaces 17 , 19 of the core 12 facing the barrier sheets 16 and 18 that are not bonded to the barrier sheets 16 , 18 ).

[0046] The width of each of the regions 22A, 22B, and 22C between adjacent rows of the barrier ink 24 on the second side 22 is smaller than the width of each of the rows E, F, and G of the barrier ink 24 on the first side 26. Similarly, the width of each of the regions 26A and 26B between adjacent rows of the barrier ink 24 on the first side 26 is smaller than the width of each of the rows B and C of the barrier ink 24 on the second side 22. The width of each of the end regions 26D and 26C is smaller than the width of the corresponding rows A and D of the barrier ink 24. With this arrangement, no portion of any of the regions 22A, 22B, and 22C is opposite to a portion of the first side 26 that is not covered by the barrier ink 24, and no portion of any of the regions 26A, 26B, 26C, and 26D is opposite to a portion of the second side 22 that is not covered by the barrier ink 24.

[0047] like Figure 2 As shown, the barrier ink 24 extends to the outer periphery 34 of the core 12 at the first side 26 of the polymer sheet 10 and the second side 22 of the polymer sheet 10. Specifically, each of the rows A, B, C, D, E, F, and G extends from a first edge 34A of the outer periphery 34 to an opposite second edge 34B along the width of the core 12. Row D extends along the entire edge 34C of the outer periphery 34, and row A extends along the entire opposite edge 34D of the outer periphery 34.

[0048] This arrangement of the pattern of the barrier ink 24 relative to the outer perimeter 34, and the placement of the core 12 so that the entire outer perimeter 34 is completely inside the peripheral bond 38 (where the first barrier sheet 16 is bonded to the second barrier sheet 18), ensures that the core 12 will tether the first barrier sheet 16 and the second barrier sheet 18 without creating any sealed chamber that is not in fluid communication with the interior cavity 21 defined between the opposing inner surfaces 17, 19 of the barrier sheets 16, 18. Thus, the core 12 will collapse under the dynamic compressive load of the cushioning component 14 to recover toward a flat state and act as a tether to control and vary the distance between the respective inner surfaces 17, 19 of the barrier sheets 16, 18 without affecting the ability of the bladder 20 to compress under load.

[0049] Conventional stretch components may include a first polymer sheet bonded only to the inner surface of a first barrier sheet, a second polymer sheet bonded only to the inner surface of a second barrier sheet, and a plurality of tethers extending from the first polymer sheet to the second polymer sheet. Due to this configuration, such conventional stretch components are not relatively flat or sheet-like prior to inflating the interior cavity of the bladder in which they are disposed, and are not suitable for heat pressing to create a core of multiple polymer sheets or to bond a single polymer sheet or a core of multiple polymer sheets to the inner surface of a barrier sheet.

[0050] The barrier sheets 16,18 of the bladder 20 can be formed by various materials including various polymers, and various polymers can elastically retain fluids such as air or another gas. The polymer sheet 10 can be formed by one or more materials identical to the barrier sheets 16,18 described herein, or can be formed by a polymer material that does not necessarily retain fluids, because unlike the barrier sheets 16,18, the polymer sheet 10 acts as a tether, but does not seal any internal cavity like the barrier sheets 16,18. The example of the polymer material for barrier sheets 16,18 and polymer sheets 10 can include thermoplastic polyurethane, polyurethane, polyester, polyester polyurethane and polyether polyurethane. In addition, barrier sheets 16,18 and polymer sheets 10 can be formed by layers of different materials. In one embodiment, the barrier sheets 16, 18 and / or polymer sheet 10 are formed of a film having one or more layers of thermoplastic polyurethane having one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH) that are impermeable to pressurized fluids contained therein, as disclosed in U.S. Pat. No. 6,082,025, which is incorporated by reference in its entirety. The barrier sheets 16, 18 and polymer sheet 10 may also be formed of a material comprising alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. Pat. Nos. 5,713,141 and 5,952,065 to Mitchell et al., which are incorporated by reference in their entirety. Alternatively, the layers may include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and regrind material of ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. The barrier sheets 16, 18 and polymer sheet 10 may also be flexible microlayer films comprising alternating layers of gas barrier material and elastomeric material, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk et al., which are incorporated by reference in their entirety. Additional suitable materials for the barrier sheets 16, 18 and polymer sheet 10 are disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy, which are incorporated by reference in their entirety. Other suitable materials for barrier sheets 16, 18 and polymer sheet 10 include thermoplastic films containing crystalline materials (such as disclosed in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy) and polyurethanes including polyester polyols (such as disclosed in U.S. Pat. Nos. 6,013,340, 6,203,868 and 6,321,465 to Bonk et al.), which are incorporated by reference in their entirety. When selecting materials for barrier sheets 16, 18 and polymer sheet 10, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent may be considered. The thickness of barrier sheets 16, 18 and polymer sheet 10 may be selected to provide these properties.

[0051] Figure 3 is a cross-sectional view of the buffer component 14. Figure 3 , a first predetermined pattern of barrier ink 24 on a first side 26 of the polymer sheet 10 is disposed against the inner surface 17 of the first barrier sheet 16, and a second predetermined pattern of barrier ink 24 on a second side 22 of the polymer sheet 10 is disposed against the inner surface 19 of the second barrier sheet 18. Portions of one or both of the inner surfaces 17, 19 outside the outer periphery of the core 12 and inside where the peripheral bond 38 is formed may also be pre-printed or otherwise treated with the barrier ink 24 so that these portions of the inner surfaces 17, 19 do not bond to each other.

[0052] A first pattern of bonds 44 is formed at the joining areas of the first side 26 of the polymer sheet 10 and the inner surface 17 of the first barrier sheet 16 (e.g., without the presence of the barrier ink 24 between the first side 26 and the inner surface 17). A second pattern of bonds 46 is formed at the joining areas of the second side 22 of the polymer sheet 10 and the inner surface 19 of the second barrier sheet 18 (e.g., without the presence of the barrier ink 24 between the second side 22 and the inner surface 19 and between the inner surfaces 19). The barrier ink 24 prevents bonding at any joining areas where it is provided. Figure 3 As can be seen in FIG. 1 , when the interior cavity 21 of the bladder 20 is unexpanded, the core 12 lies flat within the bladder 20 with the unbonded areas (areas where the barrier ink 24 is) contacting the opposing interior surfaces 17 , 19 .

[0053] Figure 4 yes Figure 3 The buffer component 14 is in an expanded state and along Figure 6 The cross-sectional view taken along line 4-4 in FIG. Inflating the interior cavity 21 with gas causes the polymer sheet 10 to be stretched between the barrier sheets 16, 18 and from Figure 3 The relatively flat state moves to Figure 8 As will be appreciated by those skilled in the art, a small portion of the peripheral bond 38 may initially remain open to allow the interior cavity 21 to be inflated with a gas, such as air or nitrogen, and then may be sealed after inflation to completely enclose the interior cavity 21, retaining the gas in the interior cavity, or a fill tube may extend through the peripheral bond 38, and then the peripheral bond 38 may be plugged after inflation.

[0054] Figure 5 is along Figure 4 The line 5-5 in Figure 4 A cross-sectional view of the buffer component. Figure 4 and Figure 5As best seen in FIG. 1 , the core 12 is disposed within the interior cavity 21 and is completely spaced inwardly from the peripheral bond 38. The four edges 34A, 34B, 34C, and 34D of the outer perimeter 34 of the core 12 are shown completely inboard of the peripheral bond 38. Figure 4 In a relatively extended state, the core 12 (more specifically the polymer sheet 10) traverses the internal cavity 21 between the relative inner surfaces 17, 19 of the first barrier sheet 16 and the second barrier sheet 18, and is directly bonded to the relative inner surfaces 17, 19 of the first barrier sheet 16 and the second barrier sheet 18 at multiple bonding portions 44, 46 to secure the first barrier sheet 16 to the second barrier sheet 18.

[0055] The polymer sheet 10 is displaced from the opposing inner surfaces 17, 19 by the gas at the unbonded areas of the polymer sheet 10 (areas where the barrier ink 24 is initially disposed). The bonds 44, 46 are arranged in a pattern (e.g., a first pattern of bonds 44 at the first barrier sheet 16 and a second pattern of bonds 46 at the second barrier sheet 18) such that the gas in the interior cavity 21 is in fluid communication around the polymer sheet 10 without the polymer sheet 10 creating any sealed chambers within the bladder 20 that are not in fluid communication with the interior cavity 21.

[0056] More specifically, because each row of the barrier ink 24 extends to the outer periphery 34 of the core 12 at the inner surface 17 of the first barrier sheet 16 (e.g., rows E, F, and G) or at the inner surface 19 of the second barrier sheet 18 (e.g., rows A, B, C, and D); there are no unbonded portions of the polymer sheet 10 that are not open to the outer periphery 34 and therefore interrupt fluid communication with the gas in the interior cavity 21. The second set of bonds 46 is offset from the first set of bonds 44, such that the second set of bonds 46 alternates with the first set of bonds 44 along the length of a single polymer sheet 10 of the core 12, as shown in FIG. Figure 4 , where the length is considered to be in the direction from edge 34C to edge 34D of polymer sheet 10. Because first set of bonds 44 are at regions 26A, 26B, 26C, and 26D, bonds 46 are linear bonds arranged in rows. Because second set of bonds 46 are at regions 22A, 22B, and 22C, bonds 46 are also linear bonds arranged in rows.

[0057] like Figure 3 to Figure 4 As is apparent from the figure, the thickness T1 of the polymer sheet 10 is no greater than the thickness T2 of the first barrier sheet 16, and no greater than the thickness T3 of the second barrier sheet 18. Maintaining the sheet thickness of the polymer sheet 10 no greater than the sheet thickness of the barrier sheets 16 and 18 helps ensure the flexibility of the core 12 to act as a tether that easily moves toward the core 12 under compressive loads. Figure 7 The relatively flat state collapses backwards.

[0058] Figure 6 It is shown that the tension created in the polymer sheet 10 by the expansion of the internal cavity 21 causes the portion of the first barrier sheet 16 inboard of the outer periphery 34 of the core 12 to be pulled downward at the bond 44, as indicated by the contoured outer surface 50 of the first barrier sheet 16. Because the outer periphery 34 of the core 12 is completely inboard of the peripheral bond 38, the barrier sheets 16, 18 are not fastened together at the peripheral portion of the internal cavity 21 outside the outer periphery 34 of the core 12 and inside the peripheral bond 38. The distance between the inner surfaces 17 and 19 and the final height of the cushioning component 14 can therefore be maximum outside the core 12. The top outer surface 50 is shown with hidden lines, where the first barrier sheet 16 is pulled downward by the polymer sheet 10 at the bond 44.

[0059] Similarly, the tension created in the polymer sheet 10 by the expansion of the interior cavity 21 causes the portion of the second barrier sheet 18 inboard of the outer periphery 34 of the core 12 to be pulled upward at the bond 46, as indicated by the contoured outer surface 52 of the second barrier sheet 18. The pattern of the barrier ink 24 printed on the polymer sheet 10 and the resulting pattern of bonds 44, 46 of the polymer sheet 10 of the core 12 to the barrier sheets 16, 18 can be selected to control the resulting profile of the outer surfaces 50, 52 of the barrier sheets 16, 18.

[0060] Figure 7 1 is a side view of an alternative embodiment of a cushioning component 114 including a bladder 120 including a first barrier sheet 116 and a second barrier sheet 118 bonded to each other at a peripheral bond 138 to enclose an interior cavity 121 and retain gas in the interior cavity 121. The cushioning component 114 includes a core 112 disposed within the interior cavity 121 of the bladder 120. The core 112 is a single polymer sheet 110. The first barrier sheet 116, the second barrier sheet 118, and the polymer sheet 110 may include the same materials and have the same properties as described with respect to the corresponding first barrier sheet 16, the second barrier sheet 18, and the polymer sheet 10 of the cushioning component 14.

[0061] The polymer sheet 110 traverses the interior cavity 121 between the interior surface 117 of the first barrier sheet 116 and the opposing interior surface 119 of the second barrier sheet 118 and is directly bonded to the interior surface 117 of the first barrier sheet 116 and the opposing interior surface 119 of the second barrier sheet 118 at a plurality of bonds 144, 146 to secure the first barrier sheet 116 to the second barrier sheet 118. The bonds 144 bond the first side 126 of the polymer sheet 110 to the interior surface 117 of the first barrier sheet 116. The bonds 146 bond the second side 122 of the polymer sheet 110 to the interior surface 119 of the second barrier sheet 118. The polymer sheet 110 is bonded to the unbonded areas of the polymer sheet 110 (e.g., Fig. 9 and Fig.10 The unbonded areas correspond to the patterns of the barrier ink 24 printed on the first side 126 and the second side 122 of the polymer sheet 110, as shown in FIG. Fig. 9 and Fig.10 Portions of one or both of the inner surfaces 117, 119 of the barrier sheets 116, 118 outside the outer perimeter 134 of the core 112 and inside the peripheral bond 138 may also be printed or otherwise treated with the barrier ink 24 so that these portions of the inner surfaces 117, 119 do not bond to each other.

[0062] The tension created in the polymer sheet 110 by the expansion of the interior cavity 121 causes the top outer surface 150 of the first barrier sheet 116, inside the peripheral bond 138, to be pulled downward at the bond 144. Similarly, the tension created in the polymer sheet 110 by the expansion of the interior cavity 121 causes the bottom outer surface 152 of the second barrier sheet 118, inside the peripheral bond 138, to be pulled upward at the bond 146. The pattern of the barrier ink 24 printed on the polymer sheet 110 and the resulting pattern of the bonds 144, 146 of the polymer sheet 110 and the barrier sheets 116, 118 of the core 112 can be selected to control the resulting profile of the outer surfaces 150, 152 of the barrier sheets 116, 118.

[0063] Because the outer perimeter 134 of the polymer sheet 110 is completely inboard of the peripheral bond 138 between the barrier sheets 116, 118, and because the plurality of bonds 144, 146 are arranged in a pattern specifically determined by the predetermined pattern of the barrier ink 24 on the first side 126 and the second side 122 of the polymer sheet 110 (as described with respect to Fig. 9 and Fig.10As described above, the gas in the interior cavity 121 is in fluid communication around the polymer sheet 110 without the polymer sheet 110 creating any sealed chambers within the capsule 120 that are not in fluid communication with the interior cavity 121. In other words, the polymer sheet 110 does not subdivide the interior cavity 121 into separate sealed sub-chambers.

[0064] The first set of bonds 144 and the second set of bonds 146 begin at the outer edge of the central region 160 and extend outward from the central region 160 of a single polymer sheet 110 to the outer periphery 134 of the polymer sheets 110 in the array. The first set of bonds 144 and the second set of bonds 146 alternate around the central region 160, such as Figure 8 Best shown in ( Figure 8 only some of the bonds are marked), and based on Fig. 9 and Fig.10 The first predetermined pattern and the second predetermined pattern of the barrier ink 24 on the first side 126 and the second side 122 of the polymer sheet 110 shown and described in the drawings will be apparent. The bonds 144, 146 cause the accordion-like, tent-like structure of the polymer sheet 110 to expand outward from the central region 160. The central region 160 is not bonded to the first barrier sheet 116 or the second barrier sheet 118. For example, between any and all adjacent pairs of the first bonds 144 and the central region 160, the fluid in the portion of the interior cavity outside the outer perimeter 134 is thus connected to the portion of the interior cavity inside the outer perimeter 134 between the first barrier sheet 116 and the polymer sheet 110 (e.g., between the first and second barrier sheets 116 and 118). Figure 7 For example, between any and all adjacent pairs of second bonding portions 146 and central region 160, fluid in the portion of interior cavity 121 outside of outer periphery 134 is therefore also in fluid communication with the portion of the interior cavity 121 inside of outer periphery 134 between second barrier sheet 118 and polymer sheet 110 (e.g., between Figure 7 The second side 122 below is fluidly connected.

[0065] Fig. 9 yes Figure 7 1. A plan view of a single polymer sheet 110 of the core 112 of the cushioning component 114 of FIG. 1, showing the first side 126 of the polymer sheet 110 having the barrier ink 24 printed thereon prior to being bonded to the first barrier sheet 116. Fig.101 is a plan view of the opposing second side 122 of a single polymer sheet 110 having a barrier ink 24 printed thereon prior to bonding to a second barrier sheet 118. As shown, the barrier ink 24 extends to the outer periphery 134 of the polymer sheet 110 at both sides 126, 122. The first predetermined pattern of the barrier ink 24 printed on the first side 126 includes all areas except for equally spaced linear strips 162 extending outwardly in an array from a central area 160. The central area is covered with the barrier ink 24. The strips 162 without the barrier ink 24 thereon become the areas at the bonding portions 144 where the polymer sheet 110 is bonded to the first barrier sheet 116 after being subjected to a heat treatment, such as by thermal bonding, to produce the cushioning component 114.

[0066] The barrier ink 24 is also printed on the second side 122 in a different predetermined pattern (referred to as a second predetermined pattern) than on the first side 126. The second predetermined pattern of the barrier ink 24 printed on the second side 122 includes all areas except for the equally spaced linear strips 164 extending outward in an array from the central area 160 on the second side 122. The strips 164 without the barrier ink 24 thereon become the areas where the polymer sheet 110 is bonded to the bonding portion 146 of the second barrier sheet 118 after heat treatment to produce the cushioning component 114. Fig.10 , the locations of the strips 162 on the opposite side 126 are indicated by dashed lines to show that they are offset from the location of the strips 164. In other words, the strips 162 and strips 164 extend radially outward from the central region 160 in an array, wherein each strip 162 falls between an adjacent pair of strips 164, but on the opposite side of the polymer sheet 110.

[0067] Similar to the core 12, before the internal cavity 121 expands, the core 112 is relatively flat together with the barrier sheets 116, 118. When expanding, the core 112 becomes tensioned to fasten the barrier sheets 116, 118 to each other. Because the bonding portions 144 and 146 are linear bonding portions arranged to extend radially outward, the distance between the adjacent bonding portions is larger at the outer periphery 34 than at the central area 160. When the internal cavity 121 expands, this configuration of the bonding portions 144, 146 makes the distance between the first barrier sheet 116 and the second barrier sheet 118 smaller at the central area 160 than at the outer periphery 134 of the core 112, wherein the distance between the sheets 116, 118 increases linearly in the outward direction. Therefore, the cushioning component 114 has a greater height at the outer periphery 134 than at the central area 160, and appears to be centrally recessed at both the outside of the first barrier sheet 116 and the outside of the second barrier sheet 118.

[0068] Figures 11 to 13 Shown is the method for forming Fig.14 The core 212 shown is composed of polymer sheets 210, 211. The core 212 includes Figures 15 to 17 In the buffer component 214 shown. Fig.11 is a perspective view of a polymer sheet 210 included in the core 212 and referred to herein as the first polymer sheet 210 . Fig.12 2 is a perspective view of another polymer sheet 211 included in the core 212 and referred to herein as the second polymer sheet 211. The core 212 is bonded to a first barrier sheet 216 and a second barrier sheet 218, which form a bladder 220 defining an interior cavity 221 between opposing inner surfaces of the first barrier sheet 216 and the second barrier sheet 218 (e.g., between an inner surface 217 of the first barrier sheet 216 and an inner surface 219 of the second barrier sheet 218). The first barrier sheet 216, the second barrier sheet 218, and the polymer sheets 210 and 211 may include the same materials and have the same properties as described with respect to the corresponding first barrier sheet 16, the second barrier sheet 18, and the polymer sheet 10.

[0069] Fig.11 A first side 222 of the first polymer sheet 210 is shown. The barrier ink 24 is disposed on the first side 222 of the first polymer sheet 210 in a pattern of linear and parallel rows, including row H, row I, row J, and row K. The barrier ink 24 may be disposed on the first polymer sheet 210 via one or more print heads (not shown) controlled by a computer according to a stored algorithm representing a predetermined print pattern. For purposes of discussing the core 212, the print pattern of rows H through K is referred to herein as a first predetermined pattern. No barrier ink is printed on the opposite second side 226 of the first polymer sheet 210.

[0070] The first polymer sheet 210 has a region 222A between rows H and I, a region 222B between rows I and J, and a region 222C between rows J and K. Region 222D is located between row H and edge 234C of the outer periphery 234 of the core 212. Region 222E is located between row K and edge 234D of the outer periphery 234 of the core. Adjacent rows H and I, adjacent rows I and J, and adjacent rows J and K are spaced an equal distance from each other, so that each of regions 222A, 222B, and 222C has an equal size. No barrier ink 24 is provided on regions 222A, 222B, 222C, 222D, and 222E.

[0071] Fig.12A second side 213 of a second polymer sheet 211 is shown having a barrier ink 24 printed thereon in a pattern of linear and parallel rows, the rows including rows L, rows N, rows P, and rows Q. For purposes of discussing the core 212, the pattern of rows L, N, P, and Q is referred to herein as a second predetermined pattern. The second predetermined pattern is identical to the first predetermined pattern in that rows L, N, P, and Q each have an equal width, which is the same width as each of rows L, N, P, and Q, and adjacent rows of the second predetermined pattern are spaced apart from one another by the same amount as adjacent rows H, I, J, and K of the first predetermined pattern.

[0072] The second polymer sheet 211 has a region 213A between rows L and N, a region 213B between rows N and P, and a region 213C between rows P and Q. Region 213D is located between row Q and edge 234C of the outer periphery 234 of the core 212. Region 213E is located between row L and edge 234D of the outer periphery 234 of the core 212. Adjacent rows L and N, adjacent rows N and P, and adjacent rows P and Q are spaced an equal distance from each other, so that each of regions 213A, 213B, and 213C has an equal size to each of regions 222A, 222B, and 222C. No barrier ink 24 is provided on regions 213A, 213B, 213C, 213D, and 213E.

[0073] exist Fig.13 , the first side 215 is shown (e.g., facing up), while the second side 213 is facing down, where the rows L, N, Q, and P are shown to have been disposed thereon. The barrier ink 24 is disposed on the first side 215 of the second polymer sheet 211 in a third predetermined pattern. Specifically, the third predetermined pattern is a pattern of linear and parallel rows R, S, T, U, and V. Fig.13 As is apparent from the figure, the rows R, S, T, U, and V on the first side 215 are at least partially offset from and at least partially overlap with the rows L, N, P, and Q of the second predetermined pattern on the second side 213. The rows R, S, T, U, and V are also at least partially offset from and at least partially overlap with the rows H, I, J, and K on the first side 222 of the first polymer sheet 210 (where overlap means that when the polymer sheets 210, 211 are as shown in FIG. Fig.14 22 and 213). Thus, the third predetermined pattern is said to deviate from both the first predetermined pattern of the first side 222 of the first polymer sheet 210 and the second predetermined pattern of the second side 213 of the second polymer sheet 211.

[0074] Reference again Fig.13, the second polymer sheet 211 has an area 215A between rows R and S, an area 215B between rows S and T, an area 215C between rows T and U, and an area 215D between rows U and V. Adjacent rows R and S, adjacent rows S and T, adjacent rows T and U, and adjacent rows U and V are spaced an equal distance from each other, so that each of the areas 215A, 215B, 215C, and 215D has an equal size, which can be the same size as each of the areas 222A, 222B, and 222C and each of the areas 213A, 213B, and 213C. No blocker ink 24 is provided on the areas 215A, 215B, 215C, and 215D.

[0075] Fig.14 2 is a perspective view of a first polymer sheet 210 and a second polymer sheet 211 stacked together, with regions 215A, 215B, 215C, and 215D of a first side 215 of the second polymer sheet 211 against a second side 226 of the first polymer sheet 210. Fig.15 , the first polymer sheet 210 is disposed between the first barrier sheet 216 and the second polymer sheet 211. The second polymer sheet 211 is disposed between the first polymer sheet 210 and the second barrier sheet 218 such that the first side 222 of the first polymer sheet 210 faces and abuts the first inner surface 217 of the first barrier sheet 216, the second side 226 of the first polymer sheet 210 faces and abuts the first side 215 of the second polymer sheet 211, and the second side 213 of the second polymer sheet 211 faces and abuts the first inner surface 219 of the second barrier sheet 218. Rows H, I, J, and K, as well as rows R, S, T, U, V, and rows L, N, P, and Q all extend from the front edge 234A of the outer perimeter 234 to the rear edge 234B of the outer perimeter. Row R extends along and to the side edge 234C. Row V extends along and to the side edge 234D.

[0076] The barrier sheets 216, 218 and the core 212 are subjected to a heat treatment so that the first side 222 of the first polymer sheet 210 is directly bonded to the first inner surface 217 of the first barrier sheet 216 at a first set of bonding portions 244 among a plurality of bonding portions, the second side 213 of the second polymer sheet 211 is directly bonded to the first inner surface 219 of the second barrier sheet 218 at a second set of bonding portions 246 among a plurality of bonding portions, and the second side 226 of the first polymer sheet 210 is bonded to the first side 215 of the second polymer sheet 211 at a third set of bonding portions 247 among a plurality of bonding portions. The bonding portions of the third set of bonding portions 247 are bonded to the bonding portions of the first set of bonding portions 244 along the length of the first polymer sheet 210 (at Fig.15The length alternates between the first end 249A and the second end 249B of the first polymer sheet 210. The bonding portions of the third set of bonding portions 247 alternate with the bonding portions of the second set of bonding portions 246 along the length of the second polymer sheet 211 (between the first end 249A and the second end 249B of the first polymer sheet 210). Fig.15 The lengths alternate between the first end 251A and the second end 251B of the second sheet 211. The second set of bonds 246 are aligned with the first set of bonds 244 and are offset from the third set of bonds 247.

[0077] The core 212 is completely spaced inwardly from the peripheral bonding portion 238. In other words, the four edges 234A, 234B, 234C, and 234D of the outer periphery 234 of the core 212 are completely inwardly of the peripheral bonding portion 238. Fig.15 As shown, portions of one or both of the inner surfaces 217, 219 outside the outer periphery 234 of the core 212 and inside where a peripheral bond 238 is formed between the first polymer sheet 210 and the second polymer sheet 211 may also have a barrier ink 24 disposed thereon so that these portions of the inner surfaces 217, 219 do not bond to each other.

[0078] Fig.15 2 is a cross-sectional view of the cushioning component 214 in an unexpanded state. The core 212 is positioned in the internal cavity 221. Fig.15 As can be seen in FIG, the core 212 lies flat within the bladder 220, wherein the unbonded areas of the first predetermined pattern at rows H, I, J, and K of the first side 222 of the first polymer sheet 210 (areas at the barrier ink 24) and the unbonded areas of the second predetermined pattern at rows L, N, P, and Q of the second side 213 of the second polymer sheet 211 contact the respective opposing inner surfaces 217, 219 when the interior cavity 21 of the bladder 220 is not expanded. The unbonded areas of the third predetermined pattern at rows R, S, T, U, and V of the first side 215 of the second polymer sheet 211 (areas at the rows of the barrier ink 24) contact the second side 226 of the first polymer sheet 210 when the interior cavity 21 of the bladder 220 is not expanded.

[0079] Fig.16 In the first expansion state Fig.15 A cross-sectional view of the buffer component 214. Fig.17 In the second expansion state Fig.15 214 is a cross-sectional view of a cushioning component 214, wherein the cushioning component 214 is expanded more than in the first expanded state.

[0080] In a relatively extended state (e.g. Fig.16 and Fig.17In any expanded state of the core 212, the core 212 is relatively extended compared to the unexpanded state. The core 212 traverses the interior cavity 221 between the opposing inner surfaces 217, 219 of the first barrier sheet 216 and the second barrier sheet 218, and is directly bonded to the opposing inner surfaces 217, 219 of the first barrier sheet 216 and the second barrier sheet 218 at the first set of bonds 244 and the second set of bonds 246, and wherein the third set of bonds 247 secures the first polymer sheet 210 to the second polymer sheet 211.

[0081] The polymer sheets 210 and 211 are bonded at the unbonded area of ​​the first side 222 of the first polymer sheet 210 (where the barrier ink 24 is initially disposed). Fig.11 H, I, J and K) and at the unbonded area of ​​the second side 213 of the second polymer sheet 211 (where the barrier ink 24 is initially disposed). Fig.12 The first polymer sheet 210 is displaced from the opposing inner surfaces 217, 219 by the gas. The second side 226 of the first polymer sheet 210 is displaced from the first side 215 of the second polymer sheet 211 at the unbonded area (the rows R, S, T, U, and V where the barrier ink 24 was initially disposed). The plurality of bonds 244, 246, and 247 are arranged in a pattern (e.g., a first pattern of bonds 244 at the first barrier sheet 216, a second pattern of bonds 246 at the second barrier sheet 218, and a third pattern of bonds 247 between the first polymer sheet 210 and the second polymer sheet 211) so that the gas in the interior cavity 221 is in fluid communication around the polymer sheets 210 and 211 without either of the polymer sheets 210 and 211 creating any sealed chamber within the capsule 220 that is not in fluid communication with the interior cavity 221.

[0082] More specifically, since each of the rows H, I, J and K of the barrier ink 24 extends to the opposite edges 234A, 234B of the outer periphery 234 of the core 212 at the inner surface 217 of the first barrier sheet 216, each of the rows L, N, P and Q extends to the opposite edges 234A, 234B of the outer periphery 234 of the core 212 at the inner surface 219 of the second barrier sheet 218, and each of the rows R, S, T, U and V extends to the opposite edges 234A, 234B of the outer periphery 234 of the core 212 between the first polymer sheet 210 and the second polymer sheet 211, wherein row R extends along edge 234C and is at edge 234C, and row V extends along edge 234D and is at edge 234D, the polymer sheets 210 and 211 have no unbonded portions that are not open to the outer periphery 234 and thus interrupt fluid communication with the gas in the internal cavity 221.

[0083] Because the first group of bonds 244 are at regions 222A, 222B, 222C, 222D, and 222E, the first group of bonds 244 are linear bonds arranged in rows. Because the second group of bonds 244 are at regions 213A, 213B, 213C, 213D, and 213E, the second group of bonds 244 are also linear bonds arranged in rows. Because the third group of bonds 247 are at regions 215A, 215B, 215C, and 215D, the third group of bonds 247 are also linear bonds arranged in rows.

[0084] like Figure 16 to Figure 17 As is apparent from the diagram, the thickness T4 of each of the polymer sheets 210, 211 is no greater than the thickness T5 of the first barrier sheet 216 and no greater than the thickness T6 of the second barrier sheet 218. Maintaining the sheet thickness of the polymer sheets 210, 211 used in the core 212 to be no greater than the sheet thickness of the barrier sheets 216 and 218 helps ensure that the flexibility of the core 212 acts as a tether that moves toward the core 212 under a compressive load. Fig.15 The relatively flat state of the earth easily collapses backwards.

[0085] Figure 16 to Figure 17 It is shown that the tension created in the polymer sheet 210 by the expansion of the interior cavity 221 causes the portion of the first barrier sheet 216 inboard of the outer perimeter 234 of the core 212 to be pulled downward at the bond 244, as indicated by the contoured outer surface 250 of the first barrier sheet 216. Because the outer perimeter 234 of the core 212 is completely inboard of the peripheral bond 238, and the barrier ink 24 is disposed on one or both of the inner surfaces 217, 219 between the peripheral bond 238 and the outer perimeter 234, the barrier sheets 216, 218 will not be tied together at the outer perimeter portion of the interior cavity 221 outside the outer perimeter 234 of the core 212 and inside the peripheral bond 238. The distance between the inner surfaces 217 and 219, and the resulting height of the cushioning component 214, can therefore be greatest outside the core 212.

[0086] Similarly, the tension created in the polymer sheet 211 by the expansion of the interior cavity 221 causes the portion of the second barrier sheet 218 inboard of the outer perimeter 234 of the core 12 to be pulled upward at the bonds 246, as indicated by the contoured outer surface 252 of the second barrier sheet 218. The pattern of the barrier ink 24 printed on the polymer sheets 210, 211 and the resulting pattern of bonds of the polymer sheets 210, 211 of the core 212 with the barrier sheets 216, 218 can be selected to control the resulting profile of the outer surfaces 250, 252 of the barrier sheets 216, 218. The cushioning component 214 having the pattern of the first set of bonds 244, the second set of bonds 246, and the third set of bonds 247 can be referred to as a honeycomb cushioning component because at least some of the resulting adjacent channels through the core 212 at the linear rows of barrier ink 24 appear to have a hexagonal shape in cross-section, creating an appearance similar to a honeycomb.

[0087] Fig.18 is a perspective view showing the top and outer side of the buffer member 314 . Fig.19 is along Fig.18 The line 19-19 in Fig.18 A cross-sectional view of a cushioning component 314 is shown having multiple polymer sheets 310, 311 and Fig.17 The core 312 has a bonding pattern similar to those of the core 212. The cushioning component 314 is included in Fig. 22 The midsole of the sole structure 370 of the footwear article 372 is shown in a lateral view. The cushioning component 314 and the footwear article 372 include a forefoot region 374, a midfoot region 376, and a heel region 378. The cushioning component 314 and the footwear article 372 also include a medial side 380 and a lateral side 382 opposite the medial side 380 (in the Fig.18 ).

[0088] Forefoot region 374 generally includes portions of footwear article 372 corresponding to the toes and joints connecting the metatarsal bones and phalanges of the wearer's foot. Midfoot region 376 generally includes portions of footwear article 372 corresponding to the arch area of ​​the foot, and heel region 378 corresponds to the rear portion of the foot, including the calcaneus. Medial side 380 and lateral side 382 extend through each of forefoot region 374, midfoot region 376, and heel region 378 and fall on opposite sides of a longitudinal midline LM of footwear article 372. Longitudinal midline LM is located at Fig.19 At the cross-sectional line, Fig.18 Forefoot region 374, midfoot region 376, heel region 378, medial side 380, and lateral side 382 are not intended to delineate precise areas of footwear 372, but rather are intended to represent general areas of footwear 372 to facilitate the following discussion.

[0089] In addition to the core 312, the cushioning component 314 includes a bladder 320 having a first barrier sheet 316 and a second barrier sheet 318. Similar to the cushioning component 214, the first barrier sheet 316 is bonded to the first polymer sheet 310 at a first set of bonds 344, the second barrier sheet 318 is bonded to the second polymer sheet 311 at a second set of bonds 346, and the first polymer sheet 310 is bonded to the second polymer sheet 311 at a third set of bonds 347. The bonds 344, 346, and 347 are linear rows of bonds and are the result of the barrier ink 24 being disposed on the first polymer sheet 310 and the second polymer sheet 311 in a first predetermined pattern, a second predetermined pattern, and a third predetermined pattern, respectively, except that there are a greater number of rows of barrier ink and therefore a greater number of linear bonds in each of the patterns of bonds in the cushioning component 314 than in the cushioning component 214, which is the same as those described with respect to the cushioning component 214. Fig.19 In the drawings, only some of the bonding portions 344, 346 and 347 and some of the barrier ink 24 are indicated with reference numerals. Fig. 20 It is shown Fig.18 A slightly perspective view of the inside of the cushioning component of FIG. 1 , wherein the first polymer sheet 310 and the second polymer sheet 311 are shown in hidden lines.

[0090] The barrier sheets 316 and 318 are bonded to each other at the peripheral seam 338 to retain fluid within the interior cavity 321 defined between the barrier sheets 316, 318. The outer periphery 334 of the core 312 is completely inside the peripheral seam 338, and the barrier ink 24 is disposed on one or both of the inner surfaces 317, 319 of the barrier sheets 316, 318 inside the peripheral bond 338 and outside the outer periphery 334, so that the barrier sheets 316, 318 are not bonded to each other between the outer periphery 334 and the peripheral seam 338.

[0091] These aspects and placement of the pattern of the barrier ink 24 relative to the outer perimeter 334 and the placement of the core 312 such that the entire outer perimeter 334 is completely inside the peripheral bond 338 ensure that the core 312 will tether the first barrier sheet 316 and the second barrier sheet 318 without creating any sealed chamber that is not in fluid communication with the interior cavity 321 defined between the opposing inner surfaces 317, 319 of the barrier sheets 316, 318. As described with respect to the core 212, the core 312 will collapse under the dynamic compressive load of the cushioning component 314 to recover toward a flat state and thus act as a tether to control and vary the distance between the inner surfaces of the barrier sheets 316, 318 without affecting the ability of the bladder 320 to compress under load.

[0092] like Fig.19As is apparent in the drawings, the plurality of bonds include a first group of bonds in a first area of ​​the bladder 320, such as the forefoot area 374, and a second group of bonds in a second area of ​​the bladder 320, such as the midfoot area 376 or the heel area 378. The first group of bonds includes bonds 344A of the first group of bonds 344, bonds 346A of the second group of bonds 346, and bonds 347A of the third group of bonds 347. The second group of bonds includes bonds 344B of the first group of bonds 344, bonds 346B of the second group of bonds 346, and bonds 347B of the third group of bonds 347.

[0093] The spacing between the adjacent bonding portions of the bonding portions 344A, 346A and 347A of the first group is less than the spacing between the adjacent bonding portions of the bonding portions 344B, 346B and 347B of the second group. In other words, for example, the two adjacent bonding portions 344A shown in the forefoot region 374 are closer to each other than the two adjacent bonding portions 344B in the midfoot region 376 or the two adjacent bonding portions 344B in the heel region 378. Similarly, for example, the two adjacent bonding portions 346A shown in the forefoot region 374 are closer to each other than the two adjacent bonding portions 346B in the midfoot region 376 or the two adjacent bonding portions 346B in the heel region 378. In addition, for example, the two adjacent bonding portions 347A shown in the forefoot region 374 are closer to each other than the two adjacent bonding portions 347B in the midfoot region 376 or the two adjacent bonding portions 347B in the heel region 378.

[0094] By placing adjacent bonds closer together in the forefoot region 374, the opposing inner surfaces 317 and 319 of the barrier sheets 316, 318 are held closer to each other by the polymer sheets 310 and 311 in the first region (forefoot region 374) than in the second region (midfoot region 376 or heel region 378). This configuration results in a toe lift that is a function of the shoe's toe lift when in a position such as Fig. 20 The second barrier sheet 318 is shown with increasing elevation in the forefoot region 374 in the forward direction away from the ground surface GS in the steady state position (e.g., unloaded or at least not under dynamic compressive load). This pre-shaping of the cushioning component 314 with toe kick placed via the bond helps create forward foot rolling and easier toe-off during the wearer's forward motion.

[0095] In some embodiments, the spacing between adjacent bonding portions of the first group of bonding portions gradually decreases from the rear of the first group of bonding portions to the front of the first group of bonding portions. In other words, the bonding portion 344A towards the rear of the forefoot region 374 is farther apart than the bonding portion 344A towards the front of the forefoot region 374. Similarly, the bonding portion 346A towards the rear of the forefoot region 374 is farther apart than the bonding portion 346A towards the front of the forefoot region 374, and the bonding portion 347A towards the rear of the forefoot region 374 is farther apart than the bonding portion 347A towards the front of the forefoot region 374.

[0096] Reference Fig.18 and Fig.21 In addition to the placement of the bond to promote toe lift, the outer perimeter 334 and peripheral bond 338 of the core 312 can be spaced farther inward in the heel region 378 than in the forefoot region 374. This creates a larger and taller peripheral portion of the interior cavity 321 around the core 312 in the heel region 378 than in the forefoot region 374, which nests the cushioning component 314 around the heel. Fig.18 and Fig.21 As best shown in FIG. 3 , the first barrier sheet 316 may be recessed slightly downwardly above the core 312 between the medial side 380 and the lateral side 382 in the heel region 378 to help cover the heel.

[0097] Fig.23 is used for Fig.24 A lateral view of another sole structure 470 of an article of footwear 472 is shown. The sole structure 470 includes a heel cushioning component 414 having a bladder 420 having a first barrier sheet 416 and a second barrier sheet 418 bonded to each other at a peripheral seam 438 to retain gas in an interior cavity 421 between opposing interior surfaces 417, 419 of the barrier sheets 416, 418. The heel cushioning component 414 includes a core 412 having a plurality of polymer sheets 410, 411 disposed within the interior cavity 421. The heel cushioning component 414 has a barrier ink 24 disposed in linear rows on the polymer sheets 410, 411 and disposed on one or both of the interior surfaces 417, 419 outside of an outer perimeter 434 of the core 412 and inside of the peripheral seam 438 in a manner corresponding to that described with respect to the cushioning component 314 to produce a barrier ink 24 that is Fig.19Cushioning component 414 extends only in heel region 478 and midfoot region 476 of sole structure 470, and fewer rows of barrier ink and resulting bonds are included than in cushioning component 414. Similar to cushioning component 414, the spacing between adjacent rows of barrier ink may be closer toward the front end of cushioning component 414 than at the rear end, such that the distance between inner surfaces 417 and 419 is smaller toward the front of cushioning component 414 than toward the rear of cushioning component 414, as shown. Fig.23 shown.

[0098] The foam midsole layer 473 covers the heel cushioning component 414 in a portion of the heel region 478 and the midfoot region 476 and extends to the forefoot region 474. An upwardly facing rear portion 414A of the heel cushioning component 414 is not covered by the foam midsole layer 473.

[0099] Fig.24 Yes Fig.23 470. The sole structure 470 also includes an outsole 475 that extends beneath the cushioning component 414 and the foam midsole 473 and forms the ground contacting surface of the footwear article 472. The sole structure 470 is shown secured to the footwear upper 477, and the heel support 481 is shown extending around the rear portion of the footwear upper 477 and covering the exterior of the upwardly facing rear portion 414A of the cushioning component 414 (at the Fig.23 472 ), where heel support 481 forms a ledge. Thus, heel support 481 both protects upwardly facing rear portion 414A of heel cushioning component 414 from direct wear and forms a ledge at the rear of article of footwear 472 that can be used for leverage when removing article of footwear 472. For example, the wearer's other foot can rest on heel support 481 to provide leverage while the other foot is withdrawn from footwear upper 477.

[0100] Fig.25 5 is a plan view of an alternative embodiment of a cushioning component 514 for a wearable article such as a footwear article. The cushioning component 514 is configured as a midsole for a sole structure for the footwear article and has a forefoot region 574, a midfoot region 576, and a heel region 578. The cushioning component 514 includes a forefoot core 512A having at least one polymer sheet and a separate heel core 512B having at least one polymer sheet. More specifically, the cushioning component 514 includes a bladder 520 that includes a first barrier sheet 516 (at the bottom) that is sealed to each other along a peripheral bond 538. Fig.25 ) and a second barrier sheet 518 (disposed in a plan view of Fig.25The inner cavity 521 is provided between the opposing inner surfaces of the first barrier sheet 516 and the second barrier sheet 518 as described with respect to the similar components of the cushioning component 14.

[0101] Cores 512A and 512B are disposed within interior cavity 521 and have respective outer perimeters 534A, 534B spaced completely inwardly from peripheral bond 538. Peripheral portion 521A of interior cavity 521 outwardly surrounds each of cores 512A, 512B between peripheral bond 538 and outer perimeters 534A, 534B.

[0102] The bonding portions 539A and 539B of the sealing barrier sheets 516, 518 protrude inward from the peripheral bonding portion 538 to partially separate the internal cavity 521, but allow fluid communication between the front portion 521A of the internal cavity 521 surrounding the front core 512A and the rear portion 521B of the internal cavity 521 surrounding the rear core 512B at the gap 541 between the bonding portions 539A, 539B.

[0103] The front core 512A includes a polymer sheet 510A that traverses an interior cavity 521 between opposing inner surfaces of a first barrier sheet 516 and a second barrier sheet 518 and is directly bonded to the opposing inner surfaces of the first barrier sheet 516 and the second barrier sheet 518 at a plurality of bonds to secure the first barrier sheet 516 to the second barrier sheet 518. The polymer sheet 510A is displaced from the opposing inner surfaces of the barrier sheets 516, 518 by gas at unbonded areas of the polymer sheet 510A.

[0104] The back core 512B includes a polymer sheet 510B that traverses the interior cavity 521 between the opposing inner surfaces of the first barrier sheet 516 and the second barrier sheet 518 and is directly bonded to the opposing inner surfaces of the first barrier sheet 516 and the second barrier sheet 518 at a plurality of bonds to secure the first barrier sheet 516 to the second barrier sheet 518. The polymer sheet 510B is displaced from the opposing inner surfaces by gas at unbonded areas of the polymer sheet 510B.

[0105] The barrier ink 24 is disposed on the front core 512A at the unbonded areas of the front core 512A and on the back core 512B at the unbonded areas of the back core 512B. As in the core 12, the barrier ink 24 is disposed in alternate linear rows in an alternating pattern on the opposing first and second sides of the polymer sheet 510A and in an additional alternating pattern on the opposing first and second sides of the polymer sheet 510B. Fig.25In addition to the area marked in FIG. 1 , the barrier ink 24 also extends directly above the location where the bonding portions 546A, 546B are located on the opposite side on the side of the polymer sheets 510A and 510B facing the inner surface of the barrier sheet 516, and the barrier ink 24 extends directly below the location where the bonding portions 544A, 544B are located on the opposite side on the side of the polymer sheets 510A, 510B facing the inner surface of the barrier sheet 518. The barrier ink may also be disposed on one or both of the inner surfaces of the first barrier sheet 516 and the second barrier sheet 518 between the peripheral bonding portions 538 and the outer peripheries 534A, 534B of the front core 512A and the back core 512B.

[0106] More specifically, a first pattern of bonding portions 544A is formed at a junction area of ​​a first side (e.g., the top side in the plan view of FIG. 35 ) of the polymer sheet 510A and an inner surface of the first barrier sheet 516 (e.g., when there is no barrier ink 24 between the first side and the inner surface). A second pattern of bonding portions 546A is formed at a junction area of ​​a second side (e.g., when there is no barrier ink 24 between the second side and the inner surface) of the polymer sheet 510A and an inner surface of the second barrier sheet 518. Bonding portions 546A are offset from bonding portions 544A. For clarity, bonding portions 544A of the top barrier sheet 516 are shown in solid lines in the plan view, and bonding portions 546A on the opposing barrier sheet 518 are shown in dashed lines.

[0107] Similarly, a first pattern of bonding portions 544B is provided on a first side (eg, Fig.25 The top side in the plan view of the polymer sheet 510B and the inner surface of the first barrier sheet 516 are formed at the junction area (e.g., in the absence of the barrier ink 24 between the first side and the inner surface). The second pattern of bonding portions 546B is formed at the junction area of ​​the second side of the polymer sheet 510B and the inner surface of the second barrier sheet 518. The bonding portions 546B are offset from the bonding portions 544B. The barrier ink 24 prevents bonding at any junction area where it is provided. For clarity, the bonding portions 544B of the top barrier sheet 516 are shown in solid lines in the plan view, and the bonding portions 546B on the opposing barrier sheet 518 are shown in dashed lines.

[0108] When the interior cavity 521 of the bladder 520 is unexpanded, the first core 512A and the second core 512B lie flat within the bladder 520 with the unbonded areas (areas at the barrier ink 24) contacting the opposing interior surfaces, and when the interior cavity 521 of the bladder 520 is expanded, the polymer sheets 510A, 510B are tensioned between the barrier sheets 516, 518 to control the height and outer profile of the bladder 520. Similar to the core 12, each of the polymer sheets 510A, 510B will have a zigzag orientation spanning the cavity 521 between the interior surface of the first barrier sheet 516 and the interior surface of the second barrier sheet 518.

[0109] With this arrangement of the pattern of bonds 544A, 544B, 546A, and 546B, gas in the interior cavity 521 is in fluid communication around the polymer sheets 510A, 510B without the polymer sheets 510A, 510B creating any sealed chambers within the bladder 520 that are not in fluid communication with the interior cavity 521 .

[0110] In addition, the spacing between adjacent bonds 544A and adjacent bonds 546A in the forefoot region 574 is smaller than the spacing between adjacent bonds 544A and adjacent bonds 546A in the midfoot region 576, and / or smaller than the spacing between adjacent bonds 544B and adjacent bonds 546B in the heel region 578, so as to provide toe lift by maintaining the relative inner surfaces of the barrier sheets 516, 518 closer to each other in the forefoot region 574 than in the midfoot region 576 or the heel region 578 by the polymer sheet 510A.

[0111] The outer perimeter 534B of the rear core 512B and the peripheral bonding portion 538 may be spaced inwardly farther in the heel region 378 than the outer perimeter 534A of the front core 512A and the peripheral bonding portion 538 are spaced inwardly in the forefoot region 574. Similar to that described with respect to the cushioning component 314, this creates a larger and taller peripheral portion 521B of the interior cavity 521 surrounding the rear core 512B in the heel region 578 than the peripheral portion 521A of the interior cavity 521 surrounding the front core 512A in the forefoot region 574, which nests the cushioning component 514 around the heel. Similar to the cushioning component 314, the bonding portions 544B, 546B may be configured such that the first barrier sheet 516 is slightly recessed downwardly above the heel core 512B between the medial side 580 and the lateral side 582 in the heel region 578 to help cradle the heel.

[0112] Fig.26is a plan view of another alternative embodiment of cushioning component 614, which is similar to cushioning component 514 in all respects except that a different pattern of bonding portions 644A, 644C1, 644C2 and 646A are used instead of bonding portions 544A, 546A, and a different pattern of bonding portions 644B, 646B are used instead of bonding portions 544B, 546B.

[0113] Bonds 644A, 644C1, and 644C2 bond polymer sheet 510A to the inner surface of barrier sheet 516. Unlike bond 544A, which extends directly through core 512A, bond 644A is V-shaped, extending outward from a vertex near the longitudinal centerline of core 512A. Bonds 644C1 and 644C2 are also V-shaped, but each is disposed between two adjacent bonds 544A, and bonds 644C1 and 644C2 extend outward from near the longitudinal centerline in directions opposite to each other.

[0114] Bonding portion 646A bonds the opposite side of polymer sheet 510A to the inner surface of barrier sheet 518 and is offset from bonding portion 644A. Bonding portion 646A has a V-shape similar to bonding portion 644A. For clarity, bonding portions 644A, 644C1, and 644C2 that bond polymer sheet 510A to top barrier sheet 516 are shown in solid lines in the plan view, and bonding portion 646A that bonds polymer sheet 510A to opposite barrier sheet 518 is shown in dashed lines.

[0115] Bonds 644B bond one side of polymer sheet 510B to the inner surface of barrier sheet 516, and at least some are generally V-shaped, similar to bonds 644A. Bonds 646B bond the opposite side of polymer sheet 510B to the inner surface of barrier sheet 518, and are offset from bonds 644B. ​​At least some of bonds 646B have a V-shape similar to bonds 644A. For clarity, bonds 644B of top barrier sheet 516 are shown in solid lines in plan view, and bonds 646B of opposite barrier sheet 518 are shown in dashed lines.

[0116] With this arrangement of the pattern of bonds 644A, 644B, 644C1 , 644C2 , 646A, and 646B, the gas in the interior cavity 521 is in fluid communication around the polymer sheets 510A, 510B without the polymer sheets 510A, 510B creating any sealed chambers within the bladder 520 that are not in fluid communication with the interior cavity 521 .

[0117] Fig. 277 is a plan view of another alternative embodiment of a cushioning component 714, which is similar in all respects to cushioning component 514 except that different patterns of bonds 744A1, 744A2, and 746A are used instead of bonds 544A and 546A, and different patterns of bonds 744B and 746B are used instead of bonds 544B and 546B. Bonds 744A1 are referred to as point bonds because they do not extend completely through the core 512A from the outer periphery 534A on the inner side 580 of the core 512A to the outer periphery 534A or 534B on the outer side 582 of the core 512A. Bonds 744A2 and 746A are referred to as linear bonds because they do extend completely through the core 512A from the outer periphery 534A or 534B on the inner side 580 to the outer periphery 534A or 534B on the outer side 582.

[0118] Bonds 744A1 and 744A2 bond one side of polymer sheet 510A to the inner surface of barrier sheet 516. Similarly, bond 744B bonds the same side of polymer sheet 510B to the inner surface of barrier sheet 516. Bond 746A bonds the opposite side of polymer sheet 510A to the inner surface of barrier sheet 518 and is offset from bonds 744A1 and 744A2. Bond 746B bonds the opposite side of polymer sheet 510B to the inner surface of barrier sheet 518 and is offset from bond 744B.

[0119] Through this arrangement of the pattern of bonding portions 744A1, 744A2 and 746A and the pattern of bonding portions 744B and 746B, the gas in the internal cavity 521 is fluidly connected around the polymer sheets 510A, 510B without the polymer sheets 510A, 510B creating any sealed chambers within the bladder 520 that are not fluidly connected to the internal cavity 521.

[0120] The following clauses provide example configurations for cushioning components of the wearable articles disclosed herein.

[0121] Clause 1. A cushioning component for a wearable article, the cushioning component comprising: a bladder, the bladder comprising a first barrier sheet and a second barrier sheet, the first barrier sheet and the second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet being sealed to each other along a peripheral bond to enclose the interior cavity and retain gas in the interior cavity; and a core, the core being disposed in the interior cavity and spaced completely inwardly from the peripheral bond, the core comprising at least one polymer sheet, the at least one polymer sheet being disposed transversely between the first barrier sheet and the second barrier sheet. The interior cavity is formed between the opposite inner surfaces of the second barrier sheet and is directly bonded to the opposite inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonding portions to secure the first barrier sheet to the second barrier sheet, the at least one polymer sheet is displaced from the opposite inner surfaces by the gas at an unbonded area of ​​the at least one polymer sheet, and the plurality of bonding portions are arranged so that the gas in the interior cavity is in fluid communication around the at least one polymer sheet without the at least one polymer sheet creating any sealed chamber within the bladder that is not in fluid communication with the interior cavity.

[0122] Clause 2. The cushioning component of Clause 1, wherein a barrier ink is disposed on the core at the unbonded area.

[0123] Clause 3. The cushioning component of any one of Clauses 1 to 2, wherein when the interior cavity of the bladder is unexpanded, the core lies flat within the bladder with the unbonded area contacting the opposing interior surfaces.

[0124] Clause 4. The cushioning component of any one of Clauses 1 to 3, wherein the thickness of each of the at least one polymer sheet of the core is no greater than the thickness of the first barrier sheet and no greater than the thickness of the second barrier sheet.

[0125] Clause 5. A cushioning component according to any one of clauses 1 to 4, wherein the plurality of bonds include a first group of bonds in a first zone of the bladder and a second group of bonds in a second zone of the bladder; and wherein the spacing between adjacent bonds of the first group of bonds is less than the spacing between adjacent bonds of the second group of bonds, such that the opposing inner surfaces are held closer to each other in the first zone than in the second zone by the at least one polymer sheet.

[0126] Clause 6. The cushioning component of Clause 5, wherein the wearable article is an article of footwear, the cushioning component is included in a sole structure of the article of footwear, the first group of bonded portions are in a forefoot region of the article of footwear, and the second group of bonded portions are in one of a midfoot region or a heel region of the article of footwear.

[0127] Clause 7. The cushioning component of Clause 6, wherein the spacing between adjacent bonds of the first group of bonds gradually decreases from a rear portion of the first group of bonds to a front portion of the first group of bonds.

[0128] Clause 8. The cushioning component of Clause 6, wherein an outer perimeter of the at least one polymer sheet is spaced further inwardly from the peripheral bond in the heel region than in the forefoot region.

[0129] Clause 9. A cushioning component according to any one of clauses 1 to 4, wherein: the opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the core is a single polymer sheet, the single polymer sheet having a first side and an opposing second side, the first side being bonded to the first inner surface of the first barrier sheet at a first set of bonds among the plurality of bonds, the opposing second side being bonded to the second inner surface of the second barrier sheet at a second set of bonds among the plurality of bonds; and the second set of bonds is offset from the first set of bonds such that the second set of bonds alternates with the first set of bonds along the length of the single polymer sheet.

[0130] Clause 10. The cushioning component of Clause 9, wherein: the first set of bonds are linear bonds arranged in rows, and the second set of bonds are linear bonds arranged in rows.

[0131] Clause 11. A cushioning component according to clause 9, wherein:

[0132] The first set of bonds are point bonds arranged in rows and the second set of bonds are linear bonds arranged in rows.

[0133] Clause 12. A cushioning component according to any one of clauses 1 to 4, wherein: the opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the core is a single polymer sheet, the single polymer sheet having a first side and an opposing second side, the first side being bonded to the first inner surface of the first barrier sheet at a first set of bonds among the plurality of bonds, the opposing second side being bonded to the second inner surface of the second barrier sheet at a second set of bonds among the plurality of bonds; and the first set of bonds and the second set of bonds extend outwardly from a central region of the single polymer sheet in an array, wherein the bonds of the second set alternate with the bonds of the first set around the central region.

[0134] Clause 13. A cushioning component according to any one of clauses 1 to 4, wherein: the opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the at least one polymer sheet of the core includes a first polymer sheet and a second polymer sheet, the first polymer sheet is disposed between the first barrier sheet and the second polymer sheet, and the second polymer sheet is disposed between the first polymer sheet and the second barrier sheet, such that a first side of the first polymer sheet faces the first inner surface of the first barrier sheet, a second side of the first polymer sheet faces the first side of the second polymer sheet, and a second side of the second polymer sheet faces the second side of the second polymer sheet The second inner surface of the second barrier sheet; and the first polymer sheet has the first side directly bonded to the first inner surface of the first barrier sheet at a first group of bonding portions among the multiple bonding portions, the second polymer sheet has the second side directly bonded to the second inner surface of the second barrier sheet at a second group of bonding portions among the multiple bonding portions, the second side of the first polymer sheet is bonded to the first side of the second polymer sheet at a third group of bonding portions among the multiple bonding portions, the third group of bonding portions alternates with the first group of bonding portions along the length of the first polymer sheet, and the third group of bonding portions alternates with the second group of bonding portions along the length of the second polymer sheet.

[0135] Clause 14. The cushioning component of Clause 13, wherein the second set of bonds are aligned with the first set of bonds.

[0136] Clause 15. The cushioning component of Clause 13, wherein at least some of the bonds in the plurality of bonds are linear bonds.

[0137] Clause 16. The cushioning component of any one of Clauses 1 to 4, wherein at least some of the bonds in the plurality of bonds are point bonds.

[0138] Clause 17. The cushioning component of Clause 16, wherein the point bonds are arranged in rows, wherein the point bonds of adjacent ones of the rows are offset from one another.

[0139] Clause 18. The cushioning component of any one of Clauses 1 to 4, wherein the plurality of bonds include linear bonds arranged in rows and point bonds arranged in rows, the rows of point bonds alternating with the rows of linear bonds.

[0140] To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply to the entire specification (including claims). Additionally, all references cited are incorporated herein in their entirety.

[0141] "Articles of footwear," "articles of footwear," and "footwear" may be considered machines and articles of manufacture. Assembled finished articles of footwear (e.g., shoes, sandals, boots, etc.) and discrete components of articles of footwear (such as midsoles, outsoles, upper components, etc.) prior to final assembly into finished articles of footwear are considered herein and are alternatively referred to in the singular or plural as "articles of footwear."

[0142] "A", "an", "the", "at least one" and "one or more" can be used interchangeably to indicate that there is at least one of an item. Unless the context clearly indicates otherwise, there may be multiple such items. Unless the context (including the appended claims) clearly or clearly indicates otherwise, all numerical values ​​of parameters (e.g., amounts or conditions) in this specification should be understood to be modified by the term "about" in all cases, regardless of whether "about" actually appears before the numerical value. "Approximately" indicates that the stated numerical value allows some slight imprecision (close to exact in value; close to or quite close to the value; approximately). If the imprecision provided by "about" is not understood in the art with this ordinary meaning, "about" as used herein at least indicates the variation that can be caused by ordinary methods of measuring and using such parameters. In addition, the disclosure of a range should be understood to specifically disclose all values ​​within the range and further divided ranges.

[0143] The terms "comprising", "including" and "having" are inclusive and thus specify the presence of stated features, steps, operations, elements or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements or components. When possible, the order of steps, processes and operations may be changed, and additional or alternative steps may be adopted. As used in this specification, the term "or" includes any and all combinations of the associated listed items. The term "any of..." should be understood to include any possible combination of the referenced items, including "any of" the referenced items. The term "any of..." should be understood to include any possible combination of the referenced claims in the appended claims, including "any of" the referenced claims.

[0144] For consistency and convenience, directional adjectives may be employed throughout the 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 without implying a limitation on the scope of the invention as defined by the claims.

[0145] The term "longitudinal" particularly refers to a direction extending the length of a component. For example, the longitudinal direction of a shoe extends between the forefoot region and the heel region of the shoe. The terms "forward" or "front" are particularly used to refer to the general direction from the heel region towards the forefoot region, and the terms "rearward" or "rear" are particularly used to refer to the opposite direction, i.e. the direction from the forefoot region towards the heel region. In some cases, a component may be identified as having a longitudinal axis and forward and rearward longitudinal directions along the axis. The longitudinal direction or axis may also be referred to as the front-to-back direction or axis.

[0146] The term "lateral" refers in particular to a direction extending the width of a component. For example, the lateral direction of a shoe extends between the lateral side and the medial side of the shoe. The lateral direction or axis may also be referred to as the lateral direction or axis or the medial lateral direction or axis.

[0147] The term "vertical" particularly refers to a direction that is substantially perpendicular to both the lateral direction and the longitudinal direction. For example, in the case where the sole is lying flat on a ground surface, the vertical direction may extend upward from the ground surface. It should be understood that each of these directional adjectives may be applied to individual components of the sole. The term "upward" or "upwardly" particularly refers to a vertical direction directed toward the top of a component, which may include the instep of the upper, the fastening area, and / or the throat of the upper. The term "downward" or "downwardly" particularly refers to a vertical direction directed toward the bottom of a component opposite to the upward direction, and may generally be directed toward the bottom of a sole structure of an article of footwear.

[0148] The "interior" of an article of footwear (such as a shoe) refers in particular to the portion at the space occupied by the foot of the wearer when the shoe is worn. The "inside" of a component refers in particular to the side or surface of the component that is oriented toward (or will be oriented toward) the interior of the component or the article of footwear in the assembled article of footwear. The "outside" or "exterior" of a component refers in particular to the side or surface of the component that is oriented away from (or will be away from) the interior of the shoe in the assembled shoe. In some cases, other components may be between the inside of the component and the interior of the assembled article of footwear. Similarly, other components may be between the outside of the component and the space outside the assembled article of footwear. In addition, the terms "inward" and "inwardly" refer in particular to the direction toward the interior of a component or an article of footwear (such as a shoe), and the terms "outward" and "outwardly" refer in particular to the direction toward the exterior of a component or an article of footwear (such as a shoe). In addition, the term "proximal" refers in particular to the direction closer to the center of the footwear component or closer to the foot when the user inserts the foot into the article of footwear when wearing the article of footwear. Likewise, the term "distal" specifically refers to a relative position farther from the center of the footwear component or farther from the foot when the user inserts the foot into the footwear when wearing the footwear. Therefore, the terms proximal and distal can be understood as generally relative terms that provide descriptions of relative spatial positions.

[0149] Although various embodiments have been described, the description is intended to be illustrative rather than restrictive, and it will be apparent to those of ordinary skill in the art that there may be more embodiments and implementations within the scope of these embodiments. Unless expressly limited, any feature of any embodiment may be used in combination with any other feature or element in any other embodiment or replace any other feature or element in any other embodiment. Therefore, these embodiments are not limited except in accordance with the attached claims and their equivalents. Moreover, various modifications and changes may be made within the scope of the attached claims.

[0150] Although several modes for implementing aspects of the present teachings have been described in detail, those skilled in the art to which these teachings relate will recognize various alternative aspects for practicing 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 be interpreted as illustrative and exemplary of the entire range of alternative embodiments that will be recognized by those skilled in the art, which are implied by the included content, structurally and / or functionally equivalent, or otherwise presented as obvious based on the included content, and are not limited to only those embodiments explicitly depicted and / or described.

Claims

1. A cushioning component for a wearable article, the cushioning component comprising: a bladder comprising a first barrier sheet and a second barrier sheet, the first barrier sheet and the second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet being sealed to each other along a peripheral bond to enclose the interior cavity and retain gas in the interior cavity; as well as A core, the core is arranged in the internal cavity and is completely spaced inwardly from the peripheral bonds, the core includes at least one polymer sheet, the at least one polymer sheet traverses the internal cavity between the relative inner surfaces of the first barrier sheet and the second barrier sheet, and is directly bonded to the relative inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonds to secure the first barrier sheet to the second barrier sheet, the at least one polymer sheet is displaced from the relative inner surfaces by the gas at unbonded areas of the at least one polymer sheet, and the plurality of bonds are arranged so that the gas in the internal cavity is fluidly connected around the at least one polymer sheet without the at least one polymer sheet creating any sealed chamber within the bladder that is not fluidly connected to the internal cavity.

2. The cushioning component of claim 1, wherein a barrier ink is disposed on the core at the unbonded area.

3. The cushioning component of any one of claims 1 to 2, wherein when the interior cavity of the bladder is unexpanded, the core lies flat within the bladder with the unbonded areas contacting the opposing interior surfaces. 4 . The cushioning component according to claim 1 , wherein the thickness of each of the at least one polymer sheet of the core is not greater than the thickness of the first barrier sheet and not greater than the thickness of the second barrier sheet.

5. The cushioning component of any one of claims 1 to 2, wherein the plurality of bonds include a first group of bonds in a first region of the bladder and a second group of bonds in a second region of the bladder; and The spacing between adjacent bonds of the first group of bonds is smaller than the spacing between adjacent bonds of the second group of bonds, so that the relative inner surfaces are maintained closer to each other in the first zone than in the second zone by the at least one polymer sheet.

6. A cushioning component according to claim 5, wherein the wearable article is a footwear article, the cushioning component is included in the sole structure of the footwear article, the first group of bonding portions are in the forefoot area of ​​the footwear article, and the second group of bonding portions are in one of the midfoot area or the heel area of ​​the footwear article. 7 . The cushioning component according to claim 6 , wherein the spacing between the adjacent bonding portions of the first group of bonding portions gradually decreases from the rear of the first group of bonding portions to the front of the first group of bonding portions.

8. The cushioning component of claim 6, wherein an outer perimeter of the at least one polymer sheet is spaced further inwardly from the peripheral bond in the heel region than in the forefoot region.

9. The buffer component according to any one of claims 1 to 2, wherein: The opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the core being a single polymer sheet having a first side bonded to the first inner surface of the first barrier sheet at a first set of bonds in the plurality of bonds and an opposing second side bonded to the second inner surface of the second barrier sheet at a second set of bonds in the plurality of bonds; and The second set of bonds is offset from the first set of bonds such that the second set of bonds alternates with the first set of bonds along the length of the single polymer sheet.

10. The cushioning component according to claim 9, wherein: The first set of bonds are linear bonds arranged in rows and the second set of bonds are linear bonds arranged in rows.

11. The cushioning component according to claim 9, wherein: The first set of bonds are point bonds arranged in rows and the second set of bonds are linear bonds arranged in rows.

12. The buffer component according to any one of claims 1 to 2, wherein: The opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the core being a single polymer sheet having a first side bonded to the first inner surface of the first barrier sheet at a first set of bonds in the plurality of bonds and an opposing second side bonded to the second inner surface of the second barrier sheet at a second set of bonds in the plurality of bonds; and The first set of bonds and the second set of bonds extend outwardly from a central region of the single polymer sheet in an array, wherein the bonds of the second set alternate with the bonds of the first set around the central region.

13. The cushioning component according to any one of claims 1 to 2, wherein: The opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the at least one polymer sheet of the core comprising a first polymer sheet and a second polymer sheet, the first polymer sheet being disposed between the first barrier sheet and the second polymer sheet, and the second polymer sheet being disposed between the first polymer sheet and the second barrier sheet such that a first side of the first polymer sheet faces the first inner surface of the first barrier sheet, a second side of the first polymer sheet faces the first side of the second polymer sheet, and a second side of the second polymer sheet faces the second inner surface of the second barrier sheet; and The first polymer sheet has its first side directly bonded to the first inner surface of the first barrier sheet at a first group of bonds among the plurality of bonds, the second polymer sheet has its second side directly bonded to the second inner surface of the second barrier sheet at a second group of bonds among the plurality of bonds, the second side of the first polymer sheet is bonded to the first side of the second polymer sheet at a third group of bonds among the plurality of bonds, the third group of bonds alternating with the first group of bonds along the length of the first polymer sheet, and the third group of bonds alternating with the second group of bonds along the length of the second polymer sheet.

14. The cushioning component of claim 13, wherein the second set of bonds are aligned with the first set of bonds.

15. The cushioning component of claim 13, wherein at least some of the bonds in the plurality of bonds are linear bonds.

16. The cushioning component according to any one of claims 1 to 2, wherein at least some of the bonding portions in the plurality of bonding portions are point bonding portions.

17. The cushioning component of claim 16, wherein the point bonds are arranged in rows, wherein the point bonds of adjacent ones of the rows are offset from one another.

18. The cushioning component according to any one of claims 1 to 2, wherein the plurality of bonds include linear bonds arranged in rows and point bonds arranged in rows, the rows of point bonds alternating with the rows of linear bonds.

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