Cushioning component for a wearable article and method of making the same

Abstract

A cushioning component includes a bladder and a core. The bladder includes a first barrier sheet and a second barrier sheet defining an interior cavity between opposing interior surfaces of the two barrier sheets. The core includes at least one polymeric sheet traversing the interior cavity between the opposing interior surfaces and directly bonded to the opposing interior surfaces at a plurality of bonds. The cushioning component includes a sidewall disposed about an outer periphery of the core and directly bonded to the first and second barrier sheets at peripheral bonds to enclose the interior cavity. The core is disposed in the interior cavity and is separate from the sidewall. A method of manufacture includes disposing a barrier ink on opposing sides of the at least one polymeric sheet, placing the at least one polymeric sheet between the barrier sheets, and thermally bonding the core to the opposing interior surfaces and thermally bonding the sidewall to the barrier sheets at the peripheral bonds.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 610,446, filed December 15, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to a cushioning component for wearable articles and a method of manufacturing the cushioning component, the cushioning component comprising a bladder and a core of at least one polymer sheet disposed in the bladder. Background Technology

[0004] Wearable products, such as footwear, typically include cushioning components. Some cushioning components are configured as fluid-filled bladders that enclose an internal cavity to retain gas within that cavity, thereby providing cushioning under load. Attached Figure Description

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

[0006] Figure 1 This is a plan view of the bottom side of the polymer sheet, on which anti-welding material is disposed.

[0007] Figure 2 yes Figure 1 A plan view of the opposite top sides of a polymer sheet, wherein anti-welding material is used with... Figure 1 The different patterns shown are set on the opposite top side.

[0008] Figure 3 This is a plan view of the top side of another polymer sheet, where anti-welding material is provided on the top side and no anti-welding material is provided on the opposite second side.

[0009] Figure 4 This is a plan view of the cushioning component in its inflated state, the cushioning component comprising... Figures 1 to 3 The core and sidewalls are formed from polymer sheets.

[0010] Figure 5 Is Figure 4 The line 5-5 was cut off. Figure 4 A cross-sectional view of the buffer component in its uninflated state.

[0011] Figure 6 Is Figure 4 The line 6-6 was cut off. Figure 4 A cross-sectional view of the buffer component in its uninflated state.

[0012] Figure 7 yes Figure 6 A cross-sectional view of the buffer component in the inflated state.

[0013] Figure 8 Is Figure 4 The line 8-8 was cut off. Figure 4 A cross-sectional view of the buffer component in the inflated state.

[0014] Figure 9 yes Figure 4 The outer view of the cushioning component in the inflated state.

[0015] Figure 10 It has the following features Figure 9 An external view of a footwear product with a cushioning component in the sole structure.

[0016] Figure 11 Is Figure 13 A cross-sectional view of an alternative embodiment of the buffer component taken at line 11-11 in the inflated state.

[0017] Figure 12 Is Figure 13 The line 12-12 was cut off. Figure 13 A cross-sectional view of the buffer component in the inflated state.

[0018] Figure 13 yes Figure 11 and Figure 12 The outer view of the cushioning component in the inflated state.

[0019] Figure 14 This is a plan view of the polymer sheet used as the sidewall of the cushioning component.

[0020] Figure 15 Is Figure 19 The section cut off at point 15-15 in the middle includes Figure 14 A cross-sectional view of an alternative embodiment of the sidewall cushioning component in the uninflated state.

[0021] Figure 16 Is Figure 19 The line 16-16 was cut off Figure 19 A cross-sectional view of the buffer component in its uninflated state.

[0022] Figure 17 yes Figure 16 A cross-sectional view of the buffer component in the inflated state.

[0023] Figure 18 Is Figure 19 The line 18-18 was cut off. Figure 19 A cross-sectional view of the buffer component in the inflated state.

[0024] Figure 19 yes Figures 15 to 18 The outer view of the cushioning component in the inflated state.

[0025] Figure 20 Is Figure 22 The line 20-20 was cut off. Figure 22 A cross-sectional view of an alternative embodiment of the cushioning component shown in the inflated state.

[0026] Figure 21 Is Figure 22 The line 21-21 was cut off. Figure 22 A cross-sectional view of the buffer component in the inflated state.

[0027] Figure 22 yes Figures 20 to 21 The outer view of the cushioning component in the inflated state.

[0028] Figure 23 It is a plan view of one side of a polymer sheet, in which anti-welding material is patterned on that side.

[0029] Figure 24 yes Figure 23 A plan view of the opposite side of a polymer sheet, wherein the anti-welding material is used with... Figure 23 The different patterns shown on one side are set on the opposite side.

[0030] Figure 25 yes Figure 23 The diagram shows a plan view of this side of the polymer sheet, in which spaced slots are cut through the polymer sheet to define strips adjacent to these slots, and the area on the opposite side not covered by anti-weld material is indicated by a dashed line.

[0031] Figure 26 This is a cross-sectional view of a cushioning component taken along the outer strip of a polymer sheet in its uninflated state. The cushioning component includes a core. Figure 23 The polymer sheet, wherein the core and sidewall are disposed between and bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet.

[0032] Figure 27 yes Figure 26 A cross-sectional view of the buffer component in the inflated state.

[0033] Figure 28 It was taken at another location along the middle strip of the core. Figure 26 A cross-sectional view of the buffer component in the inflated state. Detailed Implementation

[0034] This disclosure generally relates to a cushioning member for a wearable article, the cushioning member comprising a bladder and a core. The bladder includes a first barrier sheet and a second barrier sheet defining an internal cavity between opposing inner surfaces of the first and second barrier sheets. The core includes at least one polymer sheet traversing the internal cavity between opposing inner surfaces of the first and second barrier sheets and directly bonded to the opposing inner surfaces of the first and second barrier sheets at a plurality of joints to secure the first barrier sheet to the second barrier sheet. The cushioning member also includes sidewalls comprising at least one polymer sheet disposed around an outer periphery of the core and directly bonded to the first barrier sheet at a first peripheral joint and directly bonded to the second barrier sheet at a second peripheral joint to seal the internal cavity and retain gas within the internal cavity. The at least one polymer sheet of the core is disposed within the internal cavity and is separate from the sidewalls. The core is displaced from the opposing inner surface by gas at an unbonded area of ​​at least one polymer sheet.

[0035] In one embodiment, the plurality of joints may be arranged such that gas in the internal cavity is in fluid communication with the core, while the core does not create any sealed chambers within the bladder that are not in fluid communication with the internal cavity.

[0036] In one example, the sidewall is a single polymer sheet. In such an embodiment, the sidewall can be in a first position when the internal cavity is uninflated, and in a second position when the internal cavity is inflated. The sidewall can be folded inward toward the core in the first position and can extend relatively vertically around the internal cavity in the second position.

[0037] In one embodiment, the wearable article may be a footwear article, and the cushioning member may be included in the sole structure of the footwear article. In an example where the sidewall is a single polymer sheet, the cushioning member may extend in each of the heel area, midfoot area, and forefoot area of ​​the footwear article, and the height of the sidewall in the heel area may be greater than the height in the forefoot area.

[0038] In one aspect, the internal cavity may be a first internal cavity, and the cushioning member may further include a third barrier sheet bonded to the second barrier sheet at an additional peripheral joint. The second and third barrier sheets may define a second internal cavity between the outer surface of the second barrier sheet and the inner surface of the third barrier sheet. The first and second internal cavities may be fluidly isolated from each other by the second barrier sheet.

[0039] In one embodiment, a third barrier sheet may be disposed on the distal side of the cushioning member, and a first barrier sheet may be disposed on the foot-facing side of the cushioning member. The inflation pressure of the second internal cavity may differ from the inflation pressure of the first internal cavity. For example, the inflation pressure of the first internal cavity may be lower than that of the second internal cavity to provide a softer feel at the wearer's foot. Thus, the first barrier sheet provides a footbed, while the third barrier sheet makes the ground-facing surface relatively flat.

[0040] In one example, a third barrier sheet may be disposed on the distal side of the cushioning member, and a first barrier sheet may be disposed on the foot-facing side of the cushioning member. The core secures the first barrier sheet to the second barrier sheet such that the vertical height of the pouch at the core is less than the vertical height of the pouch at the sidewall. A concave surface on the outer surface of the first barrier sheet may serve as at least part of the footbed, and a concave surface may also be present on the outer surface of the second barrier sheet. The third barrier sheet may be relatively flat compared to the second barrier sheet, opposite the concave surface of the second barrier sheet.

[0041] In another embodiment, the core may include more than one polymer sheet. For example, at least one polymer sheet of the core may include a first polymer sheet and a second polymer sheet, wherein the first polymer sheet is disposed between a 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 of the core faces the inner surface of the first barrier sheet, a second side of the first polymer sheet of the core faces the first side of the second polymer sheet, and a second side of the second polymer sheet of the core faces the inner surface of the second barrier sheet. At least one polymer sheet of the sidewall may also include a first polymer sheet and a second polymer sheet. The first polymer sheet of the sidewall may be bonded to the first barrier sheet at a first peripheral joint, the second polymer sheet of the sidewall may be bonded to the second barrier sheet at a second peripheral joint, and the first polymer sheet of the sidewall may be bonded to the second polymer sheet of the sidewall at a third peripheral joint, the third peripheral joint being disposed along the sidewall between the first peripheral joint and the second peripheral joint.

[0042] In one or more such embodiments, the first side of the first polymer sheet of the core can be directly bonded to the inner surface of the first barrier sheet at a first set of the plurality of bonding portions, the second side of the second polymer sheet of the core can be directly bonded to the inner surface of the second barrier sheet at a second set of the plurality of bonding portions, and the second side of the first polymer sheet of the core can be directly bonded to the first side of the second polymer sheet of the core at a third set of the plurality of bonding portions.

[0043] In such an example, when the internal cavity is in an uninflated state, the sidewall can be in a first position, and when the internal cavity is inflated, the sidewall can be in a second position. In this second position, compared to the first position, the first polymer sheet and the second polymer sheet of the sidewall can extend relatively vertically between the first barrier sheet and the second barrier sheet, and wherein a third peripheral joint extends outward from the outer periphery of the core and is separated from the outer periphery by a gap.

[0044] In one aspect, a cushioning component for a wearable article may include a pouch. The pouch may include a first barrier sheet and a second barrier sheet defining an internal cavity between opposing inner surfaces of the first and second barrier sheets. The cushioning component may include a first polymer sheet and a second polymer sheet disposed between the first and second barrier sheets. Each of the first and second polymer sheets may include a core portion and a sidewall portion, the sidewall portion being separate from the core portion and extending along the outer periphery of the core portion. The core portion of the first polymer sheet may be bonded at a first plurality of joints to the inner surface of the first barrier sheet and a first side of the core portion of the second polymer sheet. The core portion of the second polymer sheet may be bonded at a second plurality of joints to the inner surface of the second barrier sheet and at a third plurality of joints to a second side of the core portion of the first polymer sheet. Thus, the core portions of the first and second polymer sheets together traverse the internal cavity and secure the first barrier sheet to the second barrier sheet. The sidewall portion of the first polymer sheet can be bonded to the first barrier sheet at a first peripheral joint. The sidewall portion of the second polymer sheet can be bonded to the second barrier sheet at a second peripheral joint. The sidewall portions of the first and second polymer sheets can be bonded to each other at a third peripheral joint, such that these sidewall portions, together with the first and second barrier sheets, seal the internal cavity and retain gas within it. The core portions of the first and second polymer sheets can be displaced from their opposing inner surfaces by gas at unbonded areas of the core portions of the first and second polymer sheets.

[0045] In one embodiment, the first plurality of joints, the second plurality of joints, and the third plurality of joints may be arranged such that gas in the internal cavity is in fluid communication with the core portions of the first polymer sheet and the core portions of the second polymer sheet, and these core portions do not create any sealed chambers within the bladder that are not in fluid communication with the internal cavity.

[0046] In one respect, the wearable article can be a footwear article, and the cushioning component can be included in the sole structure of the footwear article. For example, the cushioning component can extend in each of the heel area, midfoot area, and forefoot area of ​​the footwear article, and the height of the sidewall portion in the heel area can be greater than its height in the forefoot area.

[0047] In one aspect, the internal cavity may be a first internal cavity, and the cushioning member may include a third barrier sheet bonded to a second barrier sheet at an additional peripheral joint. The second and third barrier sheets may define a second internal cavity between the outer surface of the second barrier sheet and the inner surface of the third barrier sheet. The first and second internal cavities may be fluidly isolated from each other by the second barrier sheet. In one embodiment, the third barrier sheet may be disposed on the distal side of the cushioning member, and the first barrier sheet may be disposed on the foot-facing side of the cushioning member, and the inflation pressure of the second internal cavity may be different from the inflation pressure of the first internal cavity.

[0048] On one hand, the third barrier sheet can be disposed on the distal side of the cushioning member, and the first barrier sheet can be disposed on the foot-facing side of the cushioning member. The core portion can secure the first barrier sheet to the second barrier sheet, such that the vertical height of the pouch at the core portion is less than the vertical height of the pouch at the sidewall portion. A concave surface on the outer surface of the first barrier sheet can serve as at least a portion of the footbed. The third barrier sheet can be relatively flat compared to the second barrier sheet.

[0049] A method of manufacturing a cushioning component for a wearable article (such as the wearable article disclosed herein) may include: disposing a barrier ink on opposing first and second sides of at least one polymer sheet, and placing the at least one polymer sheet between a first barrier sheet and a second barrier sheet. The at least one polymer sheet may include a core and sidewalls, the sidewalls surrounding and being separate from the core's outer periphery. The method may further include: bonding the core to opposing inner surfaces of the first and second barrier sheets at multiple joints in areas of the at least one polymer sheet where the barrier ink is not disposed, to secure the first barrier sheet to the second barrier sheet; and also thermally bonding the sidewalls to the first barrier sheet at a first outer joint and to the second barrier sheet at a second outer joint, such that the sidewalls and barrier sheets enclose an internal cavity extending between opposing inner surfaces to define a pocket.

[0050] In one example, the method may include cutting a slot through the at least one polymer sheet prior to thermal bonding to separate the core from the sidewalls. The outer periphery of the core may be defined by the slot and may be located inside the slot, while the sidewalls may be located outside the slot.

[0051] On one hand, placing the at least one polymer sheet between the first barrier sheet and the second barrier sheet may include folded sidewalls, wherein the creases extend inward toward the outer periphery of the core.

[0052] In embodiments where the wearable article is a footwear article, the method may further include providing a cushioning component in the sole structure of the footwear article.

[0053] The above-described features and advantages of this teaching, as well as other features and advantages, will become apparent from the following detailed description of the manner in which this teaching is carried out when considered in conjunction with the accompanying drawings. It should be understood that while embodiments may be described individually below, their individual features may also be combined in additional embodiments.

[0054] Figures 1 to 3 Polymer sheets 10 and 11 are shown for forming the core 12 and the sidewall 51, which are included together with the capsule 20. Figures 4 to 9 The cushioning component 14 is shown. More specifically, the cushioning component 14 is included in the sole structure 70 of the footwear article 72, such as... Figure 10 As shown, the sole structure 70 is shown attached to the footwear upper 75. The sole structure 70 also includes an outsole 73, which is attached to the distal side of the cushioning member 14 and provides a ground contact surface. The footwear upper 75 and the sole structure 70 are not limiting. For example, a foam underlayment may also be included in the sole structure 70, which covers or lies beneath the cushioning member 14.

[0055] Each of the polymer sheets 10 and 11 includes a core portion and a sidewall portion. Specifically, polymer sheet 10 includes a core portion 12A and a sidewall portion 51A, and polymer sheet 11 includes a core portion 12B and a sidewall portion 51B. Thus, in the illustrated embodiment, the core 12 includes portions of both polymer sheets 10 and 11, and the sidewall 51 includes different portions of the same two polymer sheets 10 and 11. In other embodiments, the polymer sheets for the sidewall portions 51A and 51B may be different from the polymer sheet for the core 12. For example, if the materials of the polymer sheets 10 and 11 are different from the materials of the barrier sheets 16 and 18 included in the capsule 20, in some embodiments, the sidewall portions 51A and 51B may be cut from a sheet different from the polymer sheets 10 and 11, and the sidewall portions 51A and 51B may be positioned around the periphery of the core portions 12A and 12B between the barrier sheets 16 and 18 before heat treatment of the cushioning member 14.

[0056] The barrier sheets 16 and 18 of the capsule 20 can be formed of various materials including various polymers that can resiliently retain fluids such as air or another gas. Polymer sheets 10 and 11 can be formed of one or more of the same materials as the barrier sheets 16 and 18 described herein, or they can be formed of different polymer materials. Because the sidewall portions 51A and 51B are formed of polymer sheets 10 and 11 that also form the core portions 12A and 12B, and because the sidewall portions 51A and 51B form part of the exterior of the capsule 20, the materials of polymer sheets 10 and 11 (or at least the sidewall portions 51A of polymer sheet 10 and 51B of polymer sheet 11) are also materials that resiliently retain fluids such as air or another gas.

[0057] Examples of polymeric materials used for barrier sheets 16, 18 and polymer sheets 10 and 11 may include thermoplastic polyurethane, polyurethane, polyester, polyester-type polyurethane, and polyether-type polyurethane. Furthermore, barrier sheets 16, 18, and polymer sheets 10 and 11 may be formed from layers of different materials. In one embodiment, barrier sheets 16, 18, and / or polymer sheets 10 and 11 are formed from films having one or more thermoplastic polyurethane layers and one or more ethylene-vinyl alcohol copolymer (EVOH) barrier layers that are impermeable to pressurized fluids contained therein, as disclosed in U.S. Patent No. 6,082,025, which is incorporated herein by reference in its entirety. Barrier sheets 16, 18, and polymer sheets 10 and 11 may also be formed from materials comprising alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. Patents Nos. 5,713,141 and 5,952,065 to Mitchell et al., which are incorporated herein by reference in their entirety. Alternatively, these layers may comprise ethylene-vinyl alcohol copolymers, thermoplastic polyurethanes, and re-polished materials of ethylene-vinyl alcohol copolymers and thermoplastic polyurethanes. Barrier sheets 16, 18 and polymer sheets 10, 11 may also each be flexible microfilms comprising alternating layers of gas barrier materials and elastomeric materials, as disclosed in U.S. Patents 6,082,025 and 6,127,026 to Bonk et al., which are incorporated herein by reference in their entirety. Additional suitable materials for barrier sheets 16, 18 and polymer sheets 10, 11 are disclosed in U.S. Patents 4,183,156 and 4,219,945 to Rudy, which are incorporated herein by reference in their entirety. Other suitable materials for the barrier sheets 16 and 18 and the polymer sheets 10 and 11 include thermoplastic films containing crystalline materials (as disclosed in U.S. Patents 4,936,029 and 5,042,176 to Rudy) and polyurethanes comprising polyester polyols (as disclosed in U.S. Patents 6,013,340, 6,203,868, and 6,321,465 to Bonk et al., which are incorporated herein by reference in their entirety. In selecting the materials for the barrier sheets 16 and 18 and the polymer sheets 10 and 11, engineering properties such as tensile strength, elongation characteristics, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thickness of the barrier sheets 16 and 18 and the polymer sheets 10 and 11 can be selected to provide these properties.

[0058] For example, as this article discusses Figures 5 to 8As further explained, the cushioning member 14 includes a bladder 20, and a core 12 is disposed within the bladder 20 and coupled to the inner surface 17 of the barrier sheet 16 and the inner surface 19 of the barrier sheet 18 of the bladder 20 to act as a tension member. Providing a tension member within the bladder helps to constrain the bladder during inflation, preventing it from taking on a spherical shape. The tension member such as the core 12 according to this disclosure enables the polymer sheets 10, 11 to be coupled to the barrier sheets 16, 18 at patterned joints, which provide technical advantages in terms of the performance of the cushioning member 14 and the ease of manufacturing the cushioning member 14. The sidewall portions 51A, 51B are provided by the same polymer sheets 10 and 11 as the core portions 12A and 12B, allowing the sidewalls 51 to have a more vertical orientation than when the barrier sheets 16 and 18 are directly coupled to each other at the peripheral joints to form the sidewalls. Alternatively, manufacturing can be simplified by simultaneously placing anti-welding material 24 on the sidewall portions 51A and 51B and the corresponding core portions 12A and 12B, cutting through polymer sheets 10 and 11 to separate the sidewall portions 51A and 51B from the corresponding core portions 12A and 12B (as discussed herein), and then placing the sidewall portions 51A and 51B and the core portions 12A and 12B between the barrier sheets 16 and 18 before heat treatment to form various joints.

[0059] Figure 1 This is a plan view of the bottom side of the polymer sheet 11, on which the anti-welding material 24 is disposed. The polymer sheet 11 is referred to herein as the second polymer sheet. Figure 1 The side of the polymer sheet shown is the second side 13, and when the core 12 and sidewall 51 are bonded to the sole structure 70 of the footwear article 72, this side of the polymer sheet is also referred to as the bottom side or distal side because it is positioned further away from the foot. The second side 13 abuts against and is bonded to the inner surface 19 of the second barrier sheet 18, for example, as... Figure 5 and Figure 6 As shown and discussed in this article.

[0060] Figure 2 This is a plan view of the opposite first side 15 of the second polymer sheet 11, wherein the anti-welding material 24 is used in conjunction with... Figure 1 The second side 13 shown has a different pattern on the opposite first side 15. When the core 12 and the sidewall 51 are incorporated into the sole structure 70 of the footwear article 72, the first side 15 is also referred to as the top side or proximal side of the second polymer sheet 11 because it is positioned closer to the foot.

[0061] like Figures 9 to 10As best shown, each of the core 12, sidewall 51, cushioning component 14, and footwear 72 includes a forefoot region 50, a midfoot region 52, and a heel region 54. The forefoot region 50 typically includes a portion of the footwear 72 or core 12 corresponding to the toe and the joints connecting the metatarsal and phalangeal bones of the wearer's foot. The midfoot region 52 typically includes a portion of the footwear 72 or core 12 corresponding to the arch region of the foot, and the heel region 54 corresponds to the posterior portion of the foot (including the calcaneus). Each of the core 12, sidewall 51, cushioning component 14, sole structure 70, and footwear 72 includes a medial side 80 and a lateral side 82 extending through each of the forefoot region 50, midfoot region 52, and heel region 54 and falling within... Figure 4 On opposite sides of the longitudinal centerline (e.g., longitudinal axis LA) of the indicated cushioning component 14. The forefoot area 50, midfoot area 52, heel area 54, medial side 80, and lateral side 82 are not intended to delineate the precise areas of the footwear article 72, core 12, cushioning component 14, or sole structure 70, but rather to indicate the general areas of the footwear article 72, core 12, cushioning component 14, and sole structure 70 to facilitate the discussion below.

[0062] Figure 3 This is a plan view of the first side 22 of the first polymer sheet 10, on which the anti-welding material 24 is disposed. In the illustrated embodiment, no anti-welding material 24 is disposed on the opposite second side 26, but it abuts with the anti-welding material on the first side 15 of the second polymer sheet 11. When the core 12 is assembled, the first polymer sheet 10 is stacked on the second polymer sheet 11 such that the second side 26 abuts and bonds to the first side 15 of the second polymer sheet 11, and the first side 22 abuts and bonds to the inner surface 17 of the first barrier sheet 16, as shown. Figures 4 to 8 As shown and discussed in this article.

[0063] Anti-welding material 24 is applied to the polymer sheets 10 and 11 of the core 12 in areas that will become unbonded during heat treatment of the core 12. By utilizing the anti-welding material 24 applied to the polymer sheets 10 and 11, the bonding between the core 12 and the inner surfaces 17 and 19 of the barrier sheets 16 and 18, the bonding between the sidewall portions 51A and 51B and the inner surfaces 17 and 19, and their bonding with each other, as well as the bonding pattern between the second side 26 of the first polymer sheet 10 and the first side 15 of the second polymer sheet 11, is determined to define the final geometry of the complete cushioning component 14, including the height difference in different areas of the footwear 72 (e.g., the forefoot area 50 and the heel area 54), the toe lift, etc.

[0064] like Figure 5 and Figure 6 As shown, one or both of the inner surfaces 17 and 19, located outside the outer perimeter 34 of the core 12 and inside the positions where the outer joints 38A and 38B form with the sidewall portions 51A and 51B, are also pre-printed with anti-welding material 24 or otherwise treated, so that these portions of the inner surfaces 17 and 19 will not bond to the sidewall portions 51A and 51B or will not bond to each other. Additionally, anti-welding material 24 is disposed between some mating surfaces of the sidewall portions 51A and 51B, except for the innermost mating portion where the outer joint 38C is located. The outer joint 38A is referred to herein as the first outer joint. The outer joint 38B is referred to herein as the second outer joint. The outer joint 38C is referred to herein as the third outer joint.

[0065] Anti-welding material 24 can be applied to polymer sheets 10 and 11 via one or more computer-controlled printheads (not shown) according to a storage algorithm representing a predetermined printed pattern. Figures 5 to 6 (On a portion of the inner surface 17 of the first barrier sheet 16 and / or the inner surface 19 of the second barrier sheet 18 shown). As used herein, the anti-sealant 24 can be a barrier ink and can also be referred to as anti-sealant ink. For example, when the anti-sealant is a barrier ink, it can be printed at all selected locations according to different predetermined programming patterns on the first side 22 of the first polymer sheet 10, the first side 15 of the second polymer sheet 11, and the second side 13 of the second polymer sheet 11, where bonding of the polymer sheets 10, 11 of the core 12 to each other, to the sidewalls 51, or to the barrier sheets 16, 18 is undesirable.

[0066] refer to Figures 1 to 3 Polymer sheets 10 and 11 are cut at their outer perimeters 53A and 53B, respectively, and slits 55A and 55B are cut through the polymer sheets 10 and 11, respectively. These slits 55A and 55B can be cut at the same time as the polymer sheets 10 and 11 are cut at their outer perimeters 53A and 53B, for example, by using an automatic cutting machine. Slits 55A and 55B separate the sidewall portions 51A and 51B from the corresponding core portions 12A and 12B. When the sheets 10 and 11 are bonded together, for example by heat treatment, the adjacent surfaces of the stacked flat polymer sheets 10 and 11 and the barrier sheets 16 and 18 are bonded together except where the anti-welding material 24 is provided. Therefore, the pattern of the anti-welding material 24 determines the corresponding pattern of the joint obtained in the finished buffer member 14.

[0067] Figure 1The predetermined pattern of the anti-welding material 24 on the second side 13 of the second polymer sheet 11 is referred to as the second predetermined pattern, and a second set of joints 46 are formed. Figures 5 to 8 The joint 38B under discussion. Figure 2 The predetermined pattern of the anti-welding material 24 on the first side 15 of the second polymer sheet 11 is referred to as the third predetermined pattern, and a third set of joints 47 is formed. Figures 5 to 8 The discussed joint 38C. The predetermined pattern of the anti-welding material 24 on the first side 22 of the first polymer sheet 10 is referred to as the first predetermined pattern, and it forms the first set of joints 44 and related to Figures 5 to 8 The joint 38A under discussion.

[0068] refer to Figure 1 Anti-welding material 24 is disposed on the second side 13 of the second polymer sheet 11 in a second predetermined pattern, the second predetermined pattern having: region A along the inner edge 23A of the core portion 12B (e.g., where the slit 55B is cut, and the inner edge 23A becomes part of the outer periphery 34B of the core portion 12B), region B along the outer edge 23B of the core portion 12B (where the outer edge 23B is also cut, and the outer edge 23B becomes part of the outer periphery 34B of the core portion 12B), region C surrounded by anti-welding material 24, and an uncovered region S1 without anti-welding material. Region S1 is adjacent to the outer periphery 53B and extends only partially across the sidewall portion 51B to the slit 55B, because the remaining portion of the sidewall portion 51B on the second side 13 is covered by anti-welding material 24. Regions A, B, C, and S1 do not contain any deposited anti-welding material 24. Figure 1 Region 25 directly above the deposited anti-welding material 24 also does not contain anti-welding material 24, and region 27 directly below the deposited anti-welding material 24 also does not contain anti-welding material 24. Regions A, B, and C will become... Figure 4 The second set of joints 46, indicated by dashed lines, corresponds to one of these regions. More specifically, region A will become the inner end joint 46A, region B will become the outer end joint 46B, and region C will become the inner joint 46C located between the inner end joint 46A and the outer end joint 46B. Figure 4Only some internal joints 46C are marked. Joints 46A, 46B, and 46C can be uniformly referred to by the reference numeral 46. Regions 25 and 27 will become the foremost and last joints between the core portion 12B and the second barrier sheet 18. These foremost and last joints are not included in joint 46, which is referred to herein as the second set of joints. Region S1 will become the peripheral joint 38B between the sidewall portion 51B and the inner surface 19 of the second barrier sheet 18, as shown in the figure. Figures 5 to 8 As shown.

[0069] refer to Figure 2 Anti-welding material 24 is disposed on the first side 15 of the second polymer sheet 11 in a third predetermined pattern. Region E along the inner edge 23A of the core portion 12B, region F along the outer edge 23B of the core portion 12B, region G surrounded by anti-welding material 24, and an uncovered region S2 adjacent to the slit 55B on the sidewall portion 51B and without any deposited anti-welding material 24 are included. Region S2 extends only partially across the sidewall portion 51B toward the outer perimeter 53B. The remaining portion of the sidewall portion 51B on the first side 15 is covered by anti-welding material 24. Regions E, F, G, and S2 contain no anti-welding material. Regions E, F, and G will become... Figures 4 to 8 The third set of joints 47 shown corresponds to one of these regions. More specifically, region E will become the inner end joint 47A, region F will become the outer end joint 47B, and region G will become the inner joint 47C located between the inner end joint 47A and the outer end joint 47B. Joints 47A, 47B, and 47C can be uniformly referred to by the reference numeral 47. Region S2 will become the peripheral joint 38C between the sidewall portion 51B and the sidewall portion 51A, as shown... Figures 5 to 8 As shown.

[0070] refer to Figure 3 The anti-welding material 24 is disposed on the first side 22 of the first polymer sheet 10 in a first predetermined pattern, the first predetermined pattern having: a region H along the inner edge 37 of the core portion 12A (e.g., where the slit 55A is cut, and the inner edge 37 becomes part of the outer periphery 34A of the core portion 12A), a region I along the outer edge 39 of the core portion 12A (where the outer edge 39 is also cut, and the outer edge 39 becomes part of the outer periphery 34A), a region J surrounded by the anti-welding material 24, and an uncovered region S3 adjacent to the outer periphery 53A and extending only partially across the sidewall portion 51A toward the slit 55A. The remaining portion of the sidewall portion 51A on the first side 22 is covered by the anti-welding material 24. Regions H, I, J, and S3 do not contain any deposited anti-welding material 24. Figure 3Region 41 directly above the deposited anti-welding material 24 also does not contain anti-welding material 24, and region 43 directly below the deposited anti-welding material 24 also does not contain anti-welding material 24. Regions H, I, and J will become Figure 5 The first set of joints 44 shown corresponds to one of these regions. More specifically, region H will become the inner end joint 44A, region I will become the outer end joint 44B, and region J will become the inner joint 44C located between the inner end joint 44A and the outer end joint 44B. Joints 44A, 44B, and 44C can be uniformly referred to by the reference numeral 44. Regions 41 and 43 will become the foremost joint 45 and the last joint 49 between the core portion 12A and the first barrier sheet 16, respectively. The foremost and last joints are not included in joints 44, which are referred to herein as the first set of joints. Region S3 will become the peripheral joint 38A between the sidewall portion 51A and the inner surface 17 of the first barrier sheet 16, as shown below. Figures 5 to 8 As shown.

[0071] Figure 4 The illustration shows the cutting and trimming of the core portions 12A and 12B, as well as the sidewall portions 51A and 51B. Figure 5 and Figure 6 These portions are stacked between barrier sheets 16 and 18, and the barrier sheets 16 and 18 are heat-treated to form a buffer member 14 after being bonded to the core portions 12A and 12B and the sidewall portions 51A and 51B.

[0072] from Figures 1 to 4 As clearly visible, the anti-welding material 24 extends continuously from the inner edge 34C to the outer edge 34D between the joints 44 of adjacent rows and columns (where rows are in the transverse direction and columns are in the front-back direction), between the joints 46 of adjacent rows, and between the joints 47 of adjacent rows. When the core portions 12A and 12B are stacked together, the outer periphery 34A of the core portion 12A and the outer periphery 34B of the core portion 12B are aligned and can be collectively referred to as the outer periphery 34 of the core 12. The inner edge 34C is a portion of the outer periphery 34 of the core 12 located 80 degrees inside the longitudinal axis LA. The longitudinal axis LA is also referred to herein as the longitudinal centerline. The outer edge 34D is a portion of the outer periphery 34 of the core 12 located 82 degrees outside the longitudinal axis LA. By depositing the anti-welding material 24 such that it extends from the inner surfaces 17, 19 of the barrier sheets 16, 18 and between the polymer sheets 10, 11 (on the first side 15 of the second polymer sheet 11) to the outer periphery 34 of the core 12, and by ensuring that the outer periphery 34 of the core 12 is completely located inside the outer periphery joint 38A of the barrier sheet 16 and the outer periphery joint 38B of the barrier sheet 18 and the outer wall 51, for example, as Figure 7 As shown, the resulting pattern of the joints 44, 46, and 47 of the multi-sheet core 12 does not create any sealed chambers within the bladder 20 that are not in fluid communication with the internal cavity 21. Thus, the multi-sheet core 12 itself controls the final geometry of the inflated cushioning member 14 without affecting the cushioning response of the cushioning member 14 under dynamic loads.

[0073] Figures 4 to 6 The best illustration shows the relative positioning of multiple sets of joints 44, 46, and 47, and peripheral joints 38A, 38B, and 38C, achieved by a precise predetermined pattern of anti-welding material 24 respectively disposed on the first side 22 of the first polymer sheet 10, the second side 13 of the second polymer sheet 11, and the first side 15 of the second polymer sheet 11. Figure 4 In the diagram, the joints 44 (44A, 44B, and 44C) of the first group are indicated by solid lines. The joints 46 (46A, 46B, and 46C) of the second group are indicated by dashed lines. The joints 47 (47A, 47B, and 47C) of the third group are indicated by a combination of dashed and dotted lines. For clarity, the diagram is... Figure 4 Only some joints are marked. From Figure 4 It can be clearly seen that the joint 47 of the third group alternates with the joint 44 of the first group along the length of the core 12 (e.g., along the length of the first polymer sheet 10 of the core 12), and thus alternates along the length of the resulting buffer member 14. Figure 4 It can also be clearly seen that the joints 47 of the third group alternate with the joints 46 of the second group in the transverse direction and along the length of the core 12 (e.g., along the length of the second polymer sheet 11 of the core 12), and thus alternate along the length of the resulting buffer member 14. With this configuration, at least some of the joints 46 of the second group are aligned with at least some of the joints 44 of the first group. More specifically, the joints 44 of the first group are vertically positioned above the joints 46 of the second group, wherein the joints 47 of the third group are offset from and located at a height between the height of the joint 44 and the height of the joint 46 in each vertically stacked group of joints 44. Figures 5 to 8 As instructed.

[0074] Figure 5 and Figure 6As shown, the uncovered portion of the second side 26 of the first polymer sheet 10 at the sidewall portion 51A abuts against the uncovered portion of the first side 15 of the second polymer sheet 11 at the sidewall portion 51B, forming a third peripheral joint 38C. The sidewall portions 51A of the polymer sheet 10 and 51B of the polymer sheet 11 separate from the corresponding core portions 12A and 12B of the polymer sheets 10 and 11 at slits 55A and 55B, and therefore, when the cushioning member 14... Figures 7 to 10 As shown, during inflation, the sidewall portions 51A and 51B separate from the core portions 12A and 12B. In other words, the third peripheral joint 38C extends outward from the outer periphery 34A and 34B of the core 12, and through... Figure 7 The gap 21A indicated is separated from the outer peripheries 34A and 34B. This gap 21A is the outer periphery of the internal cavity 21. The sidewall portions 51A and 51B are joined to each other at a third peripheral joint 38C along the sidewall 51. In other words, the third peripheral joint 38C falls between the sidewall portions 51A and 51B, and is therefore considered to be along the sidewall 51. Figure 9 and Figure 10 As shown, the third peripheral joint 38C extends around the periphery of the cushioning member 14 and extends on the inner side 80 and the outer side 82 of each of the forefoot area 50, the midfoot area 52 and the heel area 54.

[0075] Figure 5 and Figure 6 The diagram shows a cushioning member 14 in an uninflated state and a sidewall 51 in a first position, with two sidewall portions 51A and 51B stacked flat between barrier sheets 16 and 18. A conventional tension member 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 multiple tethers extending from the first polymer sheet to the second polymer sheet. Due to this configuration, a conventional tension member is not relatively flat or sheet-like before inflating the internal cavity of the bladder in which the tension member is located, and is therefore unsuitable for thermoforming—whether for creating a core of multiple polymer sheets or for bonding a single polymer sheet or a core of multiple polymer sheets to the inner surface of a barrier sheet.

[0076] Figure 7 and Figure 8The buffer member 14 is shown in an inflated state, with the internal cavity 21 filled with gas (e.g., air), and portions of the first polymer sheet 10 as sidewall portions 51A and the second polymer sheet 11 as sidewall portions 51B extend vertically relative to each other between the first barrier sheet 16 and the second barrier sheet 18. A small portion of the peripheral joint 38A or 38B may initially remain open to form a port and / or receive a filling tube to allow inflation of the internal cavity 21 with a gas (such as air or nitrogen), and may then be sealed after inflation to completely close the internal cavity 21, thereby retaining the gas within the internal cavity 21.

[0077] Because the outer joint 38C is formed between the sidewall portions 51A and 51B, and the barrier sheets 16 and 18 are joined to the corresponding sidewall portions 51A and 51B at the outer joints 38A and 38B, rather than joined to each other, the inflation pressure in the internal cavity 21 allows the sidewall portions 51A and 51B to be almost vertical relative to the barrier sheets 16 and 18, rather than giving the cushioning member 14 a more rounded perimeter. Furthermore, because the sidewall portions 51A and 51B are wider in the heel area than in the forefoot area when in a flat state (as in...), Figures 1 to 3 (Clearly visible in the middle), so the vertical height of the lateral wall 51 is in the heel area 54 (in Figure 8 The height H1 shown in the figure is 50 degrees higher than that in the forefoot area. Figure 7 The height H2 shown is large, for example, by... Figure 7 and Figure 8 Compare and by looking Figures 9 to 10 And it is clearly visible.

[0078] Figure 7 and Figure 8 As shown, the tension generated in the bonded polymer sheets 10, 11 of the core 12 by inflating the internal cavity 21 causes the portion of the first barrier sheet 16 located inside the outer periphery 34A or 34B of the core portions 12A and 12B to be pulled downward at the joint 44, as indicated by the shaped outer surface 59 of the first barrier sheet 16. Because the outer periphery 34A of the core portion 12A and the outer periphery 34B of the core portion 12B are completely located inside the peripheral joints 38A, 38B and 38C, the barrier sheets 16, 18 will not be secured together at the peripheral portions of the internal cavity 21 located outside the outer peripheries 34A and 34B. The distance between the inner surfaces 17 and 19 and the resulting height of the buffer member 14 can therefore be maximized on the outer side of the core 12. Figure 7As best shown, for example, the core 12 secures the first barrier sheet 16 to the second barrier sheet 18 such that the vertical height H3 of the bladder 20 at the core 12 is less than the vertical height H2 of the bladder at the sidewall 251 at that cross-section. This height difference creates a concave surface at the outer surface 59 of the first barrier sheet 16, which serves as at least a part of the footbed. Similarly, the tension generated in the bonded polymer sheets 10, 11 of the core 12 by inflating the internal cavity 21 causes the portion of the second barrier sheet 18 located inside the outer periphery 34A of the core portion 12A and the outer periphery 34B of the core portion 12B to be pulled upward at the joint 46, as... Figure 7 and Figure 8 The second barrier sheet 18 is indicated by its shaped outer surface 61. In other words, the second barrier sheet 18 has an inwardly concave surface at its outer surface 61 facing the core 12, which is opposite to the concave surface at the outer surface 59 of the first barrier sheet 16 facing the core 12. The shaped surface 59 can be used as a footbed, including a heel cup, because most of the shaped surface 59 is pressed down toward the center of the barrier sheet 16.

[0079] Figures 11 to 13 Another example is shown of a cushioning member 114 that can be included in the sole structure of a footwear article (such as footwear article 72) instead of the sole structure 70 and the cushioning member 14. Figures 11 to 13 In the illustrated embodiment, the addition of a third barrier sheet 18A achieves a shaped outer surface 59 at the first barrier sheet 16, while also providing a flatter, ground-facing surface for the cushioning member 114. More specifically, the third barrier sheet 18A is bonded to the outer surface 61 of the second barrier sheet 18 at an additional peripheral joint 38D. In this configuration, the second barrier sheet 18 and the third barrier sheet 18A define a second internal cavity 121 between the outer surface 59 of the second barrier sheet 18 and the inner surface 63 of the third barrier sheet 18A. The internal cavity 21 (which may be referred to as the first internal cavity) is completely fluidly isolated from the second internal cavity 121 by the second barrier sheet 18.

[0080] Because the internal cavities 21 and 121 are fluidly isolated from each other, they can be inflated to different inflation pressures and can maintain gas at different inflation pressures. For example, the inflation pressure in internal cavity 121 can be greater than the inflation pressure in internal cavity 21. Figure 13As shown, the first barrier sheet 18 is disposed on the foot-facing side 55 of the cushioning member 114, and the third barrier sheet 18A is disposed on the distal side 57 (e.g., closer to the ground contact surface during wear). Therefore, providing a higher inflation pressure in the second internal cavity 121 allows the third barrier sheet 18A to extend relatively flat relative to the concave surface of the second barrier sheet 18 at the outer surface 61, where the third barrier sheet 18A is pulled inward by the core 12.

[0081] Figure 14 An example of a single polymer sheet 210 is shown, which is cut to be used as a cushioning member 214 (in Figures 15 to 19 The shape of the sidewall 251 shown in the figure indicates that the cushioning member 214 can be included in the sole structure of footwear articles (such as footwear article 72) in place of the sole structure 70 and the cushioning member 14. In one example, the sidewall 251 is a single polymer sheet. The sidewall 251 can be cut from one of the polymer sheets 10 or 11 as described with respect to sidewall portions 51A and 51B, or it can be cut from a separate polymer sheet. Figure 14 The fold line 251A is shown as a dashed line. At this fold line 251A, when the sidewall 251 is placed between the first barrier sheet 16 and the second barrier sheet 18 and located outside the outer perimeter 34A of the core portion 12A and the outer perimeter 34B of the core portion 12B, the sidewall 251 is folded, as shown. Figure 15 and Figure 16 As shown. In Figure 14 In the diagram, sidewall 251 is shown as having a discontinuity due to a cut 251B, which is configured such that sidewall 251 has ends 251C and 251D and is not a completely closed shape. This allows the polymer sheet 210 to be folded more easily at fold line 251A. In another example, sidewall 251 may not have this cut and may be a closed shape.

[0082] Anti-welding material 24 is deposited on the sidewall 251, deposited at one or both of the inner sides of the folded sidewall 251 facing each other, such as... Figure 15As shown. Anti-welding material 24 is provided on the outer sides 251G and 251H of the folded sidewall 251, except that peripheral joints 38A and 38B respectively bond the sidewall 251 to the outer edges where the inner surfaces 17 of the first barrier sheet 16 and 19 of the second barrier sheet 18 are located. Alternatively, anti-welding material 24 may be alternatively or additionally provided on the inner surfaces 17 and 19 between the outer peripheries 34A and 34B of the core 12 and the peripheral joints 38A and 38B. The ends 251C and 251D defined at the cut 251B may overlap each other without anti-welding material at their overlapping surfaces, creating a seam in the sidewall 251 such that the sidewall 251, together with the barrier sheets 16 and 18, seals the internal cavity 21.

[0083] The side wall 251 is in the first position when the internal cavity 21 is not inflated, for example, as Figure 15 and Figure 16 As shown, and in the second position when the internal cavity 21 is inflated, as... Figures 17 to 19 As shown. In the first position, the sidewall 251 is folded inward toward the core 12, and in the second position, it extends relatively vertically around the internal cavity 21. In the second position, because the sidewall 251 is integral and only has peripheral joints 38A and 38B (and no peripheral joint 38C), there is no intermediate seam extending around the sidewall 251, because an intermediate seam exists at the peripheral joint 38C of the connected sidewall portions 51A and 51B of the buffer members 14 and 114.

[0084] like Figure 19 As shown, the cushioning component 214 has a heel area 54, a midfoot area 52, and a forefoot area 50, and when included... Figure 10 When replacing the cushioning member 14 in the sole structure 70 of the footwear 72, it extends in each of these areas of the footwear 72. Similar to the cushioning member 14, the sidewall 251 has a greater height in the heel area 54 than in the forefoot area 50, and is secured by the core 12 such that the vertical height H3 at the core 12 is less than the vertical height H2 at the sidewall 251 (see...). Figure 17 This creates concave surfaces on the outer surface 59 of the barrier sheet 16 and the outer surface 61 of the barrier sheet 18.

[0085] Figures 20 to 22 A buffer member 314 similar to buffer member 214 is shown, but with the addition of a third barrier sheet 18A and the sealing of the third barrier sheet 18A to the outer surface 61 of the second barrier sheet 18, to create a fluid-isolated second internal cavity 121 with different inflation pressure at the distal side 57 of the buffer member 314, as per [reference to...]. Figures 11 to 13 The buffer component 114 is described.

[0086] Figures 23 to 24 A single polymer sheet 410 is shown, which is processed into Figure 25 The single polymer sheet core 412 shown, and with Figures 26 to 28 The sidewall 251 of the buffer member 414 shown is bonded together with the barrier sheets 16, 18. The sidewall 251 and related... Figures 14 to 22 The same as described, and in Figures 26 to 28 The first barrier sheet 16 is bonded at the outer joint 38A and the second barrier sheet 18 is bonded at the outer joint 38B.

[0087] Core 412 is bonded to a first barrier sheet 16 and a second barrier sheet 18, which together form a capsule 420. The capsule 420 defines the space between opposing inner surfaces of the first barrier sheet 16 and the second barrier sheet 18 (e.g., between the inner surface 17 of the first barrier sheet 16 and the inner surface 19 of the second barrier sheet 18, for example, as...). Figure 27 The internal cavity 21 (as indicated). The polymer sheet 410 is a single polymer sheet and is the only polymer sheet included in the core 412. The polymer sheet 410 can be any material described with respect to polymer sheet 10. Although the polymer sheet 410 is a single polymer sheet, in some instances, the polymer sheet 410 may include multiple layers of material, as discussed herein. Additionally, in some embodiments, a core comprising multiple polymer sheets may be used.

[0088] Figure 23 One side 426 of the polymer sheet 410 is shown. This side 426 is referred to herein as the second side. Anti-welding material 24 is patterned on the second side 426 of the polymer sheet 410 such that a number of areas 423 (and specifically 423A to 423I) are not covered by the anti-welding material 24. Figure 23 The printed pattern of the anti-welding material 24 is referred to herein as the second predetermined pattern. The anti-welding material 24 is indicated by shading, and uncovered areas 423 are shown without shading. Only some uncovered areas 423 are indicated by reference numerals. These uncovered areas 423 each have a generally rectangular shape and have the same dimensions (e.g., the same width and the same length). In other embodiments, the areas 423 not covered by the anti-welding material 24 may have different shapes and / or sizes.

[0089] As shown in the figure, the anti-welding material 24 has a pattern with a first edge 434A, a second edge 434B, a third edge 434C, and a fourth edge 434D. Edges 434A and 434B are opposite to each other, and edges 434C and 434D are opposite to each other. Before placing the core 412 between the barrier sheets 16 and 18, the polymer sheet 410 is cut along edges 434A, 434B, 434C, and 434D. Therefore, edges 434A, 434B, 434C, and 434D form the outer periphery 434 of the core 412.

[0090] Figure 24 An anti-welding material 24 is shown, which is applied to an opposite side 422 (referred to herein as the first side 422) in a predetermined pattern different from that on the second side 426 (referred to herein as the first predetermined pattern). Specifically, Figure 24 The first predetermined pattern shown ensures that region 425 (and specifically regions 425A to 425F) is not covered by the anti-welding material 24. Figure 24 In the figures, only some regions 425 are indicated by reference numerals. These regions 425 each have a generally rectangular shape and the same dimensions (e.g., the same width and the same length). In other embodiments, regions 425 not covered by the anti-welding material 24 may have different shapes and / or dimensions.

[0091] As shown in the figure, the first predetermined pattern of the anti-welding material 24 has a first edge 434E, a second side edge 434F, a third edge 434G, and a fourth edge 434H. The first edge 434E corresponds to and falls along the first edge 434A of the opposite side 426. The second side edge 434F corresponds to and falls along the second edge 434B of the second side 426. The third edge 434G is shifted from the center of the polymer sheet 410 and is closer to the center of the polymer sheet 410 than the third edge 434C of the opposite side 426. The fourth edge 434H is shifted from the center of the polymer sheet 410 and is closer to the center of the polymer sheet 410 than the fourth edge 434D on the second side 426. Edges 434E and 434F are opposite to each other, and edges 434G and 434H are opposite to each other. Edges 434A, 434B, 434C, 434D, 434E, and 434F may also be referred to as side edges in this document because, after the polymer sheet 410 is cut, they fall along the outer perimeter 434 of the core 412, as... Figure 25 As shown. Edge 434A can be referred to as the first side edge, and edge 434B can be referred to as the second side edge.

[0092] Figure 25A second side 426 of the polymer sheet 410 is shown after the polymer sheet has been cut to the outer perimeter 434 (e.g., to edges 434A, 434B, 434C, and 434D at the anti-weld material 24) to define the core 412. In addition to the cut at the outer perimeter 434, a plurality of spaced slots 436 are cut through the polymer sheet 410 (e.g., these slots 436 extend completely through the polymer sheet 410 from the first side 422 to the second side 426). Figure 25 In the example shown, these slots 436 are linear and extend parallel to the opposing first side edge 434A and second side edge 434B of the core 412.

[0093] These slots 436 generate multiple stripes 410A, 410B, 410C, 410D, 410E, 410F, 410G, 410H, 410I, 410J, 410K, 410L, 410M, 410N, 410O, 410P, 410Q, 410R, and 410S. Stripes 410A to 410S are adjacent to slots 436 and separated from each other at slots 436. In other words, there is one slot 436 between each pair of adjacent stripes. For example, there is a slot 436 between strips 410A and 410B, a slot 436 between strips 410B and 410C, a slot 436 between strips 410C and 410D, a slot 436 between strips 410D and 410E, a slot 436 between strips 410E and 410F, a slot 436 between strips 410F and 410G, a slot 436 between strips 410G and 410H, a slot 436 between strips 410H and 410I, and a slot 436 between strips 410I and 410J. There is a slot 436 between strips 410J and 410K, between strips 410K and 410L, between strips 410L and 410M, between strips 410M and 410N, between strips 410N and 410O, between strips 410O and 410P, between strips 410P and 410Q, between strips 410Q and 410R, and between strips 410R and 410S. As shown, each of these slots 436 has a constant width, and each of strips 410A to 410S has a constant width. In other words, each of the strips 410A to 410S maintains a constant width W between the end of the strip adjacent to the first end 436A of the slot 436 and the end of the strip adjacent to the second end 436B of the slot 436. Figure 25(As indicated in the text regarding strip 410S). In other instances, the width of one or more of these slots 436 and / or one or more of these strips 410A to 410S may vary.

[0094] Each of these slots 436 has a first end 436A and a second end 436B. For clarity, in the accompanying drawings... Figure 25 Only some of the ends 436A and 436B are marked. The first end 436A and the second end 436B are located inside the outer perimeter 434. In other words, the first end 436A is closer to the center of the polymer sheet 410 than the edge 434C (the center is halfway between ends 436A and 436B), such that after the slot 436 is cut, the end portion 410T of the polymer sheet 410 remains between the first end 436A and the edge 434C. The second end 436B is closer to the center of the polymer sheet 410 than the edge 434D, such that after the slot 436 is cut, the end portion 410U remains between the second end 436B and the edge 434D. Because the first end 436A and the second end 436B are located inside the outer perimeter 434 (e.g., inside edges 434C and 434D, respectively), the polymer sheet 410 remains a single piece (including all strips 410A to 410S and end portions 410T and 410U) after the slots 436 are cut. This is a relatively easy process to perform during manufacturing compared to processing and aligning multiple polymer sheets—which would result in multiple polymer sheets if ends 436A and 436B extended to the corresponding edges 434C and 434D. In other words, strips 410A to 410S are separated from each other at the slots 436, but all strips 410A to 410S are joined to and integral with end portions 410T and 410U. In other instances, these slots 436 may extend to edges 434C and / or edge 434D. In the example shown, there are 18 slots 436 and 19 stripes 410A to 410S. In other examples, the number of slots 436 may be less than or more than 18. In one example, there may be only one slot 436, thus producing only two stripes.

[0095] Figure 25 The uncovered area 423 on the second side 426 is shown in solid line, and the uncovered area 425 on the first side 422 is indicated in dashed line. These uncovered areas 425 form a plurality of first joints 444 (also referred to as first set of joints 444) between the first side 422 of the core 412 and the inner surface 17 of the first barrier sheet 16, some of which are in Figures 26 to 28The pattern of the first joint 444 is the same as that of the uncovered area 425. The uncovered area 423 becomes a plurality of second joints 446 (also referred to as second sets of joints) between the second side 426 of the core 412 and the inner surface 19 of the second barrier sheet 18, some of which are in Figures 26 to 28 As shown in the diagram, the pattern of the second joint 446 is the same as the pattern of the uncovered area 423.

[0096] from Figure 25 It can be clearly seen that the uncovered area 423 of the second predetermined pattern on the second side 426 is at least partially offset from the uncovered area 425 of the first predetermined pattern on the first side 422. Similarly, in Figure 25 In the diagram, only some of the uncovered areas 423 and 425 are indicated by reference numerals. In the illustrated embodiment, uncovered area 423 is completely offset from uncovered area 425. In fact, uncovered area 423 and uncovered area 425 alternate along the length of each of strips 410A to 410S. Therefore, as per the description of... Figures 27 to 28 As can be seen from strips 10A and 10J indicated, the first group of joints 444 (e.g., the joint between the first side 422 of the core 412 and the inner surface 17 of the first barrier sheet 16) alternates with the second group of joints 446 (e.g., the joint between the second side 426 of the core 412 and the inner surface 19 of the second barrier sheet 18). This alternation allows for the... Figures 27 to 28 The finest level of control is achieved over the geometry (e.g., curvature) of the outer surface 59 of the first barrier sheet 16 and the outer surface 61 of the second barrier sheet 18. The outer surface 59 of the first barrier sheet 16 is on the side of the barrier sheet 16 opposite to the inner surface 17. The outer surface 61 of the second barrier sheet 18 is on the side of the barrier sheet 18 opposite to the inner surface 19.

[0097] from Figure 25 It is also evident that the uncovered region 423 (and thus the second joint 446) between edge 434A and the middle strip 410J is symmetrical to the uncovered region 423 (and thus the second joint 446) between edge 434B and the middle strip 410J. The same applies to the uncovered region 425 and the first joint 444.

[0098] Refer again Figure 25For the purposes of discussion and comparison, strip 410A may be referred to as the first strip, and strip 410B may be referred to as the second strip, which is adjacent to the first strip 410A. The first strip 410A has two uncovered areas 423A and 423B, which are spaced apart from each other along the length of the first strip 410A at a second side 426. The first strip 410A has only one uncovered area 425A along the length of the first strip 410A on the first side 422. The uncovered area 425A is located between the uncovered areas 423A and 423B, but on the opposite second side 426. Therefore, there will be one joint 444 between the first strip 410A and the first barrier sheet 16, and two joints 446 between the first strip 410A and the second barrier sheet 18, wherein the joint 444 is between the joints 446, as shown below. Figure 26 As shown.

[0099] The second strip 410B has three uncovered areas 423C, 423D, and 423E, which are spaced apart from each other along the length of the second strip 410B at a second side 426. The second strip also has two uncovered areas 425B and 425C, which are spaced apart from each other along the length of the second strip 410B on opposite first sides 422. Uncovered area 425B is positioned along the length of the second strip 410B between uncovered areas 423C and 423D, but on opposite first sides 422. Uncovered area 425C is positioned along the length of the second strip 410B between uncovered areas 423D and 423E, but on opposite first sides 422. Two resulting second joints 446 on the inner surface 19 of the first strip 410A and the second barrier sheet 18 (e.g., at uncovered areas 423A and 423B) will thus alternate with one resulting first joint 444 on the inner surface 17 of the first strip 410A and the first barrier sheet 16 (e.g., at uncovered area 425A). Similarly, two resulting first joints 444 on the inner surface 17 of the second strip 410B and the first barrier sheet 16 (e.g., at uncovered areas 425B and 425C) will thus alternate with three resulting second joints 446 on the inner surface 19 of the second strip 410B and the second barrier sheet 18 (e.g., at uncovered areas 423C, 423D and 423E).

[0100] Each strip has a first end 437A and a second end 437B, in Figure 25Only some ends are marked. For strips 410B to 410R, the first end 437A is located between the first ends 436A of two adjacent slots 436, or for strips 410A and 410Q located at side edges 434A and 434B respectively, the first end 437A is adjacent to the ends 436A and 436B of an adjacent slot 436. The uncovered area 423A on the second side 426 of the first strip 410A closest to the first end 437A of the first strip 410A is at a distance D1 from the first end 437A of the first strip 410A. In contrast, the uncovered area 423C on the second side 426 of the second strip 410B closest to the first end 437A of the second strip 410B is at a distance D2 from the first end 437A. Distance D2 is less than distance D1.

[0101] Similarly, the distance from the uncovered area 425A on the first side 422 of the first strip 410A to the first end 437A of the first strip 410A is greater than the distance from the uncovered area 425B on the first side 422 of the second strip 410B to the first end 437A of the second strip 410B. In fact, for the strips between the edge 434A and the middle strip 410J (e.g., strips 410A to 410I), the greater the distance from the first end 437A of each of the strips 410A to 410I to the nearest uncovered area 423 on the second side 426 of the strip and to the nearest uncovered area 425 on the first side 422 of the strip, the closer the strip is to the edge 434A and the farther the strip is from the middle strip 410J. Similarly, for the strips between edge 434B and the middle strip 410J (e.g., strips 410K to 410S), the greater the distance from the first end 437A of each of strips 410K to 410S to the nearest uncovered area 423 on the second side 426 of the strip and to the nearest uncovered area 425 on the first side 422 of the strip, the closer the strip is to edge 434B and the farther the strip is from the middle strip 410J.

[0102] The same applies to the relative distances of uncovered areas 423 and 425 from the second end 437B. That is, for a strip between the edge 434A and the middle strip 410J (e.g., strips 410A to 410I), the greater the distance from the second end 437B of each of strips 410A to 410I to the nearest uncovered area 423 on the second side 426 of the strip and to the nearest uncovered area 425 on the first side 422 of the strip, the closer the strip is to the edge 434A and the farther the strip is from the middle strip 410J. Similarly, for strips between edge 434B and the middle strip 410J (e.g., strips 410K to 410S), the greater the distance from the second end 437B of each of strips 410K to 410S to the nearest uncovered area 423 on the second side 426 and to the nearest uncovered area 425 on the first side 422 of that strip, the closer the strip is to edge 434B and the farther the strip is from the middle strip 410J. This placement of uncovered areas 423 and 425 relative to the first end 437A and the second end 437B creates an arcuate arrangement of uncovered areas 425 and 423 closest to ends 437A and 437B and the corresponding resulting joints 444 and 446, as shown in Figure 25 It is clearly visible in the middle.

[0103] The geometry of the outer surfaces 59 and 61 of the corresponding barrier sheets 16 and 18 will be affected by this placement of the uncovered areas 423 and 425, because the barrier sheets 16 and 18 will be gradually secured closer to each other by the core 412 along the direction from edge 434A toward the central strip 410J and along the direction from edge 434B toward the central strip 410J. Additionally, the barrier sheets 16 and 18 will be positioned near the center of the core 412 between edges 434C and 434D (e.g., in the area including...). Figure 25 The uncovered areas 425A and 423D are kept closer to each other by the joints 444 and 446.

[0104] The desired geometry at outer surfaces 59 and 61 is also influenced by the varying spacing between the resulting joints 444 or 446 on adjacent uncovered areas 423 or 425 and on different strips 410A to 410S. For the purpose of discussion and comparison, strip 410B will now be referred to as the first strip, and strip 410C will be referred to as the second strip. Strip 410B has two uncovered areas 425B and 425C on the first side 422 and three uncovered areas 423C, 423D, and 423E on the second side 426. Strip 410C has three uncovered areas 425D, 425E, and 425F on the first side 422 and four uncovered areas 423F, 423G, 423H, and 423I on the second side 426. Uncovered regions 425B and 425C are spaced slightly further apart than uncovered regions 425D and 425E, and slightly further apart than uncovered regions 425E and 425F. Similarly, uncovered regions 423C and 423D on the second side 426 of stripe 410B are spaced further apart than uncovered regions 423F and 423G on the second side 426 of stripe 410C. Uncovered regions 423D and 423E have the same spacing as uncovered regions 423C and 423D, which is greater than the spacing between uncovered regions 423F and 423G, the spacing between uncovered regions 423G and 423H, and the spacing between uncovered regions 423H and 423I. Strip 410B is closer to the outer periphery 434 of core 412 (at edge 434A) than strip 410C, and the uncovered areas 423, 425 on the corresponding sides 426, 422 of strip 410B are more widely separated from each other than the uncovered areas 423, 425 on the corresponding sides 426, 422 of strip 410C. Specifically, as Figure 25 As shown, the number of uncovered regions 423 (and the resulting second joint 446) and the number of uncovered regions 425 (and the resulting first joint 444 on each strip) increase sequentially in the direction away from each of the side edges 434A and 434B, such that the strips closer to the side edges 434A or 434B have more resulting joints 444 and 446 than the strips farther from the side edges (e.g., the strips closer to the middle strip 410J have more joints 444 and 446 than the strips farther from the middle strip 410J). The first barrier sheet 16 and the second barrier sheet 18 are thus held closer to each other by the core 412 at strip 410C than at strip 410B, for example, creating a recess at the outer surfaces 59 and 61 of the bladder 420 from strip 410B to the second strip 410C (and more broadly, from the side edges 434A and 434B to the middle strip 410J).

[0105] Figure 26The illustration shows a buffer member 414 cut at a cross-section through the first strip 410A when the core 412 is placed between the first barrier sheet 16 and the second barrier sheet 18. When bonded together, such as by heat treatment, a joint is created between the stacked flat polymer sheets 410 of the core 412 and the adjacent surfaces of the barrier sheets 16, 18, except where the anti-welding material 24 is provided. This placement of the pattern of the anti-welding material 24 relative to the outer perimeter 434, and the positioning of the core 412 such that the entire outer perimeter 434 is completely inside the sidewall 251, ensures that the core 412 will secure the first barrier sheet 16 and the second barrier sheet 18 without creating any sealed chamber not in fluid communication with the internal cavity 21. Figure 26 The edges 434D and 434C of the core 12, located inside the peripheral junctions 38A and 38B of the sidewalls 251 and the corresponding barrier sheets 16 and 18, are shown. Therefore, the core 412 will collapse under the dynamic compressive load of the buffer member 414 to recover towards a flat state and acts as a tether to control and change the distance between the corresponding inner surfaces 17 and 19 of the barrier sheets 16 and 18 without affecting the ability of the bladder 420 to compress under load.

[0106] Chip 412 in Figure 26 Compared to the 412 chip, in Figure 25 The positions are reversed, so that the first side 422 faces upward and the edge 434D is shown on the left. Figure 24 The uncovered area between edge 434D and edge 434H on the first side 422, as shown, becomes Figure 26 The joint shown is 445A. Figure 24 The uncovered area between edge 434C and edge 434G on the first side 422, as shown, becomes Figure 26 The joint shown is 445B.

[0107] As in Figure 26 As can be seen, the first predetermined pattern of the anti-welding material 24 on the first side 422 of the polymer sheet 410 (at the strip 410A) abuts against the inner surface 17 of the first barrier sheet 16, and the second predetermined pattern of the anti-welding material 24 on the second side 426 of the polymer sheet 410 abuts against the inner surface 19 of the second barrier sheet 18. The portion of one or both of the inner surfaces 17 and 19 located outside the outer perimeter 434 of the core 412 and inside the formation positions of the peripheral joints 38A and 38B can also be pre-printed with the anti-welding material 24 or otherwise treated so that these portions of the inner surfaces 17 and 19 will not bond to each other or to the sidewall 251.

[0108] A first patterned joint 444 is formed at the mating area between the first side 422 of the polymer sheet 410 and the inner surface 17 of the first barrier sheet 16 (e.g., where there are no uncovered areas 425 of the anti-welding material 24 between the first side 422 and the inner surface 17). A second patterned joint 446 is formed at the mating area between the second side 426 of the polymer sheet 410 and the inner surface 19 of the second barrier sheet 18 (e.g., where there are no uncovered areas 423 of the anti-welding material 24 between the second side 426 and the inner surface 19). The anti-welding material 24 prevents bonding from occurring at any mating area where the anti-welding material 24 is provided. Figure 26 As can be seen, when the internal cavity 21 of the bladder 420 is not inflated, the core 412 is placed flat inside the bladder 420, where the unbonded area (the area at the anti-welding material 24) contacts the opposing inner surfaces 17 and 19.

[0109] Figure 27 yes Figure 26 A cross-sectional view of the buffer member 414 in the inflated state. Inflating the internal cavity 21 causes the polymer sheet 410 (shown at strip 410A) to be tensioned between the barrier sheets 16 and 18 and from... Figure 26 The relatively flat state moves to Figure 27 The relative extension state.

[0110] By placing the unbonded areas (and the resulting bonded portions) at different distances from the ends of the respective strips, placing different numbers along each strip, and placing them at different intervals along each strip, the desired geometry of the outer surface of the pouch 420 near the ends of the core 412 can be achieved. For example, the resulting buffer member 414 formed by the barrier sheets 16, 18 of the core 412 and the pouch 420 will therefore have a gradient recess at the bonded portions 444, 446 at the uncovered areas 425A, 423D in the direction from the edge 434C toward the middle row (e.g., in the direction from the edge 434D toward the middle row). The buffer member 414 will also have gradient recesses in the directions from the edge 434A toward the middle strip 410J and from the edge 434B toward the middle strip 410J. In other words, the resulting cushioning member 414 will have concave surfaces along the length of the cushioning member 414 and along the width of the cushioning member 414, as well as on the foot-facing side and distal side (e.g., at the two outer surfaces 59, 61). Surface 59 or 61 can therefore serve as a heel cup, for example, conforming to the convex outer surface of the wearer's heel. When the outer surface 59 is oriented on the foot-facing side, the outer surface 59 serves as a heel cup.

[0111] Figure 28 The buffer component 414 is shown as a cross-section taken along the middle strip 410J. Figure 27 and Figure 28 As can be clearly seen in the comparison, the total height H4 of the buffer member 414 at strip 410A is greater than the total height H5 of the buffer member 414 at the middle strip 410J. A greater number of joints 444 and 446 (some of which are labeled) along strip 410J secure the barrier sheets 16 and 18 closer together than a smaller number of joints along strip 410A. The tension in strip 410A caused by the inflation of the internal cavity 21 pulls the outer surfaces 59 and 61 inward at joints 444 and 446, resulting in relatively wavy or otherwise shaped outer surfaces 59 and 61 located outside strip 410A. Conversely, a greater number of joints 444, 446 closer together along strip 410J result in relatively flat outer surfaces 59 and 61 located outside strip 410J. Therefore, the pattern of the anti-welding material 24 printed on the polymer sheet 410 and the resulting pattern of the joint 444, 446 of the polymer sheet 410 of the core 412 and the barrier sheets 16, 18 can be selected to control the resulting contour of the outer surfaces 59, 61 of the barrier sheets 16, 18.

[0112] A method of manufacturing a cushioning component for wearable articles (such as cushioning components 14, 114, 214, 314, and 414 disclosed herein) may include: disposing a barrier ink 24 on opposing first and second sides of at least one polymer sheet (e.g., polymer sheets 10 and 11, or polymer sheet 410), and placing the at least one polymer sheet between a first barrier sheet 16 and a second barrier sheet 18. The at least one polymer sheet may include a core 12 or 412, and sidewalls (e.g., sidewalls 51 or 251) surrounding and separating the outer periphery 34 or 434 of the core. The method may further include: thermally bonding the core to opposing inner surfaces 17 and 19 of the first barrier sheet 16 and the second barrier sheet 18 at a plurality of joints 44 and 46 or 444 and 446 at a region of the at least one polymer sheet not provided with barrier ink (e.g., uncovered regions 425 and 423, respectively) to secure the first barrier sheet to the second barrier sheet; and thermally bonding a sidewall 51 or 251 to the first barrier sheet 16 at a first peripheral joint 38A and to the second barrier sheet 18 at a second peripheral joint 38B, the sidewall and the barrier sheet closing an internal cavity 21 that extends between opposing inner surfaces to define a bladder 20 or 420.

[0113] In one example, such as with regard to buffer member 14, the method may include: cutting a slot through the at least one polymer sheet (e.g., through slits 55A and 55B of polymer sheets 10 and 11) prior to the thermal bonding step to separate core 12 from sidewall 51 (including sidewall portions 51A and 51B). The outer peripheries 34A and 34B of core 12 may be defined by slits 55A and 55B and may be located inside slits 55A and 55B, and the sidewall 51 may be located outside the slot.

[0114] In another example, such as with any of the buffer members 214, 314, and 414, placing at least one polymer sheet (e.g., polymer sheets 10 and 11 or polymer sheet 410) between the first barrier sheet 16 and the second barrier sheet 18 may include a folded sidewall 251, wherein the crease (e.g., in...) Figure 14 and Figure 15 The fold line shown at 251A extends inward toward the outer periphery 34 or 434 of the core 12 or 412.

[0115] In embodiments where the wearable article is a footwear article (such as footwear article 72), the method may further include providing cushioning members 14, 114, 214, 314 or 414 in the sole structure of the footwear article.

[0116] The following terms provide example configurations of cushioning components for wearable articles, such as footwear, as disclosed herein, and methods for manufacturing such cushioning components.

[0117] Clause 1. A cushioning member for a wearable article, the cushioning member comprising: a pouch including a first barrier sheet and a second barrier sheet defining an internal cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet; a core including at least one polymer sheet traversing the internal cavity between the opposing inner surfaces of the first barrier sheet and the second barrier sheet and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of joints to secure the first barrier sheet... The core is secured to the second barrier sheet; and a sidewall comprising at least one polymer sheet disposed around the outer periphery of the core and directly bonded to the first barrier sheet at a first peripheral joint and directly bonded to the second barrier sheet at a second peripheral joint to seal the internal cavity and retain gas within the internal cavity, the at least one polymer sheet of the core being disposed within the internal cavity and separated from the sidewall, and the at least one polymer sheet of the core being displaced from the opposing inner surface by gas at an unbonded area of ​​the at least one polymer sheet.

[0118] Clause 2. The wearable article according to Clause 1, wherein the plurality of joints are arranged such that the gas in the internal cavity is in fluid communication with the at least one polymer sheet of the core, and the at least one polymer sheet of the core does not create any sealed chamber within the bladder that is not in fluid communication with the internal cavity.

[0119] Clause 3. A wearable article according to any one of Clauses 1 to 2, wherein the sidewall is a single polymer sheet.

[0120] Clause 4. The wearable article according to Clause 3, wherein: when the internal cavity is in an uninflated state, the sidewall is in a first position, and when the internal cavity is inflated, the sidewall is in a second position; and the sidewall is folded inward toward the core in the first position and extends relatively vertically around the internal cavity in the second position.

[0121] Clause 5. A cushioning component according to any one of Clauses 1 to 2, wherein: the wearable article is a footwear article; and the cushioning component is included in the sole structure of the footwear article.

[0122] Clause 6. The cushioning member according to Clause 5, wherein: the cushioning member extends in each of the heel area, the midfoot area, and the forefoot area of ​​the footwear; and the sidewall is higher in the heel area than in the forefoot area.

[0123] Clause 7. The buffer member according to Clause 5, wherein the internal cavity is a first internal cavity, and the buffer member further comprises: a third barrier sheet, the third barrier sheet being coupled to the second barrier sheet at an additional peripheral joint, the second barrier sheet and the third barrier sheet defining a second internal cavity between an outer surface of the second barrier sheet and an inner surface of the third barrier sheet; and wherein the first internal cavity and the second internal cavity are fluidly isolated from each other by the second barrier sheet.

[0124] Clause 8. The cushioning member according to Clause 7, wherein: the third barrier sheet is disposed on the distal side of the cushioning member, and the first barrier sheet is disposed on the foot-facing side of the cushioning member; the inflation pressure of the second internal cavity is different from the inflation pressure of the first internal cavity.

[0125] Clause 9. The cushioning member according to Clause 7, wherein: the third barrier sheet is disposed at the distal end of the cushioning member, and the first barrier sheet is disposed on the foot-facing side of the cushioning member; the core secures the first barrier sheet to the second barrier sheet such that the vertical height of the bladder at the core is less than the vertical height of the bladder at the sidewall; a concave surface at the outer surface of the first barrier sheet defines at least a portion of the footbed; and the third barrier sheet is relatively flat compared to the second barrier sheet.

[0126] Clause 10. A buffer member according to any one of Clauses 1 to 2, wherein: the at least one polymer sheet of the core comprises a first polymer sheet and a second polymer sheet, the first polymer sheet of the core being disposed between the first barrier sheet and the second polymer sheet, and the second polymer sheet of the core being disposed between the first polymer sheet and the second barrier sheet, such that a first side of the first polymer sheet of the core faces the inner surface of the first barrier sheet, a second side of the first polymer sheet of the core faces the first side of the second polymer sheet, and a second side of the second polymer sheet of the core faces the inner surface of the second barrier sheet; and the at least one polymer sheet of the sidewall comprises a first polymer sheet and a second polymer sheet, the first polymer sheet of the sidewall being bonded to the first barrier sheet at a first peripheral joint, the second polymer sheet of the sidewall being bonded to the second barrier sheet at a second peripheral joint, and the first polymer sheet of the sidewall being bonded to the second polymer sheet of the sidewall at a third peripheral joint, the third peripheral joint being disposed along the sidewall between the first peripheral joint and the second peripheral joint.

[0127] Clause 11. The buffer member according to Clause 10, wherein: the first side of the first polymer sheet of the core is directly bonded to the inner surface of the first barrier sheet at a first set of the plurality of joints; the second side of the second polymer sheet of the core is directly bonded to the inner surface of the second barrier sheet at a second set of the plurality of joints; and the second side of the first polymer sheet of the core is directly bonded to the first side of the second polymer sheet of the core at a third set of the plurality of joints.

[0128] Clause 12. The cushioning component according to Clause 10, wherein: when the internal cavity is in an uninflated state, the sidewall is in a first position, and when the internal cavity is inflated, the sidewall is in a second position; in the second position, compared to the first position, the first polymer sheet of the sidewall and the second polymer sheet of the sidewall extend relatively vertically between the first barrier sheet and the second barrier sheet, wherein the third peripheral joint extends outward from the outer periphery of the core and is separated from the outer periphery by a gap.

[0129] Clause 13. A cushioning member for a wearable article, the cushioning member comprising: a bladder including a first barrier sheet and a second barrier sheet, the first barrier sheet and the second barrier sheet defining an internal cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet; a first polymer sheet and a second polymer sheet disposed between the first barrier sheet and the second barrier sheet and each including a core portion and a sidewall portion, the sidewall portion being separate from the core portion and extending along an outer periphery of the core portion; wherein the core portion of the first polymer sheet is bonded at a first plurality of joints to the inner surface of the first barrier sheet and a first side of the core portion of the second polymer sheet, the core portion of the second polymer sheet is bonded at a second plurality of joints to the inner surface of the second barrier sheet and at a third plurality of joints to a second side of the core portion of the first polymer sheet, the first polymer sheet... The core portion of the first polymer sheet and the core portion of the second polymer sheet together traverse the internal cavity and secure the first barrier sheet to the second barrier sheet; wherein the sidewall portion of the first polymer sheet is bonded to the first barrier sheet at a first peripheral joint, the sidewall portion of the second polymer sheet is bonded to the second barrier sheet at a second peripheral joint, and the sidewall portions of the first polymer sheet and the sidewall portions of the second polymer sheet are bonded to each other at a third peripheral joint, such that the sidewall portions, the first barrier sheet, and the second barrier sheet together seal the internal cavity and retain gas within the internal cavity, and the core portion of the first polymer sheet and the core portion of the second polymer sheet are displaced from the opposing inner surfaces of the first barrier sheet and the second barrier sheet by the gas at the unbonded areas of the core portion of the first polymer sheet and the core portion of the second polymer sheet.

[0130] Clause 14. The cushioning component according to Clause 13, wherein the first plurality of joints, the second plurality of joints, and the third plurality of joints are arranged such that the gas in the internal cavity is in fluid communication around the core portion of the first polymer sheet and the core portion of the second polymer sheet, and the core portion of the first polymer sheet and the core portion of the second polymer sheet do not create any sealed chambers within the bladder that are not in fluid communication with the internal cavity.

[0131] Clause 15. A cushioning component according to any one of Clauses 13 to 14, wherein: the wearable article is a footwear article; and the cushioning component is included in the sole structure of the footwear article.

[0132] Clause 16. The cushioning member according to Clause 15, wherein: the cushioning member extends in each of the heel area, the midfoot area, and the forefoot area of ​​the footwear; and the sidewall portion is higher in the heel area than in the forefoot area.

[0133] Clause 17. The buffer member according to Clause 15, wherein the internal cavity is a first internal cavity, and the buffer member further comprises: a third barrier sheet, the third barrier sheet being coupled to the second barrier sheet at an additional peripheral joint, the second barrier sheet and the third barrier sheet defining a second internal cavity between an outer surface of the second barrier sheet and an inner surface of the third barrier sheet; and wherein the first internal cavity and the second internal cavity are fluidly isolated from each other by the second barrier sheet.

[0134] Clause 18. The cushioning member according to Clause 17, wherein: the third barrier sheet is disposed on the distal side of the cushioning member, and the first barrier sheet is disposed on the foot-facing side of the cushioning member; the inflation pressure of the second internal cavity is different from the inflation pressure of the first internal cavity.

[0135] Clause 19. The cushioning member according to Clause 17, wherein: the third barrier sheet is disposed at the distal end of the cushioning member, and the first barrier sheet is disposed on the foot-facing side of the cushioning member; the core portion secures the first barrier sheet to the second barrier sheet such that the vertical height of the bladder at the core is less than the vertical height of the bladder at the sidewall portion; a concave surface at the outer surface of the first barrier sheet defines at least a portion of the footbed; and the third barrier sheet is relatively flat compared to the second barrier sheet.

[0136] Clause 20. A method of manufacturing a cushioning component for a wearable article, the method comprising: disposing a barrier ink on opposing first and second sides of at least one polymer sheet; placing the at least one polymer sheet between a first barrier sheet and a second barrier sheet, wherein the at least one polymer sheet includes a core and sidewalls, the sidewalls surrounding an outer periphery of the core and being separate from the core; and thermally bonding: thermally bonding the core to opposing inner surfaces of the first and second barrier sheets at a plurality of joints in areas of the at least one polymer sheet not provided with the barrier ink, to secure the first barrier sheet to the second barrier sheet; and thermally bonding the sidewalls to the first barrier sheet at a first peripheral joint and to the second barrier sheet at a second peripheral joint, the sidewalls and the barrier sheets enclosing an internal cavity extending between the opposing inner surfaces to define a pocket.

[0137] Clause 21. The method according to Clause 20, further comprising: prior to the thermal bonding, cutting a slot through the at least one polymer sheet to separate the core from the sidewall, wherein the outer periphery of the core is defined by the slot and located inside the slot, and the sidewall is located outside the slot.

[0138] Clause 22. The method according to Clause 20, wherein placing the at least one polymer sheet between the first barrier sheet and the second barrier sheet comprises folding the sidewalls, wherein the creases extend inward toward the outer periphery of the core.

[0139] Clause 23. The method according to Clause 20, wherein the wearable article is a footwear article, and further comprises: providing the cushioning component in the sole structure of the footwear article.

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

[0141] "Footwear articles", "footwear manufacturing articles", and "footwear" can be considered as machines and manufactured goods. Before being finally assembled into wearable footwear articles, assembled ready-to-wear footwear articles (e.g., shoes, sandals, boots, etc.) and footwear articles' discrete components (e.g., midsoles, outsoles, upper components, etc.) are considered herein and are instead referred to in the singular or plural as "footwear articles".

[0142] The terms “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate the presence of at least one of the objects. Multiple such objects may be present unless the context explicitly indicates otherwise. Unless explicitly or clearly indicated otherwise in the context (including the appended claims), all numerical values ​​of parameters (e.g., quantities or conditions) in this specification shall be understood to be modified in all cases by the term “about,” regardless of whether “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows for some slight imprecision (numerically close to exact; close to or quite close to the value; approximately). If the imprecision provided by “about” is not otherwise understood in the art in that ordinary sense, then “about” as used herein at least indicates a variation that can be produced by common methods of measuring and using such parameters. Furthermore, the disclosure of a scope shall be understood to specifically disclose all values ​​within that scope and further subdivisions of the scope.

[0143] The terms “comprising,” “including,” and “having” are inclusive and therefore specify the presence of the stated features, steps, operations, elements, or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed where possible, and additional or alternative steps may be employed. As used herein, 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 term “any of…” should be understood to include any possible combination of the referenced claims in the appended claims, including “any of…”.

[0144] For consistency and convenience, directional adjectives may be used throughout the detailed description corresponding to the illustrated embodiments. Those skilled in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” and “bottom” may be used descriptively with respect to the drawings and are not intended to limit the scope of the invention as defined by the claims.

[0145] The term "longitudinal" specifically refers to the direction in which a component extends. For example, the longitudinal direction of a shoe extends between the forefoot and heel areas. The terms "forward" or "front" are specifically used to refer to the general direction from the heel area toward the forefoot area, and the terms "backward" or "rearward" are specifically used to refer to the opposite direction, i.e., from the forefoot area toward the heel area. In some cases, a component may be identified by a longitudinal axis and the longitudinal direction along that axis. This longitudinal direction or axis may also be referred to as the front-back direction or axis.

[0146] The term "lateral" specifically refers to the direction of the width of an extending component. For example, the lateral direction of a shoe extends between the outer and inner sides of the shoe. This lateral direction or axis can also be referred to as the lateral direction or axis, or the inner-outer direction or axis.

[0147] The term "vertical" specifically refers to a direction that is generally perpendicular to both the lateral and longitudinal directions. For example, when the sole of a shoe is laid flat on a ground surface, the vertical direction can extend upwards from that surface. It should be understood that each of these directional adjectives can be applied to various parts of the sole. The term "upward" or "upwardly" specifically refers to a vertical direction pointing towards the top of a part, which may include the instep, fastening area, and / or throat of the upper. The term "downward" or "downwardly" specifically refers to a vertical direction pointing towards the bottom of a part, opposite to the upward direction, and can generally refer to the bottom of the sole structure of footwear.

[0148] The term "interior" in footwear (such as shoes) specifically refers to the portion of the space occupied by the wearer's foot when the shoe is worn. The term "inner side" in a component specifically refers to a side or surface of a component oriented toward (or towards) the interior of the component or footwear in an assembled footwear product. The term "outer side" or "outer side" in a component specifically refers to a side or surface of a component oriented away from (or away from) the interior of the shoe in an assembled shoe. In some cases, other components may be located between the inner side of a component and the interior of the assembled footwear product. Similarly, other components may be located between the outer side of a component and the space outside the assembled footwear product. Furthermore, the terms "inward" and "inner" specifically refer to a direction toward the interior of a component or footwear product (such as shoes), and the terms "outward" and "outer" specifically refer to a direction toward the exterior of a component or footwear product (such as shoes). Additionally, the term "proximal" specifically refers to a direction closer to the center of the footwear component or closer to the foot when the user inserts their foot into the footwear product while wearing it. Similarly, the term "distal" specifically refers to a relative position further away from the center of the footwear component or further away from the foot when the user inserts their foot into the footwear. Therefore, the terms proximal and distal can be understood as providing generally relative terms to describe relative spatial positions.

[0149] While various embodiments have been described, this description is intended to be exemplary and not restrictive, and it will be apparent to those skilled in the art that many other embodiments and implementations are possible within the scope of these embodiments. Unless expressly limited, any feature of any embodiment may be used in combination with or in lieu of any other feature or element in any other embodiment. Therefore, the embodiments are not limited except for the appended claims and their equivalents. Moreover, various modifications and changes may be made within the scope of the appended claims.

[0150] While several models for implementing various aspects of this teaching have been described in detail, those skilled in the art to which this teaching relates will recognize various alternative aspects for practicing this teaching within the scope of the appended claims. It is intended that all that is contained in the above description or shown in the accompanying drawings be construed as illustrative and exemplary of the full range of alternative embodiments that will be recognized by those skilled in the art, whether implied by the inclusions, structurally and / or functionally equivalent, or otherwise clearly presented, and should not be limited to those embodiments explicitly depicted and / or described.

Claims

1. A cushioning component for wearable articles, the cushioning component comprising: The capsule includes a first barrier sheet and a second barrier sheet, the first barrier sheet and the second barrier sheet defining an internal cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet; The core includes at least one polymer sheet that extends through the internal cavity between the opposing inner surfaces of the first barrier sheet and the second barrier sheet and is directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of joints to secure the first barrier sheet to the second barrier sheet. as well as The sidewall includes at least one polymer sheet disposed around the outer periphery of the core and directly bonded to the first barrier sheet at a first peripheral joint and directly bonded to the second barrier sheet at a second peripheral joint to seal the internal cavity and retain gas in the internal cavity. The at least one polymer sheet of the core is disposed in the internal cavity and separated from the sidewall, and the at least one polymer sheet of the core is displaced from the opposing inner surface by gas at the unbonded area of ​​the at least one polymer sheet.

2. The buffer component of claim 1, wherein the plurality of joints are arranged such that the gas in the internal cavity is in fluid communication with the at least one polymer sheet of the core, and the at least one polymer sheet of the core does not create any sealed chamber within the bladder that is not in fluid communication with the internal cavity.

3. The buffer component according to any one of claims 1 to 2, wherein the sidewall is a single polymer sheet.

4. The buffer component according to claim 3, wherein: When the internal cavity is not inflated, the sidewall is in a first position, and when the internal cavity is inflated, the sidewall is in a second position; and The sidewall is folded inward toward the core in the first position and extends vertically around the internal cavity in the second position.

5. The buffer component according to any one of claims 1 to 2, wherein: The wearable product is footwear; and The cushioning component is included in the sole structure of the footwear.

6. The buffer component according to claim 5, wherein: The cushioning component extends in each of the heel area, midfoot area, and forefoot area of ​​the footwear; and The height of the sidewall in the heel area is greater than its height in the forefoot area.

7. The buffer component according to claim 5, wherein the internal cavity is a first internal cavity, and the buffer component further comprises: A third barrier sheet is bonded to the second barrier sheet at an additional peripheral joint, the second barrier sheet and the third barrier sheet defining a second internal cavity between the outer surface of the second barrier sheet and the inner surface of the third barrier sheet. and The first internal cavity and the second internal cavity are fluidly isolated from each other by the second barrier sheet.

8. The buffer component according to claim 7, wherein: The third barrier sheet is disposed on the distal side of the cushioning member, and the first barrier sheet is disposed on the foot-facing side of the cushioning member; and The inflation pressure of the second internal cavity is different from that of the first internal cavity.

9. The buffer component according to claim 7, wherein: The third barrier sheet is disposed on the distal side of the cushioning member, and the first barrier sheet is disposed on the foot-facing side of the cushioning member. The core secures the first barrier sheet to the second barrier sheet, such that the vertical height of the bladder at the core is less than the vertical height of the bladder at the sidewall; The concave surface at the outer surface of the first barrier sheet defines at least a portion of the footbed; and Compared to the second barrier sheet, the third barrier sheet is relatively flat.

10. The buffer component according to any one of claims 1 to 2, wherein: The core comprises at least one polymer sheet, including a first polymer sheet and a second polymer sheet. The first polymer sheet of the core is disposed between the first barrier sheet and the second polymer sheet, and the second polymer sheet of the core is disposed between the first polymer sheet and the second barrier sheet, such that a first side of the first polymer sheet of the core faces the inner surface of the first barrier sheet, a second side of the first polymer sheet of the core faces the first side of the second polymer sheet, and a second side of the second polymer sheet of the core faces the inner surface of the second barrier sheet. The at least one polymer sheet of the sidewall includes a first polymer sheet and a second polymer sheet, the first polymer sheet of the sidewall being bonded to the first barrier sheet at a first peripheral joint, the second polymer sheet of the sidewall being bonded to the second barrier sheet at a second peripheral joint, and the first polymer sheet of the sidewall being bonded to the second polymer sheet of the sidewall at a third peripheral joint, the third peripheral joint being disposed along the sidewall between the first peripheral joint and the second peripheral joint.

11. The buffer component according to claim 10, wherein: The first side of the first polymer sheet of the core is directly bonded to the inner surface of the first barrier sheet at a first set of joints among the plurality of joints; the second side of the second polymer sheet of the core is directly bonded to the inner surface of the second barrier sheet at a second set of joints among the plurality of joints; and the second side of the first polymer sheet of the core is directly bonded to the first side of the second polymer sheet of the core at a third set of joints among the plurality of joints.

12. The buffer component according to claim 10, wherein: When the internal cavity is in an uninflated state, the sidewall is in a first position, and when the internal cavity is inflated, the sidewall is in a second position. In the second position, compared to the first position, the first polymer sheet of the sidewall and the second polymer sheet of the sidewall extend relatively vertically between the first barrier sheet and the second barrier sheet, wherein the third peripheral joint extends outward from the outer periphery of the core and is separated from the outer periphery by a gap.

13. A cushioning component for wearable articles, the cushioning component comprising: The capsule includes a first barrier sheet and a second barrier sheet, the first barrier sheet and the second barrier sheet defining an internal cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet; A first polymer sheet and a second polymer sheet are disposed between the first barrier sheet and the second barrier sheet and each includes a core portion and a sidewall portion, the sidewall portion being separate from the core portion and extending along the outer periphery of the core portion; The core portion of the first polymer sheet is bonded to the inner surface of the first barrier sheet and the first side of the core portion of the second polymer sheet at a first plurality of joints; the core portion of the second polymer sheet is bonded to the inner surface of the second barrier sheet at a second plurality of joints and to the second side of the core portion of the first polymer sheet at a third plurality of joints; the core portions of the first polymer sheet and the core portions of the second polymer sheet together traverse the internal cavity and secure the first barrier sheet to the second barrier sheet; and The sidewall portion of the first polymer sheet is bonded to the first barrier sheet at a first peripheral joint, the sidewall portion of the second polymer sheet is bonded to the second barrier sheet at a second peripheral joint, and the sidewall portions of the first polymer sheet and the second polymer sheet are bonded to each other at a third peripheral joint, such that the sidewall portions, the first barrier sheet, and the second barrier sheet together seal the internal cavity and retain gas in the internal cavity. The core portion of the first polymer sheet and the core portion of the second polymer sheet are displaced from the opposing inner surfaces of the first barrier sheet and the second barrier sheet by the gas at the unbonded areas of the core portions of the first polymer sheet and the second polymer sheet.

14. The buffer component of claim 13, wherein the first plurality of joints, the second plurality of joints, and the third plurality of joints are arranged such that the gas in the internal cavity is in fluid communication around the core portion of the first polymer sheet and the core portion of the second polymer sheet, and the core portion of the first polymer sheet and the core portion of the second polymer sheet do not create any sealed chambers within the bladder that are not in fluid communication with the internal cavity.

15. The buffer component according to any one of claims 13 to 14, wherein: The wearable product is footwear; and The cushioning component is included in the sole structure of the footwear.

16. The buffer component according to claim 15, wherein: The cushioning component extends in each of the heel area, midfoot area, and forefoot area of ​​the footwear; and The height of the sidewall portion in the heel area is greater than its height in the forefoot area.

17. The buffer component of claim 15, wherein the internal cavity is a first internal cavity, and the buffer component further comprises: A third barrier sheet is bonded to the second barrier sheet at an additional peripheral joint, the second barrier sheet and the third barrier sheet defining a second internal cavity between the outer surface of the second barrier sheet and the inner surface of the third barrier sheet. and The first internal cavity and the second internal cavity are fluidly isolated from each other by the second barrier sheet.

18. A method of manufacturing a cushioning component for wearable articles, the method comprising: The barrier ink is applied to at least one first and second opposite sides of a polymer sheet; The at least one polymer sheet is placed between a first barrier sheet and a second barrier sheet, wherein the at least one polymer sheet includes a core and a sidewall, the sidewall surrounding the outer periphery of the core and being separate from the core; as well as Thermal bonding: The core is thermally bonded to the opposing inner surfaces of the first and second barrier sheets at multiple joints in areas of the at least one polymer sheet not provided with the barrier ink, so as to secure the first barrier sheet to the second barrier sheet. as well as The sidewall is thermally bonded to the first barrier sheet at a first peripheral joint and to the second barrier sheet at a second peripheral joint, the sidewall and the barrier sheet enclosing an internal cavity that extends between the opposing inner surfaces to define a capsule.

19. The method according to claim 18, further comprising: Prior to the thermal bonding, a slot is cut through the at least one polymer sheet to separate the core from the sidewall, wherein the outer periphery of the core is defined by the slot and located inside the slot, and the sidewall is located outside the slot.

20. The method of claim 18, wherein placing the at least one polymer sheet between the first barrier sheet and the second barrier sheet comprises folding the sidewalls, wherein the creases extend inward toward the outer periphery of the core.

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