WO2025216811A1

WO2025216811A1 - Cushioning component for a wearable article

Info

Publication number: WO2025216811A1
Application number: PCT/US2025/017339
Authority: WO
Inventors: Patrick R. Case; Scott C. Holt; Dervin A. James; Kevin C. SZE
Original assignee: Nike Inc; Nike Innovate CV USA
Current assignee: Nike Inc; Nike Innovate CV USA
Priority date: 2024-04-10
Filing date: 2025-02-26
Publication date: 2025-10-16
Anticipated expiration: 2026-10-10
Also published as: US20250318601A1

Abstract

An article of footwear includes a sole structure having a cushioning component. The cushioning component includes a bladder defining an interior cavity between opposing inner surfaces of a first barrier sheet and a second barrier sheet. The barrier sheets are sealed to one another along a peripheral bond. A core is disposed in the interior cavity and spaced entirely inward of the peripheral bond. The core includes at least one polymeric sheet traversing the interior cavity between and directly bonded to the opposing inner surfaces of the barrier sheets at a plurality of bonds to tether the barrier sheets to one another. The bonds include at least one bond extending continuously from a medial end adjacent a medial edge of the core to a lateral end adjacent a lateral edge of the core and wider at the medial and lateral ends than at a narrowed portion therebetween.

Description

CUSHIONING COMPONENT FOR A WEARABLE ARTICLE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority’ to United States Provisional Application No. 63/632,059, filed April 10, 2024, and to United States Provisional Application No. 63/681,951, filed August 12, 2024, both of which are incorporated by reference in their entirety.

TECHNICAL FIELD

[0002] The present disclosure generally relates to a cushioning component for a wearable article that includes a bladder and a core of at least one polymeric sheet disposed in the bladder.

BACKGROUND

[0003] Wearable articles, such as articles of footwear, often include cushioning components. Some cushioning components are configured as fluid-filled bladders that enclose an interior cavity to retain a gas in the interior cavity, providing cushioning when loaded.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary rather than to limit the scope of the disclosure.

[0005] FIG. 1 is a plan view of a bottom side of a polymeric sheet with antiweld material disposed thereon.

[0006] FIG. 2 is a plan view of an opposing top side of the polymeric sheet of FIG. 1 with anti-weld material disposed thereon in a different pattern than on the side shown in FIG. 1.

[0007] FIG. 3 is a plan view of a top side of another polymeric sheet with antiweld material disposed thereon and with an opposite second side not having any antiweld material disposed thereon.

[0008] FIG. 4 is a plan view of a portion of a core formed from the polymeric sheets of FIGS. 1-3, showing the polymeric sheet of FIGS. 1-2 as a lower core sheet and representing bonded areas at the top side of the polymeric sheet of FIG. 2 in solid lines and bonded areas at the bottom side of the polymeric sheet of FIG. 2 in dashed lines.

[0009] FIG. 5 is a close-up view showing the shape of one of the bonds of the lower cores sheet of FIG. 4.

[0010] FIG. 6 is a plan view of a portion of the core formed from the polymeric sheets of FIGS. 1-3 showing the polymeric sheet of FIG. 3 as an upper core sheet and representing bonded areas at the top side of the upper core sheet in solid lines and bonded areas at the bottom side of the upper core sheet in dashed lines.

[0011] FIG. 7 is a cross-sectional view of a cushioning component including the core of FIG. 6 at a cross-section taken at lines 7-7 in FIG. 8 along a longitudinal axis and including a bladder having first and second barrier sheets, with the cushioning component in an uninflated state.

[0012] FIG. 8 is a plan view of the cushioning component of FIG. 7 in an uninflated state.

[0013] FIG. 9 is a top perspective view of the cushioning component of FIGS. 7-8 in an inflated state.

[0014] FIG. 10 is a lateral side view of an article of footwear including the cushioning component of FIG. 9.

[0015] FIG. 11 is a plan view of a bottom side of a polymeric sheet with antiweld material disposed thereon.

[0016] FIG. 12 is a plan view of an opposing top side of the polymeric sheet of FIG. 1 1 with anti-weld material disposed thereon in a different pattern than on the side shown in FIG. 11.

[0017] FIG. 13 is a plan view of a top side of another polymeric sheet with anti-weld material disposed thereon and with an opposite second side not having any anti-weld material disposed thereon.

[0018] FIG. 14 is a plan view of a portion of a core formed from the polymeric sheets of FIGS. 11-13, showing the polymeric sheet of FIGS. 11-12 as a lower core sheet and representing bonded areas at the top side of the polymeric sheet of FIG. 12 in solid lines and bonded areas at the bottom side of the polymeric sheet of FIG. 12 in dashed lines. [0019] FIG. 15 is a plan view of a portion of the core formed from the polymeric sheets of FIGS. 11-13 showing the polymeric sheet of FIG. 13 as an upper core sheet and representing bonded areas at the top side of the upper core sheet in solid lines and bonded areas at the bottom side of the upper core sheet in dashed lines. [0020] FIG. 16 is a cross-sectional view of a cushioning component including the core and taken at a cross-section at lines 1 -16 in FIG. 17 along a longitudinal axis and including a bladder having first and second barrier sheets, with the cushioning component in an uninflated state.

[0021] FIG. 17 is a plan view of the cushioning component of FIG. 16 in an uninflated state.

[0022] FIG. 18 is a lateral perspective view of the cushioning component of FIGS. 16-17 in an inflated state.

[0023] FIG. 19 is a lateral side view of an article of footwear including the cushioning component of FIG. 18.

DESCRIPTION

[0024] The present disclosure generally relates to an article of footwear that includes a sole structure that has a cushioning component. In an example, the cushioning component includes a bladder and a core disposed in the bladder and bonded to inner sides of barrier sheets of the bladder to act as a tensile component. Providing a tensile component within a bladder may be useful in restraining the bladder when inflated, preventing it from adopting a ball-like shape. A tensile component, such as the core according to the present disclosure, includes at least one polymeric sheet and is bonded to the barrier sheets. The configuration of the barrier sheets as well as the bond patterns may result in technical advantages both in performance aspects of the cushioning component and ease of manufacturing the cushioning component.

[0025] More specifically, the bladder includes a first barrier sheet and a second barrier sheet. The first barrier sheet and the second barrier sheet together define an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet. The first barrier sheet and the second barrier sheet are sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity. The core is disposed in the interior cavity⁷ and is spaced entirely inward of the peripheral bond. The core includes at least one polymeric sheet traversing the interior cavity between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of nonlinear bonds to tether the first barrier sheet to the second barrier sheet. The at least one polymeric sheet of the core is displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet such that the gas in the interior cavity' is in fluid communication around the at least one polymeric sheet of the core without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity. In other words, the core does not subdivide the interior cavity into separate, sealed chambers.

[0026] The plurality of bonds may include at least one bond extending continuously from a medial end of the bond adjacent to a medial edge of the core to a lateral end of the bond adjacent to a lateral edge of the core. The bond may be wider in a fore-aft direction of the core at the medial end and at the lateral end than at a narrowed portion of the bond between the medial end and the lateral end. By configuring the at least one bond so that it is wider at its medial and lateral ends than at a narrowed portion between the ends, the resistance to delamination when forces are applied to the core during wear (such as from a lateral step or otherwise) is increased in comparison to a bond of a narrower width at its ends. Configuring the bonds to extend to the medial and lateral edges of the core may further increase the integrity of the connection of the core to the barrier sheets via the bonds.

[0027] In one or more implementations, the at least one bond may be nonlinear. In one or more configurations, at least some of the plurality of nonlinear bonds have linear segments. For example, linear segments may be arranged to provide an overall nonlinear shape of the bond.

[0028] In one or more configurations, the at least one bond may have peaks and valleys extending in the fore-aft direction of the core. By utilizing nonlinear bonds and/or bonds having peaks and valleys extending in the fore-aft direction, the fore-aft extent of each such bond may be increased relative to a straight bond of the same width. This may increase the robustness of the bond and its ability to withstand repeated stresses, such as lateral forces, reducing the likelihood of delamination. [0029] In an aspect, the narrowed portion of the at least one bond may be at a middle of the bond in a transverse direction of the core. In the same or in a different implementation, the bond may be symmetrical in a transverse direction of the core about the narrowed portion along a majority of the bond in the transverse direction. [0030] In one or more configurations, each bond of the plurality of bonds may extend continuously from the medial edge of the core to the lateral edge of the core and may be wider in the fore-aft direction of the core at the medial edge and at the lateral edge than at a narrowed portion of the bond between the medial edge and the lateral edge. Configuring the bonds to extend to the medial and lateral edges of the core may further increase the integrity of the connection of the core to the barrier sheets via the bonds.

[0031] In an implementation, anti-weld material may be disposed on the core at the unbonded areas. By utilizing anti-weld material disposed on the at least one polymeric sheet of the core, the patterns of bonds of the core to the inner surfaces of the barrier sheets (and the bonds of adjacent polymeric sheets in embodiments in which the core includes more than one polymeric sheet) are controlled to determine the final geometry of the inflated cushioning component, including height differentials in different regions of an article of footwear, toe spring, etc.

[0032] Moreover, utilizing anti-weld material enables ease in manufacturing. For example, when the anti-weld material is blocker ink, patterns may be digitally implemented relatively easily in comparison to other tensile components that require specific molds or mold inserts to control bond formation of barrier sheets to internally-placed polymeric sheets. By depositing the anti-weld material so that it extends to an outer perimeter of the core at the inner surfaces of the barrier sheets, and by ensuring that the outer perimeter of the core is entirely inward of the peripheral bond of the barrier sheets, the patterns of bonds of the core do not result in any sealed chambers within the bladder that are not in fluid communication with the interior cavity. In this way, the core itself controls the final geometry of the inflated cushioning component but does not affect the cushioning response of the cushioning component under dynamic loading. Additionally, by utilizing anti-weld material, the cushioning component may be relatively flat prior to inflation. Stated differently, the core may lay flat within the bladder with the unbonded areas contacting the opposing inner surfaces when the interior cavity of the bladder is uninflated. [0033] In an example, a thickness of each polymeric sheet of the core may be greater than (e.g., is less than or equal to) a thickness of the first barrier sheet and not greater than a thickness of the second barrier sheet.

[0034] In an implementation, the plurality of bonds may include a first group of bonds in a forefoot region of the article of footwear and a second group of bonds in a heel region of the article of footwear. Spacing in the fore-aft direction of the core between adjacent bonds of the first group of bonds may be less than spacing between adjacent bonds of the second group of bonds such that the opposing inner surfaces are held closer to one another by the at least one polymeric sheet of the core in the forefoot region than in the heel region.

[0035] In an example, an outer perimeter of the at least one polymeric sheet may be spaced further inward of the peripheral bond in a heel region of the article of footwear than in a forefoot region of the article of footwear.

[0036] In an example, the opposing inner surfaces of the bladder may include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet and the core may be a multi-sheet core. The at least one polymeric sheet of the core may include a first polymeric sheet and a second polymeric sheet. The first polymeric sheet may be disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet may be disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces the first inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces the second inner surface of the second barrier sheet. The first side of the first polymeric sheet may be directly bonded to the first inner surface of the first barrier sheet at a first set of bonds of the plurality of bonds, the second side of the second polymeric sheet may be directly bonded to the second inner surface of the second barrier sheet at a second set of bonds of the plurality of bonds and the second side of the first polymeric sheet may be directly bonded to the first side of the second polymeric sheet at a third set of bonds of the plurality of bonds. The bonds of the third set may alternate with the bonds of the first set along a length of the core, and the bonds of the third set may alternate with the bonds of the second set along the length of the core. [0037] In one or more configurations of such cores that include both a first and a second polymeric sheet, each of the first set, the second set, and the third set of bonds may include at least one bond that extends continuously from the medial edge of the core to the lateral edge of the core and is wider in the fore-aft direction of the core at the medial edge and at the lateral edge than at a narrowed portion of the bond between the medial edge and the lateral edge.

[0038] Furthermore, a difference between a width at the medial edge and a width at the narrowed portion of the at least one bond of the second set may be greater than a difference between a width at the medial edge and a width at the narrowed portion of the at least one bond of the first set. This arrangement combines the arcuate-inducing effects of providing wider bonds at a lower extent of the core with the delamination advantages of providing bonds having wider ends.

[0039] Similarly, in the same configuration or in a different configuration, a difference between a width at the medial edge and a width at the narrowed portion of the at least one bond of the second set may be greater than a difference between a width at the medial edge and a width at the narrow ed portion of the at least one bond of the third set.

[0040] In an aspect, a foremost bond of the first set and a foremost bond of the second set may be further forw ard than a foremost bond of the third set. In the same configuration or in a different configuration, a rearmost bond of the first set and a rearmost bond of the second set may be further rearward than a rearmost bond of the third set. Placing the foremost and/or rearmost bonds near the top and/or the bottom of the core (e.g., at the first set and/or the second set of bonds) rather than interior to the core (e.g., at the third set of bonds) may better distribute forces applied by the wearer over the core.

[0041] In some implementations, at least some of the bonds of the second set may be aligned with the at least some of the bonds of the first set (e.g., along the length of the core) at least w hen the interior cavity of the bladder is uninflated. For example, at least some of the bonds of the second set may be wider in the fore-aft direction of the core than the bonds of the first set with which the at least some of the bonds of the second set are aligned. As used herein, wider in the fore-aft direction may also be referred to as longer, and narrower in the fore-aft direction may also be referred to as shorter. In an example, the bonds of the second set that are wider than the bonds of the first set may be in a forefoot region or in a heel region of the article of footwear.

[0042] By providing wider bonds that will be disposed closer to the ground surface when the cushioning component is incorporated in an article of footwear, when the cushioning component is inflated, the side with the narrower (e.g., shorter) bonds (e.g., the foot-facing side of the cushioning component, also referred to as the footbed side) will allow for more pillowing between the bonds of the first set than between the bonds of the second set. The side with more pillowing will contract more in overall length as the path of the material of the barrier sheet at the foot-facing side is distributed vertically and horizontally. Accordingly, the overall shape in the longitudinal direction of the foot-facing side with narrower bonds will become more concave after inflation. Providing the narrower bonds of the first set on the footbed side and the wider bonds on the ground-facing side thus helps to shape the inflated cushioning component to promote toe spring.

[0043] In some implementations, all of the bonds of the second set may be aligned with the bonds of the first set, and each bond of the second set may be wider in the fore-aft direction of the core than the respective bond of the first set with which the bond of the second set is aligned. In some implementations, each bond of the second set may be wider in the fore-aft direction of the core than adjacent bonds of the third set.

[0044] In an example, an article of footwear within the scope of the disclosure includes a sole structure that has a cushioning component. The cushioning component includes a bladder and a core disposed in the bladder and bonded to inner sides of barrier sheets of the bladder to act as a tensile component. The bladder includes a first barrier sheet and a second barrier sheet. The first barrier sheet and the second barrier sheet together define an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet. The first barrier sheet and the second barrier sheet are sealed to one another along a peripheral bond to enclose the interior cavity⁷ and retain a gas in the interior cavity. The core is disposed in the interior cavity and is spaced entirely inward of the peripheral bond. The core includes at least one polymeric sheet traversing the interior cavity between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality⁷ of nonlinear bonds to tether the first barrier sheet to the second barrier sheet. At least some of the nonlinear bonds have linear segments. For example, linear segments are arranged to establish an overall nonlinear shape of the bond. The at least one polymeric sheet of the core is displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet such that the gas in the interior cavity is in fluid communication around the at least one polymeric sheet of the core without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity.

[0045] By utilizing nonlinear bonds having linear segments, the fore-aft extent of each bond is increased relative to a straight bond of the same width. This may increase the robustness of the bond and its ability to withstand repeated stresses, such as lateral forces, reducing the likelihood of delamination.

[0046] A medial edge of the bladder may define a first notch. An inner medial edge of the peripheral bond may protrude laterally inward (i.e., transversely inward) at the first notch. A lateral edge of the bladder may define a second notch. An inner lateral edge of the peripheral bond may protrude laterally inward (i.e., transversely inward) at the second notch. The plurality of bonds may be configured such that the gas in the interior cavity is in fluid communication around the at least one polymeric sheet without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity.

[0047] In one or more implementations, the first notch may be at least partially aligned with the second notch in a transverse direction of the sole structure such that a width of the interior cavity in a lateral direction (i.e., in a transverse direction) of the sole structure is narrowed between the first notch and the second notch.

[0048] In an aspect, the sole structure may be configured to flex at the first notch and at the second notch during dorsiflexion. For example, the placement of the notches along the length of the sole structure may be selected to promote flexing at the notches during dorsiflexion.

[0049] In an aspect, the first notch and the second notch may be disposed in a forefoot region or in a midfoot region of the article of footwear. The notches may be aligned with or just rearward of the metatarsal joints of a wearer, for example, such that flexing of the sole structure during dorsiflexion at the metatarsal joints is eased by the notches.

[0050] In one or more configurations, the medial edge of the bladder may define a third notch and the inner medial edge of the peripheral bond may protrude laterally inward (i.e., transversely inward) at the third notch. The lateral edge of the bladder may define a fourth notch and the inner lateral edge of the peripheral bond may protrude laterally inward (i.e., transversely inward) at the fourth notch.

[0051] In an aspect, the third notch may be at least partially aligned with the fourth notch in a transverse direction of the sole structure such that a width of the interior cavity in a lateral direction (i.e., in a transverse direction) of the sole structure is narrowed between the third notch and the fourth notch.

[0052] In one or more configurations, the third notch and the fourth notch may be disposed in a heel region of the article of footwear.

[0053] In an example, an article of footwear within the scope of the disclosure includes a sole structure that has a cushioning component. The cushioning component includes a bladder and a core disposed in the bladder and bonded to inner sides of barrier sheets of the bladder to act as a tensile component. The bladder includes a first barrier sheet and a second barrier sheet. The first barrier sheet and the second barrier sheet together define an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet. The first barrier sheet and the second barrier sheet are sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity. The core is disposed in the interior cavity and is spaced entirely inward of the peripheral bond. The core includes at least one polymeric sheet traversing the interior cavity between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonds to tether the first barrier sheet to the second barrier sheet. The at least one polymeric sheet of the core is displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet such that the gas in the interior cavity is in fluid communication around the at least one polymeric sheet of the core without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity. A medial edge of the bladder and a lateral edge of the bladder may respectively define a first notch and a second notch. The second notch may be at least partially aligned with the first notch in one of a forefoot region or a midfoot region of the sole structure such that an inner medial edge of the peripheral bond protrudes laterally inward at the first notch and an inner lateral edge of the peripheral bond protrudes laterally inward at the second notch. The medial edge of the bladder and the lateral edge of the bladder may respectively define a third notch and a fourth notch. The fourth notch may be at least partially aligned with the third notch in a heel region of the sole structure such that the inner medial edge of the peripheral bond protrudes laterally inward at the third notch and the inner lateral edge of the peripheral bond protrudes laterally inward at the fourth notch.

[0054] In an aspect of the article of footwear, the sole structure may be wider between the first notch and the second notch than between the third notch and the fourth notch, and an outer perimeter of the at least one polymeric sheet of the core may be spaced further inward of the peripheral bond at the third notch and the fourth notch than at the first notch and the second notch.

[0055] In an implementation of the article of footwear, the sole structure may include an outsole secured to a distal surface of the bladder and extending at least partially upward along sidewalls of the bladder.

[0056] The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings. It should be understood that even though in the following Figures embodiments may be separately described, single features thereof may be combined to additional embodiments.

[0057] FIGS. 1-3 show polymeric sheets 10 and 11 used to form a core 12 shown in FIG. 7. The core 12 is included in a cushioning component 14 shown in FIGS. 8-10. More specifically, the cushioning component 14 is included in a sole structure 70 of an article of footwear 72 as show n in FIG. 10. As further explained herein, the cushioning component 14 includes a bladder 20 including barrier sheets 16 and 18 bonded to one another at a peripheral bond 38. The core 12 is disposed in the bladder 20 and bonded to inner surfaces 17, 19 of barrier sheets 16, 18 of the bladder 20. as shown in FIG. 7, to act as a tensile component. Providing a tensile component within a bladder may be useful in restraining the bladder when inflated, preventing it from adopting a ball-like shape. A tensile component such as the core 12 according to the present disclosure enables bonding the polymeric sheets 10, 1 1 to the barrier sheets 16, 18 at bonds 44 and 46, respectively, having patterns that result in technical advantages both in performance aspects of the cushioning component 14 and ease of manufacturing the cushioning component 14.

[0058] FIG. 1 is a plan view of a bottom side of the polymeric sheet 11 with anti-weld material 24 disposed thereon. The polymeric sheet 11 is referred to herein as a second polymeric sheet. The side of the polymeric sheet shown in FIG. 1 is a second side 13 and is also referred to as a bottom side or distal side as it is disposed further from the foot when the core 12 is incorporated in the sole structure 70 of the article of footw ear 72. The second side 13 interfaces with and is bonded to the inner surface 19 of the second barrier sheet 18 as shown in FIG. 7 and discussed herein. [0059] FIG. 2 is a plan view of an opposing first side 15 of the second polymeric sheet 11 with anti-weld material 24 disposed thereon in a different pattern than on the second side 13 shown in FIG. 1. The first side 15 is also referred to as the top side or as the proximal side of the second polymeric sheet 11 as it is disposed closer to the foot when the core 12 is incorporated in the sole structure 70 of the article of footwear 72.

[0060] As best shown in FIGS. 4 and 6-10, each of the core 12, the cushioning component 14, and the article of footw ear 72 includes a forefoot region, a heel region, and a midfoot region. These regions are referred to as a forefoot region 50, a midfoot region 52, and a heel region 54 with respect to the cushioning component 14, the sole structure 70, and the article of footwear 72. However, because the core 12 is of a shorter length than each of the cushioning component 14, the sole structure 70, and article of footw ear 72, the forefoot region, midfoot region, and heel region of the core 12 are referred to as 50A, 52A, and 54A, respectively. The forefoot region 50 and 50A generally includes portions of the article of footwear 72 or the core 12 corresponding with the toes and the joints connecting the metatarsals with the phalanges of a w earer’s foot. The midfoot region 52 and 52A generally includes portions of the article of footwear 72 or the core 12 corresponding w ith the arch area of the foot, and the heel region 54 and 54A corresponds with rear portions of the foot, including the calcaneus bone. Each of the core 12, the cushioning component 14, the sole structure 70, and the article of footwear 72 include a medial side 80 and a lateral side 82 that extend through each of forefoot region 50 and 50A, the midfoot region 52 and 52A, and the heel region 54 and 54A and fall on opposite sides of a longitudinal axis LM of the cushioning component 14 in FIG. 8. The longitudinal axis LM is also referred to herein as a longitudinal midline. The forefoot region 50 and 50A, the midfoot region 52 and 52A, the heel region 54 and 54A, the medial side 80, and the lateral side 82 are not intended to demarcate precise areas of footwear 72, the core 12, the cushioning component 14, or the sole structure 70, but are instead intended to represent general areas of the article of footwear 72, the core 12, the cushioning component 14, and the sole structure 70 to aid in the following discussion.

[0061] FIG. 3 is a plan view of a first side 22 of the first polymeric sheet 10 with anti-weld material 24 disposed thereon. The opposite second side 26 does not have any anti-weld material disposed thereon. The first polymeric sheet 10 is stacked on the second polymeric sheet 11 when the core 12 is assembled such that the second side 26 interfaces with and is bonded to the first side 15 of the second polymeric sheet 1 1 and the first side 22 interfaces with and is bonded to the inner surface 17 of the first barrier sheet 16 as shown in FIG. 7 and discussed herein.

[0062] The anti -weld material 24 is disposed on the polymeric sheets 10, 11 of the core 12 at areas that will be unbonded areas when the core 12 is thermally processed. By utilizing anti -weld material 24 disposed on the polymeric sheets 10, 11, the patterns of bonds of the core 12 to the inner surfaces 17, 19 of the barrier sheets 16, 18 (and the bonds of the second side 26 of the first polymeric sheet 10 to the first side 15 of the second polymeric sheet 11) are controlled to determine the final geometry of the completed cushioning component 14. including height differentials in different regions (e.g., forefoot region 50 and heel region 54) of an article of footwear 72, toe spring, etc. As show n in FIG. 7, portions of one or both of the inner surfaces 17, 19 that are outward of the outer perimeter 34 of the core 12 and inw ard of where the peripheral bond 38 is formed may also be preprinted or otherwise prepared with anti-weld material 24 or otherwise processed so that these portions of the inner surfaces 17, 19 will not bond to one another. This enables a peripheral portion 21 A of the interior cavity 21 outward of the core 12.

[0063] The anti -weld material 24 may be disposed on the polymeric sheets 10 and 11 (and on the portions of the inner surfaces 17. 19 of the first barrier sheet 16 and/or second barrier sheet 18 shown in FIG. 7) via a computer-controlled printer head or heads (not shown) according to a stored algorithm representing a predetermined printing pattern. As used herein, the anti-weld material 24 may be blocker ink, and may also be referred to as anti-weld ink. For example, when the antiweld material is blocker ink, it may be printed according to a different predetermined programmed pattern for the first side 22 of the first polymeric sheet 10. the first side 15 of the second polymeric sheet 11 , and the second side 13 of the second polymeric sheet 11 at all selected locations where bonding of the polymeric sheets 10, 11 of the core 12 to one another or to the barrier sheets 16, 18 is not desired. After trimming the sheets 10, 11 to establish the outer perimeters 34B, 34 A and when bonded to one another such as by thermal processing, adjacent surfaces of the stacked, flat polymeric sheets 10, 11 and barrier sheets 16, 18 are bonded to one another except where the anti-weld material 24 is disposed. Accordingly, the patterns of anti-weld material 24 determine corresponding patterns of resulting bonds in the finished cushioning component 14.

[0064] The predetermined pattern of anti-weld material 24 on the second side 13 of the second polymeric sheet 11 in FIG. 1 is referred to as a second predetermined pattern and results in a second set of bonds 46 discussed with respect to FIGS. 4-5, 7- 8, and 10. The predetermined pattern of anti-weld material 24 on the first side 15 of the second polymeric sheet 11 in FIG. 2 is referred to as a third predetermined pattern and results in a third set of bonds 47 discussed with respect to FIGS. 4 and 6-10. The predetermined pattern of anti-weld material 24 on the first side 22 of the first polymeric sheet 10 is referred to as a first predetermined pattern and results in a first set of bonds 44 discussed with respect to FIGS. 6-10.

[0065] With reference to FIG. 1 , the anti-weld material 24 is disposed on the second side 13 of the second polymeric sheet 11 in the second predetermined pattern at spaced regions A, B, C, D, E, F, G, H, I, J, K, L, M, N, and O of deposited antiweld material 24. Areas of the second side 13 of the second polymeric sheet 11 between any adjacent two of the spaced regions A, B, C, D, E, F, G, H, I, J, K, L, M, N, and O are free from anti -weld material 24. More specifically, area 13A between adjacent regions A and B is free from anti-weld material 24, area 13B between adjacent spaced regions B and C is free from anti-weld material 24. area 13C between adjacent spaced regions C and D is free from anti-weld material 24. area 13D between adjacent spaced regions D and E is free from anti-weld material 24, area 13E between adjacent spaced regions E and F is free from anti-weld material 24, area 13F between adjacent spaced regions F and G is free from anti-weld material 24, area 13G between adjacent spaced regions G and H is free from anti -weld material 24, area 13H between adjacent spaced regions H and I is free from anti-weld material 24, area 131 between adjacent spaced regions I and J is free from anti-weld material 24, area 13J between adjacent spaced regions J and K is free from anti-weld material 24, area 13K between adjacent spaced regions K and L is free from anti-weld material 24, area 13L between adjacent spaced regions L and M is free from anti-weld material 24, area 13M between adjacent spaced regions M and N is free from anti -weld material 24, and area 13N between adjacent spaced regions N and O is free from anti-weld material 24. The areas 13A, 13B, 13C, 13D, 13E, 13F, 13G, 13H, 131, 13J, 13K, 13L, 13M, and 13N will become a second set of bonds 46 shown in FIGS. 4, 7-8 and 10 each corresponding with one of the areas 13A-13N.

[0066] Each of the areas 13A-13N has a nonlinear shape including linear segments such that the second set of bonds 46 are nonlinear bonds as further described with respect to FIGS. 6 and 8. The second polymeric sheet 11 is trimmed to an outer perimeter 34A shown in FIGS. 4 and 7 after printing the anti-weld material 24 such that the areas A-0 of anti-weld material 24 extend to the perimeter 34A and the areas 13A-13N and corresponding resulting bonds 46 also extend to the perimeter 34A at both the medial and lateral sides 80, 82.

[0067] With reference to FIG. 2, the anti-weld material 24 is disposed on the first side 15 of the second polymeric sheet 11 in the third predetermined pattern at spaced regions P, Q, R, S, T. U, V, W. X, Y, Z, Al. Bl. and Cl of deposited antiweld material 24. Areas of the first side 15 of the second polymeric sheet 1 1 between any adjacent two of the spaced regions P, Q, R, S, T, U, V, W, X, Y, Z, Al, Bl, and Cl are free from anti -weld material 24. More specifically, area 15P between adjacent regions P and Q is free from anti-weld material 24, area 15Q between adjacent spaced regions Q and R is free from anti -weld material 24, area 15R between adjacent spaced regions R and S is free from anti-weld material 24, area 15S between adjacent spaced regions S and T is free from anti-weld material 24, area 15T between adjacent spaced regions T and U is free from anti-weld material 24, area 15U between adjacent spaced regions U and V is free from anti-weld material 24, area 15V between adjacent spaced regions V and W is free from anti -weld material 24, area 15W between adjacent spaced regions W and X is free from anti-weld material 24, area 15X between adjacent spaced regions X and Y is free from anti-weld material 24, area 15Y between adjacent spaced regions Y and Z is free from anti-weld material 24, area 15Z between adjacent spaced regions Z and Al is free from anti -weld material 24, area 15 Al between adjacent spaced regions Al and Bl is free from anti-weld material 24. and area 15B1 between adjacent spaced regions Bl and Cl is free from anti-weld material 24. The areas 15P, 15Q, 15R, 15S, 15T, 15U, 15V, 15W, 15X, 15Y, 15Z, 15A1, and 15B1 will become a third set of bonds 47 shown in FIGS. 4 and 6-8, each corresponding with one of the areas 15P-15B1.

[0068] Each of the areas 15P-15B1 has a nonlinear shape including linear segments such that the third set of bonds 47 are nonlinear bonds as further described with respect to FIGS. 4, 6, and 8. The second polymeric sheet 11 is trimmed to an outer perimeter 34A shown in FIGS. 4 and 7 and after printing the anti-weld material 24 such that the areas P-C 1 of anti-weld material 24 extend to the perimeter 34A and the areas 15P-15B1 and corresponding resulting bonds 47 also extend to the perimeter 34A.

[0069] With reference to FIG. 3, the anti-weld material 24 is disposed on the first side 22 of the first polymeric sheet 10 in the first predetermined pattern at spaced regions DI, El, Fl, Gl, Hl, II, JI, KI, LI, Ml, Nl, Pl, QI, Rl, and SI of deposited anti-weld material 24. Areas of the first side 22 of the first polymeric sheet 10 between any adjacent two of the spaced regions DI, El, Fl, Gl, Hl, II, JI, KI, LI, Ml, Nl, PL QL Rl, and SI are free from anti-weld material 24. More specifically, area 22A between adjacent regions DI and El is free from anti-weld material 24. area 22B between adjacent spaced regions El and Fl is free from anti-weld material 24, area 22C between adjacent spaced regions Fl and Gl is free from anti-weld material 24, area 22D between adjacent spaced regions Gl and Hl is free from anti-weld material 24, area 22E between adjacent spaced regions Hl and II is free from antiweld material 24, area 22F between adjacent spaced regions II and JI is free from anti-weld material 24, area 22G between adjacent spaced regions JI and KI is free from anti-weld material 24, area 22H between adjacent spaced regions KI and LI is free from anti -weld material 24, area 221 between adjacent spaced regions LI and Ml is free from anti-weld material 24. area 22J between adjacent spaced regions Ml and Nl is free from anti-weld material 24, area 22K between adjacent spaced regions Nl and Pl is free from anti -weld material 24, area 22L between adjacent spaced regions Pl and QI is free from anti-weld material 24, area 22M between adjacent spaced regions QI and R1 is free from anti-weld material 24, and area 22N between adjacent spaced regions R1 and SI is free from anti-weld material 24. The areas 22A, 22B, 22C, 22D, 22E, 22F. 22G, 22H, 221. 22J, 22K, 22L. 22M. and 22N will become a first set of bonds 44 show n in FIGS. 6-10, each corresponding with one of the areas 22 A- 22N.

[0070] Each of the areas 22A-22N has a nonlinear shape including linear segments such that the first set of bonds 44 are nonlinear bonds as further described with respect to FIGS. 5 and 6. The first polymenc sheet 10 is trimmed to an outer perimeter 34B shown in FIGS. 6 and 7 and after printing the anti-weld material 24 such that the regions DI -SI of anti-weld material 24 extend to the outer perimeter 34B and the areas 22A-22N and corresponding resulting bonds 44 also extend to the outer perimeter 34B.

[0071] FIG. 4 is a plan view of the top side of a portion of the core 12 formed from the polymeric sheets of FIGS. 1-3, not showing the first polymeric sheet 10 or the barrier sheets 16, 18 to which the core 12 is bonded, but showing only the second polymeric sheet 11 as the lower core sheet when the core 12 is assembled in order to illustrate the relative locations of the third set of bonds 47 and the second set of bonds 46. The bonded areas at the top side (first side 15) are the third set of bonds 47 where the first side 15 of the second polymeric sheet 11 of the core 12 bonds to the bottom side (second side 26) of the first polymeric sheet 10 (not shown in FIG. 4) and are represented in solid. The bonded areas at the opposite bottom side 13 (second side) of the second polymeric sheet 11 are represented with dashed lines and are the second set of bonds 46 wherein the second side 13 of the second polymeric sheet 11 is bonded to the inner surface 19 of the second barrier sheet 18. The areas 15P-15B1 corresponding with each of the third set of bonds 47 and the areas 13A-13N corresponding with each of the second set of bonds 46 are also indicated with reference numbers.

[0072] FIG. 4 show s that the bonds 47 of the third set of bonds are offset from the bonds 46 of the second set of bonds in the longitudinal direction of the core 12 (e.g.. from a forefoot region 50 A of the core 12 to a heel region 54A of the core 12). Stated differently, each bond 47 of the third set of bonds is disposed between two adjacent bonds 46 of the second set of bonds without overlapping with the second set of bonds 46. In this manner, the second polymeric sheet 11 will extend in the vertical direction as shown in FIG. 10 between adjacent bonds 46 and 47 when the interior cavity 21 of the bladder 20 is inflated, tethering the second barrier sheet 18 to the first polymeric sheet 10.

[0073] Still referring to FIG. 4, each of the bonds 46 extends continuously from a medial end 46 A of the bond 46 adjacent to a medial edge 80 A of the core 12 to a lateral end 46B of the bond 46 adjacent to a lateral edge 82A of the core 12. Only some of the medial ends 46A and lateral ends 46B are labeled in FIG. 4 for clarity in the drawing. In the embodiment shown, the medial end 46A is at the medial edge 80A and the lateral end 46B is at the lateral edge 82A.

[0074] Similarly, each of the bonds 47 extends continuously from a medial end 47A of the bond 47 adjacent to a medial edge 80A of the core 12 to a lateral end 47B of the bond 47 adjacent to a lateral edge 82A of the core 12. Only some of the medial ends 47A and lateral ends 47B are labeled in FIG. 4 for clarity in the drawing. In the embodiment shown, the medial end 47A is at the medial edge 80A and the lateral end 47B is at the lateral edge 82A.

[0075] Configuring the bonds 46 to extend to the medial and lateral edges 80A, 82A of the core 12 and the bonds 47 to extend from the medial and lateral edges 80A, 82A may further increase the integrity of the connection of the core 12 to the barrier sheets 16, via the bonds.

[0076] Each of the bonds 46 is wider in a fore-aft direction of the core 12 at the medial end 46A and at the lateral end 46B than at a narrowed portion 46C of the bond 46 between the medial end 46A and the lateral end 46B. The fore-aft direction of the core 12 is a direction from the forefoot region 50A to the heel region 54A along the longitudinal axis LM. Although this is true for each of the bonds 46 show n in FIG. 4, in other implementations, less than all of the bonds 46, such as only one of the bonds 46, may have greater widths at its medial and lateral ends than at a narrowed portion between the ends. Stated differently, within the scope of the disclosure, at least one of the bonds 46 is wider in a fore-aft direction of the core 12 at the medial end 46A and at the lateral end 46B than at a nanowed portion 46C of the bond 46 between the medial end 46A and the lateral end 46B.

[0077] As illustrated with respect to one of the bonds 46 in the heel region 54A, the fore-aft width of the bond 46 at the medial end 46A and at the lateral end 46B is a first width W1 . The fore-aft width of the same bond 46 at a narrowed portion 46C between the medial end 46A and the lateral end 46B is a second width W2. The second width W2 is less than the first width Wl. While the width of each bond 46 at its medial end 46A and lateral end 46B may differ from the first width W 1 (e.g., widths at the medial and lateral ends 46A, 46B may be less in the forefoot region 50A than in the heel region 54A, for example), the width of the narrowed portion 46C of each bond 46 is less than the width of that same bond 46 at the medial end 46A and less than the width at the lateral end 46B. Additionally, the width of a bond 46 at the medial end 46A need not be exactly equal to the width at the lateral end 46B, but both widths are greater than the width of the narrowed portion 46C for each bond 46. By configuring a bond 46 so that it is wider at its medial and lateral ends 46A, 46B than at a narrowed portion 46C between the ends, the resistance to delamination when forces are applied to the core 12 during wear, such as from a lateral step or otherwise, is increased in comparison to a bond of a narrower width at its ends.

[0078] As is evident in FIG. 4, the narrowed portion 46C of each bond 46 (only some of which are labeled) is at a middle of the bond 46 in a transverse direction of the core 12. The transverse direction of the core 12 is a direction from the medial side 80 to the lateral side 82 and perpendicular to the longitudinal axis LM, for example. Each bond 46 is also shown as symmetrical in the transverse direction of the core 12 about the narrowed portion 46C along a majority of the bond 46 in the transverse direction.

[0079] Stresses on the core 12 may be greatest at the medial and lateral edges 80A, 82A. By configuring the bonds 46 so that they are wider at their medial and lateral ends 46A, 46B and by placing the medial and lateral ends 46A, 46B at the medial edge 80A and the lateral edge 82A of the core 12, greater force is required to overcome the bond 46 and the risk of delamination of the core 12 from the barrier sheet 18 is reduced. Stated differently, the wider ends 46A, 46B reinforce the integrity⁷ of the bond 46 at the medial and lateral edges 80A, 82A in comparison to a bond having narrower ends. Additionally, configuring the bonds to be relatively narrow between the ends 46 A. 46B, e.g., such as at the narrowed portion 46C, enables greater vertical displacement of the barrier sheet 18 and the low er sheet 11 of the core 12 adjacent to the narrower portion 46C (e.g., between the narrower portions 46C of adjacent bonds 46). The second polymeric sheet 11 of the core 12 may thus be further displaced from the second barrier sheet 18 near the narrowed portion 46C than near the ends 46A, 46B. The wider ends 46A, 46B of the bond 46 thus serve to reinforce the connection of the second polymeric sheet 11 to the second barrier sheet 18 while more of the second polymeric sheet 11 is free from (and further displaced from) the barrier sheet 18 near the narrowed portion 46C.

[0080] The bonds 47 shown in FIG. 4 are similarly configured to be wider in the fore-aft direction of the core 12 at a medial end 47 A of the bond 47 and at a lateral end 47B of the bond 47 than at a narrowed portion 47C of the bond 47 between the medial end 47A and the lateral end 47B. As illustrated with respect to one of the bonds 47, a width W4 at the medial end 47A and at the lateral end 47B is less than a width W5 at a narrowed portion 47C.

[0081] It is apparent in FIG. 4 that each of the bonds 46 and 47 is nonlinear. Although nonlinear, each bond 46 and 47 is made up of a series of linear segments. The series of linear segments of each bond 46 and 47 create a relatively blocky wave shape. FIG. 5 is a close-up view of the shape of one of the bonds 46. The bond 46 is illustrated with a center axis CA running through along a center of its transverse length between the medial end 46A and the lateral end 46B. It is clear in FIG. 5 that the bond 46, as illustrated by its center axis CA, is a series of linear segments. For example, the center axis CA progresses from the medial end 46A to the lateral end 46B as a series of linear segments CAI, CA2, CA3, CA4, CA5. CA6, CA7, CA8, CA9. CA10, CA11, CA12, and CAB. The linear segments CAI, CA2, CA3, CA4, CA5, CA6, CA7, CA8, CA9, CA10, CAI 1, CAI 2, and CAB of the center axis CA correspond with linear segments 46A1, 46A2, 46A3, 46A4, 46A5, 46A6, 46A7, 46A8, 46A9, 46A10, 46A11, 46A12, and 46A13 of the bond 46, respectively. The linear segments 46A1, 46A2, 46A3, 46A4, 46A5, 46A6, 46A7, 46A8, 46A9, 46A10. 46A1 1, 46A12, and 46A13 are arranged to provide an overall nonlinear shape of the bond 46.

[0082] As shown, the nonlinear segments result in the bond 46 having flattened peaks and flattened valleys extending in the fore-aft direction of the core 12. The flattened peaks are at the top edge of the bond 46 in FIG. 5 at the segments 46A5 and 46 A9 and the flattened valleys are at the bottom edge of the bond 46 in FIG. 5 at the segments 46 A3, 46A7, and 46A11. By utilizing nonlinear bonds and/or bonds having flattened peaks and flattened valleys extending in the fore-aft direction, such as illustrated in FIG. 5, the fore-aft extent of each such bond may be greater than that of a straight bond of the same width. This may increase the robustness of the bond and its ability to withstand repeated stresses, such as lateral forces, reducing the likelihood of delamination.

[0083] The bonds 47 shown in FIG. 4, 6, and 8 and the bonds 44 shown in FIGS. 6, 8, and 9 are also nonlinear bonds, shaped similarly as described with respect to bond 46 in FIG. 5 with nonlinear segments resulting in flattened peaks and flattened valleys. The flattened peaks and flattened valleys of the other bonds 44 and 47 are not labeled for clarity in the drawings. The number of peaks and valleys of each bond 44, 46, and 47 depends upon the transverse w idth of the core 12 at the particular bond. By utilizing nonlinear bonds having linear segments, the fore-aft extent of each bond (e.g., the longitudinal distance between a top edge of a segment defining a flattened peak and a segment defining a flattened valley of the bond) is increased relative to a straight bond of the same width. This may increase the robustness of the bond and its ability to withstand repeated stresses, such as lateral forces, reducing the likelihood of delamination.

[0084] It is clear in the close-up view of the bond 46 in FIG. 5 that the narrow ed portion 46C is at a middle of the bond 46 in what will be a transverse direction. Additionally, the bond 46 is symmetrical in the transverse direction of the core 12 about the narrowed portion 46C along a majority of the bond 46 in the transverse direction. Stated differently, the bond 46 is symmetrical about its centerline CL (the portion of the bond 46 from the medial end 46A to the centerline CL is symmetrical with the portion of the bond 46 betw een the lateral end 46B and the centerline CL). The bonds 44 and 47 are also configured with a narrowed portion at a middle of the bond in the transverse direction of the core 12 and are symmetrical in the transverse direction of the core 12 about the narrowed portion along a majority of the bond 46 in the transverse direction as shown herein. Some of the bonds may be symmetrical in the transverse direction except at their outermost segments (e.g., segments CAI and CA13 in the example shown) due to the differences in the curvature of the perimeter 34A at the medial side 80 and the lateral side 82.

[0085] FIG. 6 is a plan view of a portion of the core 12 showing only the polymeric sheet 10 of FIG. 3 as an upper core sheet and representing bonded areas at the top side 22 of the polymeric sheet 10 in solid and bonded areas at the bottom side 26 of the polymeric sheet 10 in dashed lines in order to illustrate the relative locations of the third set of bonds 47 and the first set of bonds 44. The bonded areas at the top side (first side 22) are the first set of bonds 44 where the first side 22 of the first polymeric sheet 10 of the core 12 bonds to the inner surface 17 of the first barrier sheet 1 . The bonded areas at the opposite bottom side 26 (second side) of the first polymeric sheet 10 are represented with dashed lines and are the third set of bonds 47 where the second side 26 of the first polymeric sheet 10 is bonded to the first side 15 of the second polymeric sheet 11. The areas 15P-15B1 corresponding with each of the third set of bonds 47 and the areas 22A-22N corresponding with each of the first set of bonds 44 are also indicated with reference numbers. FIG. 6 shows that the bonds 47 of the third set of bonds are offset from the bonds 44 of the first set of bonds in the longitudinal direction of the core 12 (e.g.. from a forefoot region 50A of the core 12 to a heel region 54A of the core 12). Stated differently, each bond 47 of the third set of bonds is disposed between two adjacent bonds 44 of the first set of bonds without overlapping with the first set of bonds 44. In this manner, the first polymeric sheet 10 will extend in the vertical direction as shown in FIG. 10 between adjacent bonds 44 and 47 when the interior cavity 21 of the bladder 20 is inflated, tethering the first barrier sheet 16 to the first polymeric sheet 10 and tethering the second polymeric sheet 11 to the first polymeric sheet 10.

[0086] Each of the bonds 44 extends continuously from a medial end 44A of the bond 44 adjacent to the medial edge 80 A of the core 12 to a lateral end 44B of the bond 44 adjacent to the lateral edge 82A of the core 12. Only some of the medial ends 44A and lateral ends 44B are labeled in FIG. 6 for clarity in the drawing.

[0087] Each of the bonds 44 is wider in a fore-aft direction of the core 12 (e.g., a direction from the forefoot region 50A to the heel region 54A along the longitudinal axis LM) at the medial end 44A and at the lateral end 44B than at a narrowed portion 44C of the bond 44 between the medial end 44A and the lateral end 44B. Although this is true for each of the bonds 44 shown in FIG. 6, in other implementations, less than all of the bonds 44, such as only one of the bonds 44, may have greater widths at its medial and lateral ends than at a narrowed portion between the ends. Stated differently, within the scope of the disclosure, at least one of the bonds 44 is w ider in a fore-aft direction of the core 12 at the medial end 44A and at the lateral end 44B than at a narrowed portion 44C of the bond 44 between the medial end 44 A and the lateral end 44B.

[0088] As illustrated with respect to one of the bonds 44 in the heel region 54A, the fore-aft width of the bond 44 at the medial end 44A and at the lateral end 44B is a first width W6. The fore-aft width of the same bond 44 at a narrowed portion 44C is a second width W7. The second width W7 is less than the first width W6. While the width of each bond 44 at its medial end 44A and lateral end 44B may differ from the first width W6 (e g., widths at the medial and lateral ends 44A, 44B may be less in the forefoot region 50A than in the heel region 54A. for example), the width of the narrowed portion 44C of each bond 44 is less than the width of each bond 44 at the medial end 44A and less than the width at the lateral end 44B. Additionally, the width at the medial end 44A need not be exactly equal to the width at the lateral end 44B, but both widths are greater than the width of the narrowed portion 44C for each bond 44.

[0089] Furthermore, a difference between the width W1 at the medial end 46 A and the width W2 at the narrowed portion 46C of the bond 46 of the second set shown in FIG. 4 may be greater than the difference between the width W6 at the medial end 44A and the width W7 at the narrowed portion 44C of the bond 44 of the first set shown in FG. 4. Similarly, a difference between the width W1 at the medial end 46A and the width W2 at the narrowed portion 46C of the bond 46 of the second set may be greater than a difference between the width W4 at the medial end 47A and the width W5 at the narrowed portion 47C of the bond 47 of the third set. This arrangement may combine the arcuate-inducing effects of providing wider bonds at a lower extent of the core 12 with the delamination advantages of providing relatively wide medial and lateral ends of the bonds.

[0090] As is evident in FIG. 6. the narrowed portion 44C of each bond 44 (only some of which are labeled) is at a middle of the bond 44 in the transverse direction of the core 12. Each bond 44 is also show n as symmetrical in the transverse direction of the core 12 about the narrowed portion 44C along a majority of the bond 44 in the transverse direction.

[0091] Referring again to FIG. 7, after trimming the first polymeric sheet 10 and the second polymeric sheet 11 to establish the respective outer perimeters 34B, 34A, the first polymeric sheet 10 is stacked on the second polymeric sheet 11 with the second side 13 of the second polymeric sheet 1 1 adjacent to the inner surface 19 of the second barrier sheet 18 and the first side 22 of the first polymeric sheet 10 adj acent to the inner surface 17 of the first barrier sheet 16. The aligned outer perimeters 34B and 34A of the stacked polymeric sheets 10 and 11 establish and may- together be referred to as an outer perimeter 34 of the core 12. In this relative positioning, the barrier sheets 16, 18 and the polymeric sheets 10, 11 are thermally processed to form the bonds 38, 44, 46, and 47 discussed herein. The first barrier sheet 16 and the second barrier sheet 18 together define the interior cavity- 21 between the opposing inner surfaces 17, 19 of the first barrier sheet 16 and the second barn er sheet 18.

[0092] As shown in FIG. 7, the cushioning component 14 is relatively flat prior to inflation. Stated differently, the core 12 lays flat within the bladder 20 with the unbonded areas contacting the opposing inner surfaces 17, 19 when the interior cavity 21 of the bladder 20 is uninflated. The unbonded areas are as discussed with respect to FIGS. 1-6 and are where anti-weld material 24 is shown in FIG. 7. Only- some of the areas w ith anti-w eld material 24 are indicated w ith a reference number in FIG. 7 for clarity in the drawing.

[0093] Traditional tensile components may include a first polymeric sheet bonded only to the inner surface of the first barrier sheet, a second polymeric sheet bonded only to the inner surface of the second barrier sheet, and a plurality- of tethers extending from the first polymeric sheet to the second polymeric sheet. Due to this configuration, such traditional tensile components are not relatively flat or sheet-like prior to inflating the interior cavity of a bladder in which they' are disposed and are not amendable to heat pressing either to create a core of multiple polymeric sheets or to bond a core of a single polymeric sheet or multiple polymeric sheets to the inner surfaces of the barrier sheets.

[0094] As indicated in FIG. 7, the polymeric sheets 10 and 11 are each shown as having the same thickness Tl. The barrier sheets 16 and 18 are each shown as having the same thickness T2. The thickness Tl is not greater than the thickness T2. Maintaining a sheet thickness of each polymeric sheet 10 and 11 not greater than that of each of the barrier sheets 16 and 18 helps to ensure the flexibility- of the core 12 to function as a tether that collapses back toward the relatively flat state of FIG. 7 relatively easily under compressive loading. [0095] As shown in FIGS. 7-10, the first barrier sheet 16 and the second barrier sheet 18 are sealed to one another along the peripheral bond 38 to enclose the interior cavity 21 and retain a gas in the interior cavity. The barrier sheets 16, 18 of the bladder 20 can be formed from a variety of materials including various polymers that can resiliently retain a fluid such as air or another gas. The polymeric sheets 10 and 11 may be formed of the same material or materials as the barrier sheets 16, 18 as described herein, or may be formed of a polymeric material that does not necessarily retain fluid. Unlike the barrier sheets 16, 18, the polymeric sheets 10 and 11 function as tethers but do not seal any interior cavity as do the barrier sheets 16. 18. Examples of polymeric materials for the barrier sheets 1 , 18 and the polymeric sheets 10 and 11 can include thermoplastic urethane, polyurethane, polyester, polyester polyurethane, and poly ether polyurethane. Moreover, the barrier sheets 16, 18 and the polymeric sheets 10 and 11 can be formed of layers of different materials. In one embodiment, the barrier sheets 16, 18 and/or the polymeric sheets 10 and 1 1 are formed from thin films having one or more thermoplastic polyurethane layers with one or more barrier layers of a copolymer of ethylene and vinyl alcohol (EV OH) that is impermeable to the pressurized fluid contained therein as disclosed in U.S. Patent No. 6,082,025, which is incorporated by reference in its entirety. The barrier sheets 1 , 18 and the polymeric sheets 10 and 11 may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. Patent Nos. 5.713,141 and 5,952,065 to Mitchell et al. which are incorporated by reference in their entireties. Alternatively, the layers may include ethyl ene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. The barrier sheets 16, 18 and the polymeric sheets 10 and 11 may also each be a flexible microlayer membrane that includes alternating layers of a gas barrier material and an elastomeric material, as disclosed in U.S. Patent Nos. 6,082,025 and 6,127,026 to Bonk et al. which are incorporated by reference in their entireties. Additional suitable materials for the barrier sheets 16, 18 and the polymeric sheets 10 and 11 are disclosed in U.S. Patent Nos. 4,183,156 and 4,219,945 to Rudy which are incorporated by reference in their entireties. Further suitable materials for the barrier sheets 16, 18 and the polymeric sheets 10 and 11 include thermoplastic films containing a crystalline material, as disclosed in U.S. Patent Nos. 4,936,029 and 5,042,176 to Rudy, and polyurethane including a polyester polyol, as disclosed in U.S. Patent Nos. 6,013,340, 6,203,868, and 6,321,465 to Bonk et al. which are incorporated by reference in their entireties. In selecting materials for the barrier sheets 16, 18 and the polymeric sheets 10 and 11, engineering properties such as tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent can be considered. The thickness of the barrier sheets 16, 18 and the polymeric sheets 10 and 11 can be selected to provide these characteristics.

[0096] In FIG. 8. the bonds 44 of the first set are indicated with solid lines. The bonds 46 of the second set are indicated with dashed lines. The bonds 47 of the third set are indicated with a combination of dashed and dotted lines. As shown in FIG. 8, each bond 44, 46, and 47 of the plurality of nonlinear bonds extends continuously from a medial edge 34C of the core 12 to a lateral edge 34D of the core 12. The medial edge 34C is a portion of the perimeter 34 at a medial side 80 of the longitudinal axis LM. The lateral edge 34D is a portion of the perimeter 34 at a lateral side 82 of the longitudinal axis LA. The medial side 80 and lateral side 82 also describe the respective sides of the cushioning component 14 and the article of footwear 72 as well as its other components. By depositing the anti-weld material 24 so that it extends to an outer perimeter 34 of the core 12 at the inner surfaces 17, 19 of the barrier sheets 16, 18 and between the polymeric sheets 10, 11 (e.g., on the first side 15 of the second polymeric sheet 11), and by ensuring that the outer perimeter 34 of the core 12 is entirely inward of the peripheral bond 38 of the barrier sheets 16, 18 as shown in FIG. 8, for example, the resulting pattern of bonds 44, 46, and 47 of the core 12 does not result in any sealed chambers within the bladder 20 that are not in fluid communication with the interior cavity' 21. In this way, the core 12 itself controls the final geometry of the inflated cushioning component 14 but does not affect the cushioning response of the cushioning component 14 under dynamic loading.

[0097] FIG. 8 illustrates the relative alignment of the sets of bonds 44, 46, and 47 afforded by the precise predetermined patterns of the anti-weld material 24 disposed on the first side 22 of the first polymeric sheet 10 (see FIG. 3), on the second side 13 of the second polymeric sheet 11 (see FIG. 1). and on the first side 15 of the second polymeric sheet 11 (see FIG. 2), respectively. Only some of the bonds 44, 46, and 47 are labelled with reference numbers for clarity in FIG. 8. It is clear from FIG. 6 and FIG. 8 that the bonds 47 of the third set alternate with the bonds 44 of the first set along a length of the core 12 (e.g., along a length of the first polymeric sheet 10 of the core 12) and hence along a length of the resulting cushioning component 14. It is also clear from FIGS. 4 and 8 that the bonds 47 of the third set alternate with the bonds 46 of the second set along the length of the core 12 (e.g., along a length of the second polymeric sheet 11 of the core 12) and hence along the length of the resulting cushioning component 14. With this configuration, as best indicated in FIGS. 8 and 10, at least some of the bonds 46 of the second set are aligned with the at least some of the bonds 44 of the first set. More specifically, the bonds 44 of the first set are disposed vertically above the bonds 46 of the second set with a bond 47 of the third set offset from and vertically at a height between that of bond 44, 46 of each vertically-stacked set of bonds 44, 46.

[0098] FIGS. 8 and 10 also show that a foremost bond 44E of the first set and a foremost bond 46E of the second set are further forward than a foremost bond 47E of the third set. Additionally, a rearmost bond 44F of the first set and a rearmost bond 46F of the second set are further rearward than a rearmost bond 47F of the third set. Placing the foremost and/or rearmost bonds near the top and/or the bottom of the core 12 (e.g., at the first set and/or at the second set) rather than interior to the core (e.g., at the third set) may further better distribute forces applied by the wearer over the core 12.

[0099] Additionally, as best shown in FIGS. 8 and 10, at least some of the bonds 46 of the second set are wider in a fore-aft direction of the core 12. of the cushioning component 14, and of the article of footwear 72 than the bonds 44 of the first set with which the bonds 46 of the second set are aligned. In the example shown, all of the bonds 46 of the second set are aligned with the bonds 44 of the first set. and each bond 46 of the second set is wider than the respective bond 44 of the first set with which the bond 46 of the second set is aligned. The bonds 46 of the second set that are wider than the bonds 44 of the first set are thus in both the forefoot region 50 and the heel region 54 as well as in the midfoot region 52 of the article of footwear 72. In other examples, the bonds 46 of the second set may be wider than the bonds 44 of the first set only in the forefoot region 50 or only in the heel region 54. for example. [00100] By providing wider bonds 46 that are disposed closer to the ground surface GS when the cushioning component 14 is incorporated into the article of footwear 72 as shown in FIG. 10, when inflated, the side with the narrower (e.g., shorter) bonds (e.g., the first barrier sheet 16 at the foot-facing side of the cushioning component 14) will allow for more pillowing between the bonds 44 of the first set than between the bonds 46 of the second set when inflated. The side with more pillowing (e.g., the first barrier sheet 16 at the foot-facing side) will contract more in overall length as the path of the material of the barrier sheet 16 at the foot-facing side (e.g.. the footbed side) is distributed vertically and horizontally. Accordingly, the first barrier sheet 16 at the foot-facing side with narrower bonds 44 will become more concave after inflation than the second barrier sheet 18 with the wider bonds 46 and may cause the overall shape of the cushioning component 14 to curve upwards at the forefoot region 50 and at the heel region 54 at the ground-facing side (e.g., at the second barrier sheet 18). Providing the narrower bonds 44 of the first set on the footbed side and the wider bonds 46 of the second set on the ground-facing side thus helps to shape the inflated cushioning component 14 to promote toe spring.

[00101] FIG. 10 shows that the tension created in the bonded polymeric sheets 10, 11 of the core 12 by the inflation of the interior cavity 21 causes portions of the first barrier sheet 16 inward of the outer perimeter 34 of the core 12 to be pulled downward at the bonds 44, as also indicated by the contoured exterior surface 39 of the first barrier sheet 16 in the slightly perspective top view of the FIG. 9. Because the outer perimeter 34 of the core 12 is entirely inward of the peripheral bond 38. the barrier sheets 16, 18 will not be tethered together at a peripheral portion 21 A of the interior cavity 21 that is outward of the outer perimeter 34 of the core 12 and inw ard of the peripheral bond 38. The distance between the inner surfaces 17 and 19 and the resulting height of the cushioning component 14 may thus be greatest outward of the core 12. The top exterior surface 39 is only partly shown and is represented with hidden lines in FIG. 10 where the first barrier sheet 16 is pulled downw ard by the first polymeric sheet 10 at the bonds 44.

[00102] Similarly, tension created in the bonded polymeric sheets 10, 11 of the core 12 by the inflation of the interior cavity 21 causes portions of the second barrier sheet 18 inward of the outer perimeter 34 of the core 12 to be pulled upw ard at the bonds 46, as indicated by the contoured exterior surface 41 of the second barrier sheet 18 in FIG. 10 (e.g., the bottom surface of the cushioning component 14). The pattern of anti -weld material 24 disposed on the polymeric sheets 10 and 11, and the resulting patterns of bonds 44, 46 of the polymeric sheets 10 and 11 to the barrier sheets 16, 18, respectively, can be selected to control the resulting contours of the exterior surfaces 39, 41 of the barrier sheets 16, 18.

[00103] FIG. 10 shows that the sole structure 70 also includes an outsole 73 secured to the bottom of the cushioning component 14 (e.g., to the second barrier sheet 18). A footwear upper 75 is secured to the sole structure 70 to support a foot over the cushioning component 14. The sole structure 70 is a non-limiting example, and the cushioning component 14 may be used in a sole structure with a different configuration than in FIG. 9. For example, there may be another midsole layer, such as a foam midsole layer, secured to and overlying the cushioning component 14 (e.g., secured to the first barrier sheet 16) with the upper 75 secured to the foam midsole layer.

[00104] Additionally, FIGS. 7-10 best show that the bonds 47 of the third set are offset from the bonds 46 of the second set and from the bonds 44 of the first set, and each bond 46 of the second set is wider than adjacent bonds 47 of the third set. [00105] As shown in FIG. 10, some or all of the nonlinear bonds 46 of the second set progressively decrease in width from the heel region 54 to the forefoot region 50 of the article of footwear 72. For example, the bonds 46 generally decrease in width from a bond 46F in the heel region 54 to a bond 46E in the forefoot region 50 in FIG. 8. In some implementations, the bonds 44 may also similarly decrease in width from the heel region 54 to the forefoot region 50.

[00106] Moreover, as is evident in FIGS. 8 and 10 the bonds 44 are spaced closer to one another in the forefoot region 50 than in the heel region 54, the bonds 46 are spaced closer to one another in the forefoot region 50 than in the heel region 54, and the bonds 47 are also spaced closer to one another in the forefoot region 50 than in the heel region 54. For example, as indicated in FIGS. 8 and 10, the plurality of nonlinear bonds includes a first group of bonds (e.g., adjacent bonds 44E and 44G) in the forefoot region 50 and a second group of bonds (e g., adjacent bonds 44F and 44H) in the heel region 54. Spacing between the adjacent bonds 44E and 44G of the first group of bonds is less than spacing between the adjacent bonds 44F and 44H of the second group of bonds such that the opposing inner surfaces 17, 19 of the barrier sheets 16, 18 are held closer to one another in the forefoot region 50 than in the heel region 54. This configuration also results in toe spring, which is the gradual increasing elevation of the second barrier sheet 18 away from the ground surface GS in the forefoot region 50 in a forward direction when in a steady state position (e.g., unloaded or at least not under a dynamic compressive load) as shown in FIG. 10. This pre-shaping of the cushioning component 14 with a toe spring via the bond placement helps to create a forward foot roll and easier toe-off during a forward motion of the wearer.

[00107] Referring to FIGS. 8-9. in addition to bond placement to promote toe spring, the outer perimeter 34 of the core 12 is spaced further inward of the peripheral bond 38 in the heel region 54 than in the forefoot region 50. This is best shown in FIG. 8 where a distance D2 from the outer perimeter 34 of the core 12 to the peripheral bond 38 in the heel region 54 is greater than a distance D3 from the outer perimeter 34 of the core 12 to the peripheral bond 38 in the forefoot region 50. This creates a larger and taller peripheral portion 21 A of the interior cavity 21 around the core 12 in the heel region 54 than in the forefoot region 50, as best shown in FIG. 10. The peripheral portion 21 A is disposed outward of the core 12 (e.g., forward of the core 12, rearward of the core 12, and further outward at the medial side 80 and at the lateral side 82). This causes the cushioning component 14 to nest around the heel where the bonds 44 on the first barrier sheet 16 tend to pull the barrier sheet 16 dow n inward of peripheral portion 21 A. Stated differently, as best shown in FIG. 9, the first barrier sheet 16 may recess slightly downward between the medial side 80 and the lateral side 82 above the core 12 in the heel region 54, helping to cup the heel.

[00108] FIGS. 11-13 show polymeric sheets 110 and 111 used to form a core 112 shown in FIGS. 14-16. The core 112 is included in a cushioning component 114 shown in FIGS. 16-19. More specifically, the cushioning component 114 is included in a sole structure 170 of an article of footwear 172 as shown in FIG. 19. As further explained herein, the cushioning component 114 includes a bladder 120 including barrier sheets 116 and 118 bonded to one another at a peripheral bond 138. The core 112 is disposed in the bladder 120 and bonded to inner surfaces 117, 119 of barrier sheets 116. 118 of the bladder 120, as shown in FIG. 16, to act as a tensile component. A tensile component such as the core 112 according to the present disclosure enables bonding the polymeric sheets 110, 111 to the barrier sheets 116, 118 at bonds 144 and 146, respectively, having paterns that result in technical advantages both in performance aspects of the cushioning component 114 and ease of manufacturing the cushioning component 114.

[00109] FIG. 11 is a plan view of a botom side of the polymeric sheet 111 with anti-weld material 24 disposed thereon. The polymeric sheet I l l is referred to herein as a second polymeric sheet. The side of the polymeric sheet show n in FIG. 11 is a second side 113 and is also referred to as a botom side or distal side as it is disposed further from the foot when the core 112 is incorporated in the sole structure 170 of the article of footwear 172. The second side 113 interfaces with and is bonded to the inner surface 119 of the second barrier sheet 118 as shown in FIG. 16 and discussed herein.

[00110] FIG. 12 is a plan view of an opposing first side 115 of the second polymeric sheet 111 with anti-weld material 24 disposed thereon in a different patern than on the second side 113 shown in FIG. 11 . The first side 115 is also referred to as the top side or as the proximal side of the second polymeric sheet 111 as it is disposed closer to the foot when the core 112 is incorporated in the sole structure 170 of the article of footwear 172.

[00111] As best shown in FIGS. 14-17 and 19, each of the core 1 12, the cushioning component 114, and the article of footw ear 172 includes the forefoot region 50, the heel region 54 , and the midfoot region 52 as described with respect to the cushioning component 14, the sole structure 70, and the article of footwear 72. Because the core 112 is of a shorter length than each of the cushioning component 1 14, the sole structure 170, and article of footwear 172, the forefoot region, midfoot region, and heel region of the core 112 are referred to as 50A, 52A, and 54A, respectively, as described with respect to the core 12.

[00112] More specifically, the forefoot region 50 and 50A generally includes portions of the article of footwear 172 or the core 112 corresponding with the toes and the joints connecting the metatarsals with the phalanges of a wearer’s foot. The midfoot region 52 and 52A generally includes portions of the article of footwear 172 or the core 112 corresponding with the arch area of the foot, and the heel region 54 and 54A corresponds with rear portions of the foot, including the calcaneus bone. Each of the core 112, the cushioning component 114, the sole structure 170, and the article of footwear 172 include a medial side 180 and a lateral side 182 similar to the medial side 80 and the lateral side 82 as previously described, that extend through each of forefoot region 50 and 50A, the midfoot region 52 and 52 A, and the heel region 54 and 54A, and fall on opposite sides of a longitudinal axis LM (also referred to herein as a longitudinal midline) of the cushioning component 114 in FIG. 17. The forefoot region 50 and 50A, the midfoot region 52 and 52A, the heel region 54 and 54A, the medial side 180, and the lateral side 182 are not intended to demarcate precise areas of footwear 172, the core 112, the cushioning component 114, or the sole structure 170, but are instead intended to represent general areas of the article of footwear 172, the core 112, the cushioning component 114. and the sole structure 170 to aid in the following discussion.

[00113] FIG. 13 is a plan view of a first side 122 of the first polymeric sheet 110 with anti-weld material 24 disposed thereon. The opposite second side 126 does not have any anti-weld material disposed thereon. The first polymeric sheet 110 is stacked on the second polymeric sheet 1 11 when the core 112 is assembled such that the second side 126 interfaces with and is bonded to the first side 115 of the second polymeric sheet 111 and the first side 122 interfaces with and is bonded to the inner surface 117 of the first barrier sheet 116 as shown in FIG. 16 and discussed herein.

[00114] The anti-weld material 24 is disposed on the polymeric sheets 110, 11 1 of the core 112 at areas that will be unbonded areas when the core 112 is thermally processed. By utilizing anti -weld material 24 disposed on the polymeric sheets 110, 111, the patterns of bonds of the core 112 to the inner surfaces 117, 119 of the barrier sheets 116. 118 (and the bonds of the second side 126 of the first polymeric sheet 110 to the first side 1 15 of the second polymeric sheet 1 1 1 ) are controlled to determine the final geometry of the completed cushioning component 114, including height differentials in different regions (e.g., forefoot region 50 and heel region 54) of the article of footwear 172, toe spring, etc. As shown in FIG. 16. portions of one or both of the inner surfaces 117, 119 that are outward of the outer perimeter 134 of the core 112 and inward of where the peripheral bond 138 is formed may also be preprinted or otherwise prepared with anti-weld material 24 or otherwise processed so that these portions of the inner surfaces 117, 119 will not bond to one another. This enables a peripheral portion 121 A of the interior cavity 121 outward of the core 112.

[00115] The anti-weld material 24 may be disposed on the polymeric sheets 110 and 111 (and on the portions of the inner surfaces 117, 119 of the first barrier sheet 1 16 and/or second barrier sheet 1 18 shown in FIG. 16) via a computer- controlled printer head or heads (not shown) according to a stored algorithm representing a predetermined printing pattern. The anti-weld material 24 may be printed according to a different predetermined programmed pattern for the first side 122 of the first polymeric sheet 110, the first side 115 of the second polymeric sheet 111, and the second side 113 of the second polymeric sheet 111 at all selected locations where bonding of the polymeric sheets 110, 111 of the core 112 to one another or to the barrier sheets 116, 118 is not desired. After trimming the sheets 110, 111 to establish the outer perimeters 134B, 134A and when bonded to one another such as by thermal processing, adjacent surfaces of the stacked, flat polymeric sheets 110, 111 and barrier sheets 116, 118 are bonded to one another except where the antiweld material 24 is disposed. Accordingly, the patterns of anti-weld material 24 determine corresponding patterns of resulting bonds in the finished cushioning component 114.

[00116] The predetermined pattern of anti -weld material 24 on the second side 113 of the second polymeric sheet 111 in FIG. 11 is referred to as a second predetermined pattern and results in a second set of bonds 146 discussed with respect to FIGS. 14, 16, 17, and 19. The predetermined pattern of anti-weld material 24 on the first side 115 of the second polymeric sheet 111 in FIG. 12 is referred to as a third predetermined pattern and results in a third set of bonds 147 discussed with respect to FIGS. 14-17 and 19. The predetermined pattern of anti-weld material 24 on the first side 122 of the first polymeric sheet 110 is referred to as a first predetermined pattern and results in a first set of bonds 144 discussed with respect to FIGS. 15-19.

[00117] With reference to FIG. 11, the anti-weld material 24 is disposed on the second side 113 of the second polymeric sheet 111 in the second predetermined pattern at spaced regions AZ, BZ, CZ. DZ, EZ, FZ, GZ. HZ, IZ, JZ, KZ, LZ, and MZ of deposited anti-weld material 24. Areas of the second side 113 of the second polymeric sheet 111 between any adjacent two of the spaced regions AZ, BZ, CZ, DZ, EZ, FZ, GZ, HZ, IZ, JZ, KZ, LZ, and MZ are free from anti-weld material 24. More specifically, area 113 A between adjacent regions AZ and BZ is free from antiweld material 24, area 113B between adjacent spaced regions BZ and CZ is free from anti-weld material 24, area 113C between adjacent spaced regions CZ and DZ is free from anti-weld material 24, area 113D between adjacent spaced regions DZ and EZ is free from anti-weld material 24, area 113E between adjacent spaced regions EZ and FZ is free from anti-weld material 24, area 113F between adjacent spaced regions FZ and GZ is free from anti- weld material 24. area 113G between adjacent spaced regions GZ and HZ is free from anti -weld material 24, area 113H between adjacent spaced regions HZ and IZ is free from anti-weld material 24, area 1 131 between adjacent spaced regions IZ and JZ is free from anti-weld material 24, area 113 J between adjacent spaced regions JZ and KZ is free from anti -weld material 24, area 113K between adjacent spaced regions KZ and LZ is free from anti-weld material 24, and area 113L between adjacent spaced regions LZ and MZ is free from anti-weld material 24. The areas 1 13A, 113B, 113C, 113D, 1 13E, 113F, 113G, 113H, 1131, 113J, 113K, and 113L will become a second set of bonds 146 shown in FIGS. 14, 16, 17, and 19 each corresponding with one of the areas 113A-113L.

[00118] Each of the areas 113A- 113L has a nonlinear shape such that the second set of bonds 146 are nonlinear bonds as further described with respect to FIG. 14. Nonlinear bonds discussed herein may also be referred to as wavy bonds. The second polymeric sheet 111 is trimmed to an outer perimeter 134A shown in FIGS. 14 and 16 after printing the anti-weld material 24 such that the areas AZ-MZ of anti-weld material 24 extend to the perimeter 134A and the areas 113A-113L and corresponding resulting bonds 146 also extend to the perimeter 134A at both the medial and lateral sides 180, 182.

[00119] With reference to FIG. 12, the anti-weld material 24 is disposed on the first side 115 of the second polymeric sheet 111 in the third predetermined pattern at spaced regions NZ, OZ, PZ, QZ, RZ, SZ, TZ, UZ, VZ, WZ, XZ, YZ, and ZZ of deposited anti-weld material 24. Areas of the first side 115 of the second polymeric sheet 111 between any adjacent two of the spaced regions NZ, OZ, PZ, QZ, RZ, SZ, TZ. UZ, VZ, WZ, XZ, YZ, and ZZ are free from anti-weld material 24. More specifically, area 1 15A between adjacent regions NZ and OZ is free from anti-weld material 24, area 115B between adjacent spaced regions OZ and PZ is free from antiweld material 24, area 115C between adjacent spaced regions PZ and QZ is free from anti-weld material 24, area 115D between adjacent spaced regions QZ and RZ is free from anti-weld material 24, area 115E between adjacent spaced regions RZ and SZ is free from anti-weld material 24, area 115F between adjacent spaced regions SZ and TZ is free from anti-weld material 24, area 115G between adjacent spaced regions TZ and UZ is free from anti-weld material 24, area 1 15H between adjacent spaced regions UZ and VZ is free from anti-weld material 24, area 1151 between adjacent spaced regions VZ and WZ is free from anti-weld material 24, area 115 J between adjacent spaced regions WZ and XZ is free from anti-weld material 24. area 115K between adjacent spaced regions XZ and YZ is free from anti-weld material 24, and area 115L between adjacent spaced regions YZ and ZZ is free from anti-weld material 24. The areas 115A, 115B, 115C, 115D, 115E, 115F, 115G, 115H, 1151, 115J, 115K, and 115L will become a third set of bonds 147 shown in FIGS. 14-17 and 19, each corresponding with one of the areas 115A-115L.

[00120] Each of the areas 115A-115L has a nonlinear shape such that the third set of bonds 147 are nonlinear bonds (e.g., waxy bonds) as further described w ith respect to FIG. 14. The second polymeric sheet 111 is trimmed to an outer perimeter 134 A shown in FIG. 14 and after printing the anti -weld material 24 such that the areas NZ-ZZ of anti-weld material 24 extend to the perimeter 134A and the areas 115A- 115L and corresponding resulting bonds 147 also extend to the perimeter 134 A.

[00121] With reference to FIG. 13, the anti-weld material 24 is disposed on the first side 122 of the first polymeric sheet 110 in the first predetermined pattern at spaced regions A1Z, BIZ, C1Z, DIZ, E1Z, F1Z, G1Z, H1Z, I1Z, J1Z, K1Z, and LIZ of deposited anti-weld material 24. Areas of the first side 122 of the first polymeric sheet 110 between any adjacent two of the spaced regions A1Z, BIZ, C1Z, DIZ, E1Z, F1Z, G1Z, H1Z, I1Z, J1Z, K1Z, and LIZ are free from anti-weld material 24. More specifically, area 122 A between adjacent regions A1Z and BIZ is free from anti -weld material 24, area 122B between adjacent spaced regions BIZ and C1Z is free from anti-weld material 24, area 122C between adjacent spaced regions C1Z and DIZ is free from anti-weld material 24, area 122D between adjacent spaced regions DIZ and E1Z is free from anti-weld material 24, area 122E between adjacent spaced regions E1Z and F1Z is free from anti-weld material 24, area 122F between adjacent spaced regions F1Z and G1Z is free from anti-weld material 24, area 122G between adjacent spaced regions G1Z and H1Z is free from anti-weld material 24, area 122H between adjacent spaced regions H1Z and UZ is free from anti-weld material 24, area 1221 between adjacent spaced regions 11Z and J1Z is free from anti-weld material 24, area 122J between adjacent spaced regions J1Z and K1Z is free from anti-weld material 24, and area 122K between adjacent spaced regions K1Z and LIZ is free from anti- weld material 24. The areas 122A, 122B, 122C, 122D, 122E, 122F, 122G, 122H, 1221, 122J, and 122K will become a first set of bonds 144 shown in FIGS. 15-19, each corresponding with one of the areas 122A-122K.

[00122] Each of the areas 122A-122K has a nonlinear shape such that the first set of bonds 144 are nonlinear bonds (e.g., wavy bonds) as further described with respect to FIG. 15. The first polymeric sheet 110 is trimmed to an outer perimeter 134B shown in FIGS. 15 and 16 and after printing the anti-weld material 24 such that the regions A1Z-L1Z of anti-weld material 24 extend to the outer perimeter 134B and the areas 122A-122K and corresponding resulting bonds 144 also extend to the outer perimeter 134B.

[00123] FIG. 14 is a plan view of the top side of a portion of the core 112 formed from the polymeric sheets of FIGS. 11-13, not showing the first polymeric sheet 110 or the barrier sheets 116, 118 to which the core 112 is bonded, but showing only the second polymeric sheet 111 as the lower core sheet when the core 112 is assembled in order to illustrate the relative locations of the third set of bonds 147 and the second set of bonds 146. The bonded areas at the top side (first side 115) are the third set of bonds 147 where the first side 115 of the second polymeric sheet 111 of the core 112 bonds to the bottom side (second side 126) of the first polymeric sheet 110 (not shown in FIG. 14) and are represented in solid. The bonded areas at the opposite bottom side 113 (second side) of the second polymeric sheet 111 are represented with dashed lines and are the second set of bonds 146 wherein the second side 113 of the second polymeric sheet 111 is bonded to the inner surface 119 of the second barrier sheet 1 18. The areas 1 15A-1 15L corresponding with each of the third set of bonds 147 and the areas 113A-113L corresponding with each of the second set of bonds 146 are also indicated with reference numbers. A forw ard end of the second side 113 of the second polymeric sheet 111 results in a bond 146 Al just forward of where blocker ink 24 was placed at region AZ in FIG. 1 1 (after trimming at the perimeter 134A).

[00124] FIG. 14 shows that the bonds 147 of the third set of bonds are offset from the bonds 146 of the second set of bonds in the longitudinal direction of the core 112 (e.g.. from a forefoot region 50A of the core 112 to a heel region 54A of the core 1 12). Stated differently, each bond 147 of the third set of bonds is disposed between tw o adjacent bonds 146 of the second set of bonds without overlapping with the second set of bonds 146. In this manner, the second polymeric sheet 1 11 will extend in the vertical direction as shown in FIG. 19 between adjacent bonds 146 and 147 when the interior cavity' 121 of the bladder 120 is inflated, tethering the second barrier sheet 118 to the first polymeric sheet 110.

[00125] Still referring to FIG. 14, each of the bonds 146 extends continuously from a medial end 146A of the bond 146 adjacent to a medial edge 180A of the core 112 to a lateral end 146B of the bond 146 adjacent to a lateral edge 182 A of the core 112. Only some of the medial ends 146A and lateral ends 146B are labeled in FIG. 14 for clarity in the drawing. In the embodiment shown, the medial end 146A is at the medial edge 180A and the lateral end 146B is at the lateral edge 182A.

[00126] Similarly, each of the bonds 147 extends continuously from a medial end 147A of the bond 147 adjacent to a medial edge 180A of the core 112 to a lateral end 147B of the bond 147 adjacent to a lateral edge 182A of the core 112. Only some of the medial ends 147A and lateral ends 147B are labeled in FIG. 14 for clarity in the drawing. In the embodiment shown, the medial end 147A is at the medial edge 180A and the lateral end 147B is at the lateral edge 182 A.

[00127] Configuring the bonds 146 and 147 to extend to the medial and lateral edges 180A, 182A of the core 112 may further increase the integrity of the connection of the core 112 to the barrier sheets 116, 118 via the bonds.

[00128] FIG. 14 also illustrates that the bonds 146 of the second set of bonds and the bonds 147 of the third set of bonds are wavy bonds. Stated differently, each of the bonds 146 and each of the bonds 147 has waves having peaks P1Z and valleys VIZ extending in a fore-aft direction when the core 1 12 is disposed in the article of footwear 172. For example, bond 147 at area 115C is illustrated having three peaks P1Z and two valleys VIZ. Adjacent bond 146 at area 113C has three peaks P1Z and three valleys VIZ. Some of the bonds 146, 147 have partial peaks or partial valleys near the perimeter 134 A. The peaks and valleys of the other bonds 146 and 147 are not labeled for clarity in the drawings. The number of peaks P1Z and valleys VIZ of each bond 146 and each bond 147 depends upon the w idth of the core 112 at the particular bond as spacing between peaks P1Z and valleys VIZ of each of the bonds 146 and 147 is maintained as relatively equal. By utilizing wavy bonds, the fore-aft extent of each bond (e.g., the longitudinal distance betw een a peak P1Z and a valley VIZ of the bond) is increased relative to a straight bond of the same width. This may increase the robustness of the bond and its ability to withstand repeated stresses, such as lateral forces, reducing the likelihood of delamination.

[00129] One or more of the bonds 144, 146, and/or 147 may be wider in a fore- aft direction of the core 112 at their medial end and at their lateral end than at a narrowed portion of the bond between the medial end and the lateral end. The fore-aft direction of the core 112 is a direction from the forefoot region 50A to the heel region 54A along the longitudinal axis LM.

[00130] Stresses on the core 112 may be greatest at the medial and lateral edges 180A, 182A. By configuring one or more of the bonds 144, 146. and/or 147 so that they are wider at their medial and lateral ends and/or by placing the medial and lateral ends at the medial edge 180 A and the lateral edge 182A of the core 112, greater force is required to overcome the bond and the risk of delamination of the core 112 from the barrier sheets 116, 118 is reduced. Stated differently, the wider ends reinforce the integrity of the bond at the medial and lateral edges 180A, 182A in comparison to a bond having narrower ends. Additionally, configuring the bonds to be relatively narrow between the ends enables greater vertical displacement of the barrier sheet 118 from the core adjacent to the narrower portion. The wider ends of the bond thus serve to reinforce the connection of the core 1 12 to the second barrier sheet 1 16 and/or 1 18 while more of the core 112 is free from (and further displaced from) the barrier sheet 116 and/or 118 near the narrowed portion. For example, one of the bonds 144 shown in FIG. 15 is indicated as having a width W9 at its medial end 144A and at its lateral end 144B that is greater than a width W10 at a narrowed portion 144C between the medial and lateral ends 144 A, 144B. A review of FIGS. 14 and 17 shows that the same is true for at least one of the bonds 146 and at least one of the bonds 147.

[00131] FIG. 15 is a plan view of a portion of the core 112 showing only the polymeric sheet 110 of FIG. 13 as an upper core sheet and representing bonded areas at the top side 122 of the polymeric sheet 110 in solid and bonded areas at the bottom side 126 of the polymeric sheet 110 in dashed lines in order to illustrate the relative locations of the third set of bonds 147 and the first set of bonds 144. The bonded areas at the top side (first side 122) are the first set of bonds 144 where the first side 122 of the first polymeric sheet 110 of the core 112 bonds to the inner surface 117 of the first barrier sheet 116. The bonded areas at the opposite bottom side 126 (second side) of the first polymeric sheet 110 are represented with dashed lines and are the third set of bonds 147 where the second side 126 of the first polymeric sheet 1 10 is bonded to the first side 115 of the second polymeric sheet 111. The areas 115A-115L corresponding with each of the third set of bonds 147 and the areas 122A-122K corresponding with each of the first set of bonds 144 are also indicated with reference numbers. A forward end of the first side 122 of the first polymeric sheet 110 results in a bond 144A1 just forward of where blocker ink 24 was placed at region A1Z in FIG. 13 (after trimming at perimeter 134B). A rear end of the first side 122 similarly results in a bond 144B1 just rearward of where blocker ink 24 was placed at region LIZ. FIG. 15 shows that the bonds 147 of the third set of bonds are offset from the bonds 144 of the first set of bonds in the longitudinal direction of the core 112 (e.g., from a forefoot region 50A of the core 112 to a heel region 54A of the core 112). Stated differently, each bond 147 of the third set of bonds is disposed between two adjacent bonds 144 of the first set of bonds without overlapping with the first set of bonds 144. In this manner, the first polymeric sheet 110 will extend in the vertical direction as shown in FIG. 19 between adjacent bonds 144 and 147 when the interior cavity 121 of the bladder 120 is inflated, tethering the first barrier sheet 116 to the first polymeric sheet 110 and tethering the second polymeric sheet 111 to the first polymeric sheet 110.

[00132] Each of the bonds 144 extends continuously from a medial end 144A of the bond 144 adjacent to the medial edge 180 A of the core 112 to a lateral end 144B of the bond 144 adjacent to the lateral edge 182A of the core 112. Only some of the medial ends 144A and lateral ends 144B are labeled in FIG. 15 for clarity in the drawing.

[00133] FIG. 15 also illustrates that the bonds of the first set of bonds 144 and the bonds of the third set of bonds 147 are w avy bonds. Stated differently, each of the bonds 144 and each of the bonds 147 has waves having peaks P1Z and valleys VIZ extending in a fore-aft direction when the core is disposed in the article of footwear 172. For example, bond 144 at area 122C is illustrated having three peaks P1Z and three valleys VIZ. Adjacent bond 147 at area 115D also has three peaks P1Z and three valleys VIZ (not labeled). The peaks and valleys of the other bonds 144, 147 are not labeled for clarity in the drawings. Some of the bonds 144, 147 have partial peaks or partial valleys near the outer perimeter 134B. The number of peaks P1Z and valleys VIZ of each bond 144, 147 depends upon the width of the core 112 at the particular bond as spacing between peaks P1Z and valleys VIZ of each of the bonds 144, 147 is maintained as relatively equal.

[00134] Referring again to FIG. 16, after trimming the first polymeric sheet

110 and the second polymeric sheet 111 to establish the respective outer perimeters 134B, 134A, the first polymeric sheet 110 is stacked on the second polymeric sheet

111 with the second side 113 of the second polymeric sheet 111 adjacent to the inner surface 119 of the second barrier sheet 118 and the first side 122 of the first polymeric sheet 110 adjacent to the inner surface 117 of the first barrier sheet 116. The aligned outer perimeters 134B and 134 A of the stacked polymeric sheets 110 and 111 establish and may together be referred to as an outer perimeter 134 of the core 112. In this relative positioning, the barrier sheets 116, 118 and the polymeric sheets 110, 111 are thermally processed to form the bonds 138, 144. 146, and 147 discussed herein. The first barrier sheet 116 and the second barrier sheet 118 together define the interior cavity 121 between the opposing inner surfaces 117, 119 of the first barrier sheet 116 and the second barrier sheet 118.

[00135] As shown in FIG. 16, the cushioning component 114 is relatively flat prior to inflation. Stated differently, the core 112 lays flat within the bladder 120 with the unbonded areas contacting the opposing inner surfaces 117, 119 when the interior cavity 121 of the bladder 120 is uninflated. The unbonded areas are as discussed with respect to FIGS. 11-15 and are where anti-weld material 24 is shown in FIG. 16. Only some of the areas with anti-weld material 24 are indicated with a reference number 24 in FIG. 16 for clarity in the drawing.

[00136] As indicated in FIG. 16, the polymeric sheets 1 1 and 11 1 are each shown as having the same thickness T1. The barrier sheets 116 and 118 are each shown as having the same thickness T2. The thickness T1 is not greater than the thickness T2 in the example shown. Maintaining a sheet thickness of each polymeric sheet 110 and 11 1 not greater than that of each of the barrier sheets 116 and 118 helps to ensure the flexibility of the core 112 to function as a tether that collapses back toward the relatively flat state of FIG. 16 relatively easily under compressive loading. [00137] As shown in FIGS. 16-19, the first barrier sheet 116 and the second barrier sheet 118 are sealed to one another along the peripheral bond 138 to enclose the interior cavity 121 and retain a gas in the interior cavity. The barrier sheets 116, 118 of the bladder 120 and the polymeric sheets 110 and 111 may be formed from any of the materials as described herein with respect to the barrier sheets 16, 18 and polymeric sheets 10, 11, respectively.

[00138] In FIG. 17, the bonds 144 of the first set are indicated with solid lines. The bonds 146 of the second set are indicated with dashed lines. The bonds 147 of the third set are indicated with a combination of dashed and dotted lines. As shown in FIG. 17, each bond 144, 146, and 147 of the plurality of nonlinear bonds extends continuously from a medial edge 134C of the core 112 to a lateral edge 134D of the core 112. The medial edge 134C is a portion of the perimeter 134 at a medial side 180 of the longitudinal axis LM. The lateral edge 134D is a portion of the perimeter 34 at a lateral side 182 of the longitudinal axis LM. The medial side 180 and lateral side 182 also describe the respective sides of the cushioning component 114 and the article of footwear 172 as well as its other components. By depositing the anti-weld material 24 so that it extends to an outer perimeter 134 of the core 112 at the inner surfaces 117, 119 of the barrier sheets 116, 118 and between the polymeric sheets 110, 111 (e.g., on the first side 115 of the second polymeric sheet 111), and by ensuring that the outer perimeter 134 of the core 112 is entirely inward of the peripheral bond 138 of the barrier sheets 116, 118 as shown in FIG. 17. for example, the resulting pattern of bonds 144, 146, and 147 of the core 112 does not result in any sealed chambers within the bladder 120 that are not in fluid communication with the interior cavity 121. In this way, the core 112 itself controls the final geometry of the inflated cushioning component 114 but does not affect the cushioning response of the cushioning component 114 under dynamic loading.

[00139] FIG. 17 illustrates the relative alignment of the sets of bonds 144, 146, and 147 afforded by the precise predetermined patterns of the anti-weld material 24 disposed on the first side 122 of the first polymeric sheet 110 (see FIG. 13), on the second side 113 of the second polymeric sheet 111 (see FIG. 11). and on the first side 115 of the second polymeric sheet 111 (see FIG. 12), respectively. Only some of the bonds 144, 146, and 147 are labelled with reference numbers for clarity⁷ in FIG. 17. It is clear from FIG. 16 and FIG. 17 that the bonds 147 of the third set alternate with the bonds 144 of the first set along a length of the core 112 (e.g., along a length of the first polymeric sheet 110 of the core 112) and hence along a length of the resulting cushioning component 1 14. It is also clear from FIGS. 16 and 17 that the bonds 147 of the third set alternate with the bonds 146 of the second set along the length of the core 112 (e.g., along a length of the second polymeric sheet 1 1 1 of the core 1 12) and hence along the length of the resulting cushioning component 114. With this configuration, as best indicated in FIGS. 17 and 19, at least some of the bonds 146 of the second set are aligned with the at least some of the bonds 144 of the first set. More specifically, the bonds 144 of the first set are disposed vertically above the bonds 146 of the second set with a bond 147 of the third set offset from and vertically at a height between that of bond 144, 146 of each vertically-stacked set of bonds 144, 146 when the article of footwear 172 is in the upright position with the outsole 173 resting on the ground surface GS as shown in FIG. 19.

[00140] FIGS. 17 and 19 also show that a foremost bond 144A1 of the first set and a foremost bond 146A1 of the second set are further forw ard than a foremost bond 147A1 of the third set. Additionally, a rearmost bond 144B1 of the first set and a rearmost bond 146B1 of the second set are further rearward than a rearmost bond 147B1 of the third set. Placing the foremost and/or rearmost bonds near the top and/or the bottom of the core 112 (e.g., at the first set and/or at the second set) rather than interior to the core 112 (e.g., at the third set) may further better distribute forces applied by the wearer over the core 112.

[00141] Additionally, as best shown in FIGS. 17 and 19, at least some of the bonds 146 of the second set are wider in a fore-aft direction of the core 112, of the cushioning component 114, and of the article of footw ear 172 than the bonds 144 of the first set with which the bonds 146 of the second set are aligned. In the example shown, all of the bonds 146 of the second set are aligned with the bonds 144 of the first set, and each bond 146 of the second set is wider than the respective bond 144 of the first set with which the bond 146 of the second set is aligned. The bonds 146 of the second set that are wider than the bonds 144 of the first set are thus in both the forefoot region 50 and the heel region 54 as well as in the midfoot region 52 of the article of footw ear 172. In other examples, the bonds 146 of the second set may be wider than the bonds 144 of the first set only in the forefoot region 50 or only in the heel region 54, for example.

[00142] By providing wider bonds 146 that are disposed closer to the ground surface GS when the cushioning component 114 is incorporated into the article of footwear 172 as shown in FIG. 19, when the cushioning component 114 is inflated, the side with the narrower (e.g., shorter) bonds (e.g., the first barrier sheet 116 at the foot-facing side of the cushioning component 114) will allow for more pillowing between the bonds 144 of the first set than between the bonds 146 of the second set when inflated. The side with more pillowing (e.g., the first barrier sheet 116 at the foot-facing side) will contract more in overall length as the path of the material of the barrier sheet 116 at the foot-facing side (e.g., the footbed side) is distributed vertically and horizontally. Accordingly, the first barrier sheet 116 at the foot-facing side with narrower bonds 144 will become more concave after inflation than the second barrier sheet 118 with the wider bonds 146 and may cause the overall shape of the cushioning component 114 to curve upwards at the forefoot region 50 and at the heel region 54 at the ground-facing side (e.g., at the second barrier sheet 118). Providing the narrower bonds 144 of the first set on the footbed side and the wider bonds 146 of the second set on the ground-facing side thus helps to shape the inflated cushioning component 114 to promote toe spring.

[00143] Referring to FIG. 17, a medial edge 190 of the bladder 120 defines a first notch 191. An inner medial edge 192 of the peripheral bond 138 protrudes laterally inward at the first notch 191. A lateral edge 193 of the bladder 120 defines a second notch 194. An inner lateral edge 195 of the peripheral bond 138 protrudes laterally inward at the second notch 194.

[00144] The first notch 191 is at least partially aligned with the second notch 194 in the transverse direction of the sole structure 170 such that a width WA of the interior cavity 121 in the lateral direction (also referred to as the transverse direction) of the sole structure 170 is narrowed between the first notch 191 and the second notch 194. For example, the width WB of the interior cavity 121 just forward of the notches 191, 194 is greater than the width WA. The width of the interior cavity 121 is measured perpendicular to the longitudinal axis LM. As can be seen in FIG. 17, the first and second notches 191, 194 are near a forward extent of the midfoot region 52. Alternatively, the notches 191, 194 may be in the forefoot region 50. Specifically, the first and second notches 191, 194 are placed in the vicinity of the metatarsal joints of a foot resting on the sole structure 170. The notches 191, 194 may be aligned with or just rearward of the metatarsal joints of a wearer, for example, such that flexing of the sole structure 170 during dorsiflexion at the metatarsal joints is eased by the notches 191, 194. With this placement and due to the narrowing of the interior cavity⁷ 121 in the lateral direction at the notches 191 , 194, the sole structure 170 is configured to flex at the first notch 191 and at the second notch 194 during dorsiflexion.

[00145] The medial edge 190 of the bladder 120 also defines a third notch 196 and the inner medial edge 192 of the peripheral bond 138 protrudes laterally inward at the third notch 196. The lateral edge 193 of the bladder 120 defines a fourth notch 197 and the inner lateral edge 195 of the peripheral bond 138 protrudes laterally inward at the fourth notch 197. The inner medial edge 192 of the peripheral bond 138 protrudes laterally inward at the third notch 196 and the inner lateral edge 195 of the peripheral bond 138 protrudes laterally inward at the fourth notch 197. The third and fourth notches 196, 197 are shown disposed in the heel region 54, near a forward extent of the heel region 54.

[00146] The third notch 196 is at least partially aligned with the fourth notch 197 in the transverse direction of the sole structure 170 such that a width of the interior cavity 121 in the lateral direction of the sole structure 170 is narrowed between the third notch 196 and the fourth notch 197, as can be seen by comparing the width WC between the third and fourth notches 196, 197, to the width WD just forward on the notches 196, 197.

[00147] As shown, the sole structure 170 is wider between the first notch 191 and the second notch 194 than between the third notch 196 and the fourth notch 197. Stated differently, the width WA is greater than the width WC. The outer perimeter 134 (e.g.. outer perimeters 134B, 134A, respectively) of polymeric sheets 110, 111 of the core 112 is spaced further inward of the peripheral bond 138 at the third notch 196 and the fourth notch 197 than at the first notch 191 and the second notch 194. For example, the distances WE and WF shown in FIG. 17 are greater than the distances WG and WH, respectively. The taller height of the bladder 120 in the heel region 54 is thus maintained at the third and fourth notches 196. 197 relatively to the height of the bladder 120 at the first and second notches 191, 194, as is evident in FIG. 19.

[00148] FIG. 19 shows that the tension created in the bonded polymeric sheets 110, 111 of the core 112 by the inflation of the interior cavity 121 causes portions of the first barrier sheet 116 inward of the outer perimeter 134 of the core 112 to be pulled downward at the bonds 144, as also indicated by the contoured exterior surface 139 of the first barrier sheet 116 in FIG. 18. Because the outer perimeter 134 of the core 112 is entirely inward of the peripheral bond 138, the barrier sheets 116, 118 will not be tethered together at a peripheral portion 121 A of the interior cavity 121 that is outward of the outer perimeter 134 of the core 112 and inward of the peripheral bond 138. The distance between the inner surfaces 117 and 119 and the resulting height of the cushioning component 114 may thus be greatest outward of the core 112. The top exterior surface 139 is only partly shown and is represented with hidden lines in FIG. 19 where the first barrier sheet 116 is pulled downward by the first polymeric sheet 110 at the bonds 144.

[00149] Similarly, tension created in the bonded polymeric sheets 110. I l l of the core 112 by the inflation of the interior cavity 121 causes portions of the second barrier sheet 118 inward of the outer perimeter 134 of the core 112 to be pulled upward at the bonds 146, as indicated by the contoured exterior surface 141 of the second barrier sheet 118 in FIG. 19 (e.g., the bottom surface of the cushioning component 114). The pattern of anti-weld material 24 disposed on the polymeric sheets 110 and 111, and the resulting patterns of bonds 144, 146 of the polymeric sheets 110 and 111 to the barrier sheets 116, 118, respectively, can be selected to control the resulting contours of the exterior surfaces 139, 141 of the barrier sheets 116, 118.

[00150] FIG. 19 shows that the sole structure 170 also includes an outsole 173 secured to the bottom of the cushioning component 114 (e.g., to the second barrier sheet 118). A footwear upper 175 is secured to the sole structure 170 to support a foot over the cushioning component 114. The sole structure 170 is a non-limiting example, and the cushioning component 114 may be used in a sole structure with a different configuration than in FIG. 19. For example, there may be another midsole layer, such as a foam midsole layer, secured to and overlying the cushioning component 114 (e.g.. secured to the first barrier sheet 116) with the upper 175 secured to the foam midsole layer.

[00151] Additionally, FIG. 19 best shows that the bonds 147 of the third set are offset from the bonds 146 of the second set and from the bonds 144 of the first set, and each bond 146 of the second set is wider than adjacent bonds 147 of the third set. [00152] As shown in FIG. 19. some or all of the nonlinear bonds 146 of the second set may progressively decrease in width from the heel region 54 to the forefoot region 50 of the article of footwear 172. For example, the bonds 146 generally decrease in width from the bond 146B1 in the heel region 54 to the bond 146A1 in the forefoot region 50 in FIG. 19. In some implementations, the bonds 144 may also similarly decrease in width from the heel region 54 to the forefoot region 50.

[00153] Moreover, as is evident in FIG. 19 the bonds 144 are spaced closer to one another in the forefoot region 50 than in the heel region 54. the bonds 146 are spaced closer to one another in the forefoot region 50 than in the heel region 54, and the bonds 147 are also spaced closer to one another in the forefoot region 50 than in the heel region 54. For example, as indicated in FIG. 19, the plurality of nonlinear bonds includes a first group of bonds (e.g., adjacent bonds 144A1 and 144G) in the forefoot region 50 and a second group of bonds (e.g., adjacent bonds 144B1 and 144H) in the heel region 54. Spacing between the adjacent bonds 144A1 and 144G of the first group of bonds is less than spacing between the adjacent bonds 144B1 and 144H of the second group of bonds such that the opposing inner surfaces 117, 119 of the barrier sheets 116, 118 are held closer to one another in the forefoot region 50 than in the heel region 54. This configuration also results in toe spring, which is the gradual increasing elevation of the second barrier sheet 118 away from the ground surface GS in the forefoot region 50 in a forward direction when in a steady state position (e.g., unloaded or at least not under a dynamic compressive load) as shown in FIG. 19. This pre-shaping of the cushioning component 114 with a toe spring via the bond placement helps to create a forw ard foot roll and easier toe-off during a forward motion of the w earer.

[00154] Referring to FIG. 17, in addition to bond placement to promote toe spring, the outer perimeter 134 of the core 112 is spaced further inward of the peripheral bond 138 in the heel region 54 than in the forefoot region 50. This is best show n in FIG. 17 w here a distance D2Z from the outer perimeter 134 of the core 112 to the peripheral bond 138 in the heel region 54 is greater than a distance D3Z from the outer perimeter 134 of the core 112 to the peripheral bond 138 in the forefoot region 50. This creates a larger and taller peripheral portion 121A of the interior cavity 121 around the core 112 in the heel region 54 than in the forefoot region 50, as best shown in FIGS. 18 and 19. The peripheral portion 121 A is disposed outward of the core 112 (e g., forward of the core 112, rearward of the core 112, and further outward at the medial side 180 and at the lateral side 182). This causes the cushioning component 114 to nest around the heel where the bonds 144 on the first barrier sheet 116 tend to pull the barrier sheet 116 down inw ard of peripheral portion 121 A. Stated differently, as best shown in FIG. 18, the first barrier sheet 1 16 may recess slightly downward between the medial side 180 and the lateral side 182 above the core 112 in the heel region 54, helping to cup the heel.

[00155] Accordingly, by providing an article of footwear that has a sole structure with notches at the medial and/or lateral edge of the bladder as shown and described, and with an inner medial edge of the peripheral bond protruding laterally inward at the first notch and an inner lateral edge of the peripheral bond protruding laterally inward at the second notch, increased flexibility of the sole structure is achieved in addition to the tethering via the core and cushioning charactenstics of the sole structure. In implementations in which a third and fourth notch are included as described herein, further flexibility is afforded.

[00156] The following Clauses provide example configurations of an article of footwear having a cushioning component as disclosed herein.

[00157] Clause 1. An article of footwear comprising: a sole structure having a cushioning component, the cushioning component including: a bladder including a first barrier sheet and a second barrier sheet defining an interior cavity betw een opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity; and a core disposed in the interior cavity and spaced entirely inw ard of the peripheral bond, the core including at least one polymeric sheet traversing the interior cavity between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonds to tether the first barrier sheet to the second barrier sheet, the at least one polymeric sheet displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet, the plurality of bonds including at least one bond extending continuously from a medial end of the at least one bond adjacent to a medial edge of the core to a lateral end of the at least one bond adjacent to a lateral edge of the core; wherein the at least one bond is wider in a fore- aft direction of the core at the medial end and at the lateral end than at a narrow ed portion of the at least one bond between the medial end and the lateral end; and wherein the plurality of bonds are configured such that the gas in the intenor cavity is in fluid communication around the at least one polymeric sheet without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity.

[00158] Clause 2. The article of footwear of clause 1, wherein the at least one bond is nonlinear.

[00159] Clause 3. The article of footwear of any of clauses 1-2, wherein the at least one bond has peaks and valleys extending in the fore-aft direction of the core.

[00160] Clause 4. The article of footwear of any of clauses 1-2, wherein the narrowed portion of the at least one bond is at a middle of the at least one bond in a transverse direction of the core.

[00161] Clause 5. The article of footwear of any of clauses 1-2, wherein the at least one bond is symmetrical in a transverse direction of the core about the narrowed portion along a majority of the at least one bond in the transverse direction.

[00162] Clause 6. The article of footwear of any of clauses 1-2, wherein each bond of the plurality of bonds extends continuously from the medial edge of the core to the lateral edge of the core and is wider in the fore-aft direction of the core at the medial edge and at the lateral edge than at a narrowed portion of the bond between the medial edge and the lateral edge.

[00163] Clause 7. The article of footwear of any of clauses 1-2, wherein antiweld material is disposed on the core at the unbonded areas.

[00164] Clause 8. The article of footwear of any of clauses 1-2, wherein the core lays flat within the bladder with the unbonded areas contacting the opposing inner surfaces when the interior cavity of the bladder is uninflated.

[00165] Clause 9. The article of footwear of any of clauses 1-2, wherein a thickness of each polymeric sheet of the at least one polymeric sheet of the core is less than or equal to a thickness of the first barrier sheet and is less than or equal to than a thickness of the second barrier sheet.

[00166] Clause 10. The article of footwear of any of clauses 1-2, wherein: the plurality of bonds includes a first group of bonds in a forefoot region of the article of footwear and a second group of bonds in a heel region of the article of footwear; and spacing in the fore-aft direction of the core between adjacent bonds of the first group of bonds is less than spacing in the fore-aft direction of the core between adjacent bonds of the second group of bonds such that the opposing inner surfaces are held closer to one another by the at least one polymeric sheet of the core in the forefoot region than in the heel region.

[00167] Clause 11. The cushioning component of any of clauses 1-2, wherein an outer perimeter of the at least one polymeric sheet of the core is spaced further inward of the peripheral bond in a heel region of the article of footwear than in a forefoot region of the article of footwear.

[00168] Clause 12. The article of footwear of any of clauses 1-2, wherein: the opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the at least one polymeric sheet of the core includes a first polymeric sheet and a second polymeric sheet, the first polymeric sheet disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces the first inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces the second inner surface of the second barrier sheet; and the first side of the first polymeric sheet is directly bonded to the first inner surface of the first barrier sheet at a first set of bonds of the plurality of bonds, the second side of the second polymeric sheet is directly bonded to the second inner surface of the second barrier sheet at a second set of bonds of the plurality⁷ of bonds, the second side of the first polymeric sheet is directly bonded to the first side of the second polymeric sheet at a third set of bonds of the plurality of bonds, the bonds of the third set alternating with the bonds of the first set along a length of the core, and the bonds of the third set alternating with the bonds of the second set along the length of the core.

[00169] Clause 13. The article of footw ear of clause 12, wherein each of the first set, the second set, and the third set includes at least one bond that extends continuously from the medial edge of the core to the lateral edge of the core and is wider in the fore-aft direction of the core at the medial edge and at the lateral edge than at a narrow ed portion of the bond betw een the medial edge and the lateral edge. [00170] Clause 14. The article of footwear of clause 13, wherein a difference between a width at the medial edge and a width at the narrowed portion of the at least one bond of the second set is greater than a difference between a width at the medial edge and a width at the narrowed portion of the at least one bond of the first set. [00171 ] Clause 15. The article of footwear of clause 13, wherein a difference between a width at the medial edge and a width at the narrowed portion of the at least one bond of the second set is greater than a difference between a width at the medial edge and a width at the narrowed portion of the at least one bond of the third set. [00172] Clause 16. The article of footwear of clause 12, wherein a foremost bond of the first set and a foremost bond of the second set are further forward than a foremost bond of the third set.

[00173] Clause 17. The article of footwear of clause 12, wherein a rearmost bond of the first set and a rearmost bond of the second set are further rearward than a rearmost bond of the third set.

[00174] Clause 18. The article of footwear of clause 12, wherein at least some of the bonds of the second set are aligned with the at least some of the bonds of the first set along the length of the core when the interior cavity of the bladder is in an uninflated state.

[00175] Clause 19. The article of footwear of clause 18, wherein the at least some of the bonds of the second set are wider in the fore-aft direction of the core than the at least some of the bonds of the first set with which the at least some of the bonds of the second set are aligned.

[00176] Clause 20. The article of footwear of clause 19, wherein the at least some of the bonds of the second set are in a forefoot region of the article of footwear. [00177] Clause 21. The article of footwear of clause 19, wherein the at least some of the bonds of the second set are in a heel region of the article of footwear.

[00178] Clause 22. The article of footwear of clause 19, wherein: all of the bonds of the second set are aligned with the bonds of the first set; and each bond of the second set is wider in the fore-aft direction of the core than the respective bond of the first set with which the bond of the second set is aligned.

[00179] Clause 23. The article of footwear of clause 19, wherein each bond of the second set is wider in the fore-aft direction of the core than adjacent bonds of the third set.

[00180] Clause 24. An article of footwear comprising: a sole structure having a cushioning component, the cushioning component including: a bladder including a first barrier sheet and a second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity; and a core disposed in the interior cavity' and spaced entirely inward of the peripheral bond, the core including at least one polymeric sheet traversing the interior cavity’ between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of nonlinear bonds to tether the first barrier sheet to the second barrier sheet, the at least one polymeric sheet displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet such that the gas in the interior cavity is in fluid communication around the at least one polymeric sheet without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity'; and at least some of the plurality of nonlinear bonds have linear segments.

[00181] Clause 25. The article of footwear of clause 24, wherein anti-weld material is disposed on the core at the unbonded areas.

[00182] Clause 26. The article of footwear of any of clauses 24-25, wherein the core lays flat within the bladder with the unbonded areas contacting the opposing inner surfaces when the interior cavity of the bladder is uninflated.

[00183] Clause 27. The article of footwear of any of clauses 24-25, wherein a thickness of each polymeric sheet of the at least one polymeric sheet of the core is less than or equal to a thickness of the first barrier sheet and is less than or equal to than a thickness of the second barrier sheet.

[00184] Clause 28. The article of footwear of any of clauses 24-25, wherein: the plurality of nonlinear bonds includes a first group of bonds in a forefoot region of the article of footwear and a second group of bonds in a heel region of the article of footwear; and spacing in a fore-aft direction of the core between adjacent bonds of the first group of bonds is less than spacing in the fore-aft direction of the core between adjacent bonds of the second group of bonds such that the opposing inner surfaces are held closer to one another by the at least one polymeric sheet in the forefoot region than in the heel region.

[00185] Clause 29. The cushioning component of any of clauses 24-25, wherein an outer perimeter of the at least one polymeric sheet of the core is spaced further inward of the peripheral bond in a heel region of the article of footwear than in a forefoot region of the article of footwear. [00186] Clause 30. The article of footwear of any of clauses 24-25, wherein: the opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the at least one polymeric sheet of the core includes a first polymeric sheet and a second polymeric sheet, the first polymeric sheet disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces the first inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces the second inner surface of the second barrier sheet; and the first side of the first polymeric sheet is directly bonded to the first inner surface of the first barrier sheet at a first set of bonds of the plurality of nonlinear bonds, the second side of the second polymeric sheet is directly bonded to the second inner surface of the second barrier sheet at a second set of bonds of the plurality of nonlinear bonds, the second side of the first polymeric sheet is directly bonded to the first side of the second polymeric sheet at a third set of bonds of the plurality of nonlinear bonds, the bonds of the third set alternating with the bonds of the first set along a length of the core, and the bonds of the third set alternating with the bonds of the second set along the length of the core.

[00187] Clause 31. The article of footwear of clause 30, wherein at least some of the bonds of the second set are aligned with the at least some of the bonds of the first set when the interior cavity of the bladder is in an uninflated state.

[00188] Clause 32. The article of footwear of clause 31 , wherein the at least some of the bonds of the second set are wider in a fore-aft direction of the core than the at least some of the bonds of the first set with which the at least some of the bonds of the second set are aligned.

[00189] Clause 33. The article of footwear of clause 32, wherein the at least some of the bonds of the second set are in a forefoot region of the article of footwear. [00190] Clause 34. The article of footwear of clause 32, wherein the at least some of the bonds of the second set are in a heel region of the article of footwear. [00191] Clause 35. The article of footwear of clause 32. wherein: all of the bonds of the second set are aligned with the bonds of the first set; and each bond of the second set is wider in the fore-aft direction of the core than the respective bond of the first set with which the bond of the second set is aligned.

[00192] Clause 36. The article of footwear of clause 32, wherein each bond of the second set is wider in the fore-aft direction of the core than adjacent bonds of the third set.

[00193] Clause 37. An article of footwear comprising: a sole structure having a cushioning component, the cushioning component including: a bladder including a first barrier sheet and a second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity⁷; and a core disposed in the interior cavity and spaced entirely inward of the peripheral bond, the core including at least one polymeric sheet traversing the interior cavity⁷ between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonds to tether the first barrier sheet to the second barrier sheet, the at least one polymeric sheet displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet; wherein a medial edge of the bladder defines a first notch and an inner medial edge of the peripheral bond protrudes laterally inward at the first notch; w herein a lateral edge of the bladder defines a second notch and an inner lateral edge of the peripheral bond protrudes laterally inward at the second notch; and wherein the plurality of bonds are configured such that the gas in the interior cavity is in fluid communication around the at least one polymeric sheet without the at least one polymeric sheet creating any⁷ sealed chambers within the bladder that are not in fluid communication with the interior cavity⁷.

[00194] Clause 38. The article of footwear of clause 37, wherein the first notch is at least partially aligned with the second notch in a transverse direction of the sole structure such that a width of the interior cavity in a lateral direction of the sole structure is narrowed between the first notch and the second notch.

[00195] Clause 39. The article of footw ear of any of clauses 37-38, wherein the sole structure is configured to flex at the first notch and at the second notch during dorsiflexion. [00196] Clause 40. The article of footwear of any of clauses 37-38, wherein the first notch and the second notch are disposed in a forefoot region or in a midfoot region of the article of footwear.

[00197] Clause 41. The article of footwear of clause 40, wherein: the medial edge of the bladder defines a third notch and the inner medial edge of the peripheral bond protrudes laterally inward at the third notch; and the lateral edge of the bladder defines a fourth notch and the inner lateral edge of the peripheral bond protrudes laterally inward at the fourth notch.

[00198] Clause 42. The article of footwear of clause 41. wherein the third notch is at least partially aligned with the fourth notch in a transverse direction of the sole structure such that a width of the interior cavity' in a lateral direction of the sole structure is narrowed between the third notch and the fourth notch.

[00199] Clause 43. The article of footwear of clause 41, wherein the third notch and the fourth notch are disposed in a heel region of the article of footwear.

[00200] Clause 44. The article of footwear of any of clauses 37-38, wherein the plurality' of bonds include at least one bond having a medial end adjacent to or at the medial edge of the core and a lateral end adjacent to or at a lateral edge of the core, the at least one bond extending continuously from the medial end of the at least one bond to the lateral end of the at least one bond.

[00201] Clause 45. The article of footwear of clause 44, wherein the at least one bond is nonlinear.

[00202] Clause 46. The article of footwear of clause 44, wherein the at least one bond has peaks and valleys extending in a fore-aft direction of the core.

[00203] Clause 47. The article of footwear of any of clauses 37-38, wherein anti-weld material is disposed on the core at the unbonded areas.

[00204] Clause 48. The article of footwear of any of clauses 37-38, wherein the core lays flat within the bladder with the unbonded areas contacting the opposing inner surfaces when the interior cavity⁷ of the bladder is uninflated.

[00205] Clause 49. The article of footwear of any of clauses 37-38, wherein a thickness of each polymeric sheet of the at least one polymeric sheet of the core is less than or equal to a thickness of the first barrier sheet and is less than or equal to than a thickness of the second barrier sheet. [00206] Clause 50. The article of footwear of any of clauses 37-38, wherein: the plurality⁷ of bonds includes a first group of bonds in a forefoot region of the article of footwear and a second group of bonds in a heel region of the article of footwear; and spacing in a fore-aft direction of the core between adjacent bonds of the first group of bonds is less than spacing in the fore-aft direction of the core between adjacent bonds of the second group of bonds such that the opposing inner surfaces are held closer to one another by the at least one polymeric sheet of the core in the forefoot region than in the heel region.

[00207] Clause 51. The article of footwear of any of clauses 37-38, wherein an outer perimeter of the at least one polymeric sheet of the core is spaced further inward of the peripheral bond in a heel region of the article of footwear than in a forefoot region of the article of footwear.

[00208] Clause 52. The article of footwear of any of clauses 37-38, wherein: the opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the at least one polymeric sheet of the core includes a first polymeric sheet and a second polymeric sheet, the first polymeric sheet disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces the first inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces the second inner surface of the second barrier sheet; and the first side of the first polymeric sheet is directly bonded to the first inner surface of the first barrier sheet at a first set of bonds of the plurality⁷ of bonds, the second side of the second polymeric sheet is directly bonded to the second inner surface of the second barrier sheet at a second set of bonds of the plurality of bonds, the second side of the first polymeric sheet is directly bonded to the first side of the second polymeric sheet at a third set of bonds of the plurality of bonds, the bonds of the third set alternating with the bonds of the first set along a length of the core, and the bonds of the third set alternating with the bonds of the second set along the length of the core. [00209] Clause 53. The article of footwear of clause 52, wherein each of the first set, the second set, and the third set includes at least one bond that extends continuously from the medial edge of the core to the lateral edge of the core.

[00210] Clause 54. The article of footwear of clause 52, wherein a foremost bond of the first set and a foremost bond of the second set are further forward than a foremost bond of the third set.

[00211] Clause 55. The article of footwear of clause 52, wherein a rearmost bond of the first set and a rearmost bond of the second set are further rearward than a rearmost bond of the third set.

[00212] Clause 56. The article of footwear of clause 52, wherein at least some of the bonds of the second set are aligned w ith the at least some of the bonds of the first set along the length of the core when the interior cavity of the bladder is in an uninflated state.

[00213] Clause 21. The article of footwear of clause 20, w herein the at least some of the bonds of the second set are wider in a fore-aft direction of the core than the at least some of the bonds of the first set with which the at least some of the bonds of the second set are aligned.

[00214] Clause 57. The article of footwear of clause 56, wherein the at least some of the bonds of the second set are in a forefoot region of the article of footwear. [00215] Clause 59. An article of footwear comprising: a sole structure having a cushioning component, the cushioning component including: a bladder including a first barrier sheet and a second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity; and a core disposed in the interior cavity and spaced entirely inward of the peripheral bond, the core including at least one polymeric sheet traversing the interior cavity between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonds to tether the first barrier sheet to the second barrier sheet, the at least one polymeric sheet displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet; wherein a medial edge of the bladder and a lateral edge of the bladder respectively define a first notch and a second notch at least partially aligned with the first notch in one of a forefoot region or a midfoot region of the sole structure such that an inner medial edge of the peripheral bond protrudes laterally inward at the first notch and an inner lateral edge of the peripheral bond protrudes laterally inward at the second notch; wherein the medial edge of the bladder and the lateral edge of the bladder respectively define a third notch and a fourth notch at least partially aligned with the third notch in a heel region of the sole structure such that the inner medial edge of the peripheral bond protrudes laterally inward at the third notch and the inner lateral edge of the peripheral bond protrudes laterally inward at the fourth notch; and wherein the plurality of bonds are configured such that the gas in the interior cavity is in fluid communication around the at least one polymeric sheet without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity.

[00216] Clause 60. The article of footwear of clause 59, wherein: the sole structure is wider between the first notch and the second notch than between the third notch and the fourth notch; and an outer perimeter of the at least one polymeric sheet of the core is spaced further inward of the peripheral bond at the third notch and the fourth notch than at the first notch and the second notch.

[00217] Clause 61. The article of footwear of clause 59, wherein the sole structure further includes: an outsole secured to a distal surface of the bladder and extending at least partially upward along sidewalls of the bladder.

[00218] To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Additionally, all references referred to are incorporated herein in their entirety.

[00219] An ‘‘article of footwear”, a “footwear article of manufacture”, and “footwear” may be considered to be both a machine and a manufacture. Assembled, ready to wear footwear articles (e.g., shoes, sandals, boots, etc.), as well as discrete components of footwear articles (such as a midsole, an outsole, an upper component, etc.) prior to final assembly into ready-to-wear footwear articles, are considered and alternatively referred to herein in either the singular or plural as “article(s) of footwear”.

[00220] “A”, “an”, “the”, “at least one”, and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality⁷ of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term ■‘about’’ whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.

[00221] The terms “comprising”, “including”, and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term "or" includes any one and all combinations of the associated listed items. The term “any of’ is understood to include any possible combination of referenced items, including “any one of’ the referenced items. The term “any of’ is understood to include any possible combination of referenced claims of the appended claims, including “any one of’ the referenced claims.

[00222] For consistency and convenience, directional adjectives may be employed throughout this detailed description corresponding to the illustrated embodiments. Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may be used descriptively relative to the figures, without representing limitations on the scope of the invention, as defined by the claims.

[00223] The term “longitudinal” particularly refers to a direction extending a length of a component. For example, a longitudinal direction of a shoe extends between a forefoot region and a heel region of the shoe. The term “forward” or “anterior” is used to particularly refer to the general direction from a heel region toward a forefoot region, and the term “rearward” or “posterior” is used to particularly refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

[00224] The term “transverse” particularly refers to a direction extending a width of a component. For example, a transverse direction of a shoe extends between a lateral side and a medial side of the shoe. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

[00225] The term “vertical” particularly refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole. The term “upward” or “upwards” particularly refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term “downward” or "downw ards" particularly refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.

[00226] The “interior” of an article of footwear, such as a shoe, particularly refers to portions at the space that is occupied by a wearer’s foot when the shoe is worn. The “inner side” of a component particularly refers to the side or surface of the component that is (or will be) oriented tow ard the interior of the component or article of footwear in an assembled article of footwear. The “outer side” or “exterior” of a component particularly refers to the side or surface of the component that is (or will be) oriented aw ay from the interior of the shoe in an assembled shoe. In some cases, other components may be betw een the inner side of a component and the interior in the assembled article of footwear. Similarly, other components may be between an outer side of a component and the space external to the assembled article of footwear. Further, the terms “inward” and “inwardly” particularly refer to the direction toward the interior of the component or article of footwear, such as a shoe, and the terms “outward” and “outwardly” particularly refer to the direction toward the exterior of the component or article of footwear, such as the shoe. In addition, the term “proximal” particularly refers to a direction that is nearer a center of a footwear component, or is closer toward a foot when the foot is inserted in the article of footwear as it is worn by a user. Likewise, the term “distal” particularly refers to a relative position that is further away from a center of the footwear component or is further from a foot when the foot is inserted in the article of footwear as it is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposing terms to describe relative spatial positions.

[00227] While various embodiments have been described, the description is intended to be exemplary', rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

[00228] While several modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary' of the entire range of alternative embodiments that an ordinarily skilled artisan would recognize as implied by, structurally and/or functionally equivalent to, or otherwise rendered obvious based upon the included content, and not as limited solely to those explicitly depicted and/or described embodiments.

Claims

WHAT IS CLAIMED IS:

1. An article of footwear comprising: a sole structure having a cushioning component, the cushioning component including: a bladder including a first barrier sheet and a second barrier sheet defining an interior cavity between opposing inner surfaces of the first barrier sheet and the second barrier sheet, the first barrier sheet and the second barrier sheet sealed to one another along a peripheral bond to enclose the interior cavity and retain a gas in the interior cavity: and a core disposed in the interior cavity and spaced entirely inward of the peripheral bond, the core including at least one polymeric sheet traversing the interior cavity between and directly bonded to the opposing inner surfaces of the first barrier sheet and the second barrier sheet at a plurality of bonds to tether the first barrier sheet to the second barrier sheet, the at least one polymeric sheet displaced from the opposing inner surfaces by the gas at unbonded areas of the at least one polymeric sheet, the plurality of bonds including at least one bond extending continuously from a medial end of the at least one bond adjacent to a medial edge of the core to a lateral end of the at least one bond adjacent to a lateral edge of the core; wherein the at least one bond is wider in a fore-aft direction of the core at the medial end and at the lateral end than at a narrowed portion of the at least one bond between the medial end and the lateral end; and wherein the plurality’ of bonds are configured such that the gas in the interior cavity is in fluid communication around the at least one polymeric sheet without the at least one polymeric sheet creating any sealed chambers within the bladder that are not in fluid communication with the interior cavity.

2. The article of footwear of claim 1, wherein the at least one bond is nonlinear.

3. The article of footwear of claim 2. wherein the at least one bond that is nonlinear has linear segments.

4. The article of footwear of any of claims 1 -2, wherein the at least one bond has peaks and valleys extending in the fore-aft direction of the core.

5. The article of footwear of any of claims 1-2. wherein the narrowed portion of the at least one bond is at a middle of the at least one bond in a transverse direction of the core.

6. The article of footwear of any of claims 1-2, wherein the at least one bond is symmetrical in a transverse direction of the core about the narrowed portion along a majority of the at least one bond in the transverse direction.

7. The article of footwear of any of claims 1-2, wherein each bond of the plurality of bonds extends continuously from the medial edge of the core to the lateral edge of the core and is wider in the fore-aft direction of the core at the medial edge and at the lateral edge than at a narrowed portion of the bond between the medial edge and the lateral edge.

8. The article of footwear of any of claims 1-2, wherein anti -weld material is disposed on the core at the unbonded areas.

9. The article of footwear of any of claims 1-2, wherein the core lays flat within the bladder with the unbonded areas contacting the opposing inner surfaces when the interior cavity of the bladder is uninflated.

10. The article of footwear of any of claims 1 -2, wherein a medial edge of the bladder defines a first notch and an inner medial edge of the peripheral bond protrudes laterally inward at the first notch; and/or wherein a lateral edge of the bladder defines a second notch and an inner lateral edge of the peripheral bond protrudes laterally inward at the second notch.

11. The article of footwear of any of claims 1 -2. wherein: the plurality of bonds includes a first group of bonds in a forefoot region of the article of footwear and a second group of bonds in a heel region of the article of footwear; and spacing in the fore-aft direction of the core between adjacent bonds of the first group of bonds is less than spacing in the fore-aft direction of the core between adjacent bonds of the second group of bonds such that the opposing inner surfaces are held closer to one another by the at least one polymeric sheet of the core in the forefoot region than in the heel region.

12. The cushioning component of any of claims 1 -2, wherein an outer perimeter of the at least one polymeric sheet of the core is spaced further inward of the peripheral bond in a heel region of the article of footwear than in a forefoot region of the article of footwear.

13. The article of footwear of any of claims 1-2, wherein: the opposing inner surfaces of the bladder include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet; the at least one polymeric sheet of the core includes a first polymeric sheet and a second polymeric sheet, the first polymeric sheet disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces the first inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces the second inner surface of the second barrier sheet; and the first side of the first polymeric sheet is directly bonded to the first inner surface of the first barrier sheet at a first set of bonds of the plurality of bonds, the second side of the second polymeric sheet is directly bonded to the second inner surface of the second barrier sheet at a second set of bonds of the plurality of bonds, the second side of the first polymeric sheet is directly bonded to the first side of the second polymenc sheet at a third set of bonds of the plurality of bonds, the bonds of the third set alternating with the bonds of the first set along a length of the core, and the bonds of the third set alternating with the bonds of the second set along the length of the core.

14. The article of footwear of claim 13, wherein each of the first set, the second set, and the third set includes at least one bond that extends continuously from the medial edge of the core to the lateral edge of the core and is wider in the fore-aft direction of the core at the medial edge and at the lateral edge than at a narrowed portion of the bond between the medial edge and the lateral edge.

15. The article of footwear of claim 14, wherein a difference between a width at the medial edge and a width at the narrow ed portion of the at least one bond of the second set is greater than a difference between a width at the medial edge and a width at the narrowed portion of the at least one bond of the first set.

1 . The article of footwear of claim 14, wherein a difference between a width at the medial edge and a width at the narrow ed portion of the at least one bond of the second set is greater than a difference between a width at the medial edge and a width at the narrowed portion of the at least one bond of the third set.

17. The article of footwear of claim 14, wherein a foremost bond of the first set and a foremost bond of the second set are further forward than a foremost bond of the third set.

18. The article of footwear of claim 14, wherein a rearmost bond of the first set and a rearmost bond of the second set are further rearward than a rearmost bond of the third set.

19. The article of footwear of claim 14, wherein at least some of the bonds of the second set are aligned with the at least some of the bonds of the first set along the length of the core when the interior cavity of the bladder is in an uninflated state.

20. The article of footwear of claim 19, wherein the at least some of the bonds of the second set are wider in the fore-aft direction of the core than the at least some of the bonds of the first set with which the at least some of the bonds of the second set are aligned.