Abstract: An article of footwear including an upper and a sole structure. The sole structure includes a midsole, wherein the midsole includes an enclosed cavity, a thermoformed cushioning element disposed within the enclosed cavity, wherein the cushioning element includes an upper barrier film and a bottom barrier film enclosing an internal volume, and an outsole layer, wherein the outsole layer forms a ground-engaging surface of the article of footwear.

Abstract: A method of manufacturing a cushioning article comprises wrapping a polymeric sheet around a support so that the polymeric sheet surrounds a perimeter of the support. A first portion of the polymeric sheet adjacent a first side edge of the polymeric sheet overlaps and is stacked on a second portion of the polymeric sheet adjacent a second side edge of the polymeric sheet. The first portion is welded to the second portion at a first weld disposed between the first side edge and the second side edge while the polymeric sheet is wrapped around the support so that the polymeric sheet forms an open-ended sheath with a top wall, a bottom wall, a first side wall and a second side wall with the first weld disposed at only one of the top wall and the bottom wall. A cushioning article manufactured according to the method is disclosed.

Abstract: A method of manufacturing a cushioning article comprises wrapping a polymeric sheet around a support so that the polymeric sheet surrounds a perimeter of the support. A first portion of the polymeric sheet adjacent a first side edge of the polymeric sheet overlaps and is stacked on a second portion of the polymeric sheet adjacent a second side edge of the polymeric sheet. The first portion is welded to the second portion at a first weld disposed between the first side edge and the second side edge while the polymeric sheet is wrapped around the support so that the polymeric sheet forms an open-ended sheath with a top wall, a bottom wall, a first side wall and a second side wall with the first weld disposed at only one of the top wall and the bottom wall. A cushioning article manufactured according to the method is disclosed.

Abstract: A method of manufacturing a cushioning article comprises wrapping a polymeric sheet around a support so that the polymeric sheet surrounds a perimeter of the support. A first portion of the polymeric sheet adjacent a first side edge of the polymeric sheet overlaps and is stacked on a second portion of the polymeric sheet adjacent a second side edge of the polymeric sheet. The first portion is welded to the second portion at a first weld disposed between the first side edge and the second side edge while the polymeric sheet is wrapped around the support so that the polymeric sheet forms an open-ended sheath with a top wall, a bottom wall, a first side wall and a second side wall with the first weld disposed at only one of the top wall and the bottom wall. A cushioning article manufactured according to the method is disclosed.

Abstract: An athletic shoe has a sole with a rearfoot strike zone segmented from the remaining heel area by a line of flexion which permits articulation of the strike zone during initial heel strike of a runner. The line of flexion is located to delimit a rearfoot strike zone reflecting the heel to toe running style of the majority of the running population. In addition to allowing articulation of the rearfoot strike zone about the line of flexion, the sole incorporates cushioning elements, including a resilient gas filled bladder, to provide differential cushioning characteristics in different parts of the heel, to attenuate force applications and shock associated with heel strike, without degrading footwear stability during subsequent phases of the running cycle. The line of flexion may be formed by various means including a deep groove, a line of relatively flexible midsole material, and a relatively flexible portion of a segmented fluid bladder.

Abstract: An athletic shoe has a sole with a rearfoot strike zone segmented from the remaining heel area by a line of flexion which permits articulation of the strike zone during initial heel strike of a runner. The line of flexion is located to delimit a rearfoot strike zone reflecting the heel to toe running style of the majority of the running population. In addition to allowing articulation of the rearfoot strike zone about the line of flexion, the sole incorporates cushioning elements, including a resilient gas filled bladder, to provide differential cushioning characteristics in different parts of the heel, to attenuate force applications and shock associated with heel strike, without degrading footwear stability during subsequent phases of the running cycle. The line of flexion may be formed by various ways including a deep groove, a line of relatively flexible midsole material, and a relatively flexible portion of a segmented fluid bladder.

Abstract: An athletic shoe has a sole with a rearfoot strike zone segmented from the remaining heel area by a line of flexion which permits articulation of the strike zone during initial heel strike of a runner. The line of flexion is located to delimit a rearfoot strike zone reflecting the heel to toe running style of the majority of the running population. In addition to allowing articulation of the rearfoot strike zone about the line of flexion, the sole incorporates cushioning elements, including a resilient gas filled bladder, to provide differential cushioning characteristics in different parts of the heel, to attenuate force applications and shock associated with heel strike, without degrading footwear stability during subsequent phases of the running cycle. The line of flexion may be formed by various means including a deep groove, a line of relatively flexible midsole material, and a relatively flexible portion of a segmented fluid bladder.

Abstract: The invention is directed to a method for inflating a bladder including a first and a second distinct chamber linked in fluid communication by an interconnecting port, and a fluid fill inlet linked in fluid communication with the first chamber. A first nozzle set at a first predetermined pressure level and connected to a first fluid pressure source is inserted in the fill inlet to thereby inflate the first and second chambers to the first predetermined pressure. The interconnecting port is sealed to isolate the first chamber from the second chamber out of fluid communication with each other such that the second chamber is isolated at the first predetermined pressure. The first nozzle is removed from the fluid fill inlet. A second nozzle set at a second predetermined pressure level and connected to a second pressure source is inserted into the fluid fill inlet to thereby inflate the first chamber to the second predetermined pressure.

Abstract: Footwear having an improved cushioning sole structure is disclosed. The footwear includes an upper and a sole member attached to the upper. The sole member includes a sealed inner member of a flexible material which is inflated with a gaseous medium to form a compliant and resilient insert. An elastomeric yieldable outer member encapsulates the insert about preselected portions of the insert. The inner and outer members function together to form a viscoelastic unit for attenuating the shock and returning the energy of foot impact. A mechanism adjusts the impact response of the unit so that the effect of the insert dominates the impact response function in a predetermined area adjacent at least one side of the insert. The adjusting mechanism includes a gap in the outer member along the side of the insert adjacent the predetermined area so that the flexible material of the sealed inner member can flex in the gap during foot impact.