HK40016937B - Article of footwear with first and second outsole components and method of manufacturing an article of footwear - Google Patents

Description

Footwear articles having first and second outsole components and a method for manufacturing footwear articles

This application is a divisional application of the application filed on March 13, 2017, with application number 201780018504.8 and entitled "Footwear Articles Having First and Second Outsole Components and a Method for Manufacturing Footwear Articles".

Cross-references to related applications

This application claims the benefit of priority to U.S. Application No. 15/070,082, filed March 15, 2016, which is incorporated herein by reference in its entirety.

Technical Field

This teaching generally relates to footwear articles, including the sole structure, and to methods of manufacturing such footwear articles.

background

Footwear typically includes a sole structure that is designed to sit beneath the wearer's foot to separate the foot from the ground or floor surface. In particular, athletic footwear sometimes uses polyurethane foam, rubber, or other elastic materials in its sole structure to provide cushioning.

Summary of the Invention

This disclosure provides the following:

1) A sole structure for footwear articles, the sole structure comprising:

A midsole, the midsole comprising a polymer capsule element surrounding a fluid-filled internal cavity;

A first outsole component, the first outsole component being fixed to the bottom surface and side surface of the polymer capsule element and comprising:

First base; and

A wall integral with the first base;

The second outsole component includes:

The second base is fixed to the first base; and

The wall that is integral with the second base and fixed to the outer surface of the wall of the first outsole component;

in:

The first base has an integral tread element protruding at a first portion of the bottom surface of the first base; wherein a second portion of the bottom surface of the first base has no tread element.

The wall of the first outsole component has an outer surface adjacent to the second portion of the bottom surface;

The second base is fixed to the second portion of the bottom surface of the first base; and

The ground contact surface of the sole structure includes the integral tread element of the first outsole component and the second outsole component.

2) The sole structure as described in 1), wherein:

The bladder element has an arcuate tubular portion in the forefoot region of the sole structure; and

The side surface of the capsule element is located at the inner curved wall of the capsule element at the arcuate tubular portion.

3) The sole structure as described in 1), wherein the first outsole component is a first material, and the second outsole component is a second material different from the first material.

4) The outsole structure as described in 3), wherein the first outsole component is thermoplastic polyurethane, and the second outsole component is rubber.

5) The sole structure as described in any one of 1)-4), wherein:

The outer surface of the wall of the first outsole component has a recess adjacent to the second portion of the bottom surface of the first outsole component; and

The wall of the second outsole component is fixed in the recess to the outer surface of the wall of the first outsole component.

6) The sole structure as described in 5), wherein:

The wall of the second outsole component has a first thickness;

The recess has a first depth; and

The first thickness is greater than the first depth, such that the second outsole component protrudes outward from the first outsole component at the wall of the second outsole component.

7) The sole structure as described in any one of 1)-6), wherein:

The wall of the first outsole component is the outer wall of the first outsole component, and the wall of the second outsole component is the outer wall of the second outsole component;

The first outsole component has an inner wall integral with the first base;

The recess extends upward only along the outer wall of the first outsole component to the middle, extends along the bottom surface of the base, and extends upward along the inner wall of the first outsole component.

The second outsole component has an inner wall, the inner wall of the second outsole component being integral with the second base and fixed to the outer surface of the inner wall of the first outsole component; and

The inner wall of the second outsole component extends upward along the first outsole component beyond the outer wall of the second outsole component.

8) The sole structure as described in any one of 1)-7), wherein:

The polymer capsule element is configured such that at least a portion of the fluid-filled internal cavity has a U-shape, the U-shape having an arcuate portion at the outer periphery of the sole structure; and

The first outsole component has a U-shaped shape corresponding to the U-shaped shape of the fluid-filled inner cavity, wherein the wall of the first outsole component is located at the arcuate portion of the fluid-filled inner cavity.

9) The sole structure as described in any one of 1)-8), wherein:

The integral tread element of the first outsole component is the first tread element;

The second outsole component has a plurality of integral second tread elements protruding from the bottom surface of the second outsole component; and

The first tread element and the second tread element establish the ground contact surface of the sole structure.

10) The sole structure as described in any one of 1)-9), wherein:

The footwear includes shoe uppers;

The sole interlayer, the first outsole component, and the second outsole component are configured as a forefoot sole structure fixed to the forefoot region of the upper, and the sole structure further includes:

A heel-sole structure fixed to the heel area of the shoe upper; wherein the heel-sole structure includes:

A sole midsole with a polymer capsule element, the polymer capsule element forming a separate fluid-filled internal cavity isolated from the fluid-filled internal cavity of the polymer capsule element in the forefoot sole structure;

A first outsole component fixed to the bottom surface of the bladder element of the heel-sole structure; and

A second outsole component is fixed to the first outsole component of the heel and sole structure.

11) A method for manufacturing footwear, the method comprising:

A pre-formed first outsole component is placed into a thermoforming mold; wherein the pre-formed first outsole component has:

A base having an integral tread element projecting from a first portion of the base's bottom surface, and a second portion of the bottom surface without any tread element; and

The wall, which is integral with the base and adjacent to the second portion of the bottom surface;

The first polymer sheet and the second polymer sheet are placed together with the first outsole component in the thermoforming mold;

The thermoforming mold is closed to encapsulate the first polymer sheet, the second polymer sheet, and the first outsole component within the mold cavity;

A vacuum is applied to make the first polymer sheet conform to the first mold surface of the thermoforming mold and to make the second polymer sheet conform to the upper surface of the first outsole component and the second mold surface of the thermoforming mold, with an internal cavity between the first polymer sheet and the second polymer sheet;

The first polymer sheet is thermally bonded to the second polymer sheet to form the internal cavity;

The lower surface of the second polymer sheet is thermally bonded to the upper surface of the first outsole component;

After a predetermined cooling cycle, the thermally bonded first polymer sheet, second polymer sheet, and first outsole component are removed from the thermoforming mold as a unit.

Position the second outsole component on the second portion of the bottom surface of the first outsole component; and

The second outsole component is bonded to the first outsole component.

12) As described in 11), wherein:

The first outsole component has a recess in the outer surface of the wall; and

The second outsole component is positioned by nesting it within the recess.

13) The method as described in 12), wherein the nesting includes placing the upper edge of the second outsole component along the lip of the first outsole component at the upper extent of the recess.

14) As described in 13), wherein:

The wall in question is the outer wall;

The first outsole component includes an inner wall integral with the base; and

The recess extends along the bottom surface of the base, extends upward along the outer wall to the middle, and extends upward along the inner wall further than the outer wall.

15) The method as described in any one of 11)-14) further includes:

The footwear upper is attached to the upper surface of the first polymer sheet.

16) The method of any one of 11)-15), wherein the first polymer sheet, the second polymer sheet, the first outsole component, and the second outsole component are configured as a forefoot sole structure and are fixed to the forefoot region of the footwear upper; and the method further comprises:

A heel-sole structure is fixed to the heel area of the footwear upper, wherein the front edge of the heel-sole structure is adjacent to the rear edge of the forefoot sole structure.

17) The method of any one of 11)-16), wherein the surface of the second mold has a positioning mark; and wherein placing the first outsole component into the thermoforming mold comprises placing a predetermined portion of the first outsole component at the positioning mark, thereby orienting the first outsole component at a predetermined position in the thermoforming mold.

Attached Figure Description

The invention can be better understood by referring to the following figures and description. The components in the figures are not necessarily drawn to scale, but rather the emphasis is on illustrating the principles of the invention. Furthermore, in the figures, similar reference numerals refer to corresponding parts in all different views.

Figure 1 is a cross-sectional view of footwear including co-molded articles;

Figure 2 is a cross-sectional view of the co-molded article;

Figure 3 is a cross-sectional view of the open mold, illustrating the relationship between the parts used to produce the article;

Figure 4 is a cross-sectional view of a closed mold, illustrating the relationship between the parts used to produce the article in Figure 3;

Figure 5 is a cross-sectional view of the open mold, illustrating the relationship between the parts used to produce the article;

Figure 6 is a cross-sectional view of a closed mold, illustrating the relationship between the parts used to produce the article in Figure 5.

Figure 7 is a cross-sectional view of an open mold, illustrating the relationship between the parts used to produce the article of this disclosure;

Figure 8 is a cross-sectional view of a portion of the open mold, illustrating the relationship between the parts used to produce the article of Figure 7;

Figure 9 is a cross-sectional view of a closed mold, illustrating the relationship between the parts used to produce the article in Figure 7;

Figure 10 is a cross-sectional view of an open mold, illustrating the relationship between the parts used to produce another article of this disclosure;

Figure 11 is a cross-sectional view of a closed mold, illustrating the relationship between the parts used to produce the article of Figure 10;

Figure 12 is a cross-sectional view of an open mold, illustrating the relationship between the parts used to produce yet another article of this disclosure.

Figure 13 is a cross-sectional view of a closed mold, illustrating the relationship between the parts used to produce the article of Figure 12;

Figure 14 is a bottom view of a sole structure for footwear articles, including a forefoot sole structure and a heel sole structure, attached to the upper of a footwear.

Figure 15 is an external side view of a footwear article including the sole structure of Figure 14 attached to the footwear upper;

Figure 16 is a perspective view of the lower surface of the forefoot bladder element of the sole structure in Figure 14;

Figure 17 is a perspective view of the lower surface of the first outsole component of the forefoot sole structure of Figure 14;

Figure 18 is a perspective view of the upper surface of the first outsole component of Figure 17;

Figure 19 is a cross-sectional perspective view of the first outsole component of Figure 18, taken at line 19-19 in Figure 18;

Figure 20 is a perspective view of the lower surface of the heel pouch element of the sole structure in Figure 14;

Figure 21 is a perspective view of the lower surface of the first outsole component of the heel and sole structure of Figure 14;

Figure 22 is a perspective view of the upper surface of the first outsole component of Figure 21;

Figure 23 is a cross-sectional view of the sole structure of Figure 14 taken at line 23-23 in Figure 14;

Figure 24 is a cross-sectional view of the sole structure of Figure 14 taken at line 24-24 in Figure 14;

Figure 25 is a cross-sectional view of the injection mold used for the first outsole component of Figure 17;

Figure 26 is a cross-sectional view of the injection mold used for the first outsole component of Figure 22;

Figure 27 is a cross-sectional and exploded view of an open thermoforming mold, illustrating some of the relationships among the components of the sole structure in Figure 14; and

Figure 28 is a cross-sectional view of the mold and components of Figure 27, with the mold in the closed position.

Detailed Implementation

A sole structure for footwear includes a sole interlayer, a first outsole component, and a second outsole component. The sole interlayer has a polymer bladder element that encloses a fluid-filled internal cavity. The first outsole component is fixed to the bottom and side surfaces of the polymer bladder element. The first outsole component includes a first base and a wall integrally formed with the first base. The second outsole component includes a second base fixed to the first base and a wall integrally formed with the second base and fixed to the outer surface of the wall of the first outsole component. The first base has an integral tread element projecting at a first portion of the bottom surface of the first base, but a second portion of the bottom surface has no tread element. The wall of the first outsole component has an outer surface adjacent to the second portion of the bottom surface. The second base of the second outsole component is fixed to the second portion of the bottom surface of the first base. Therefore, the first tread element does not interfere with the second base. Furthermore, the ground contact surface of the sole structure includes the integral tread element of the first outsole component and includes the second outsole component.

In one or more embodiments, the bladder element has an arcuate tubular portion in the forefoot region of the sole structure. The lateral surfaces of the bladder element are located at the inner curved walls of the arcuate tubular portion. In this configuration, the walls of the second outsole component support and reinforce the inner curved walls of the bladder element, such as during dorsiflexion in the forefoot region.

In one or more embodiments, the first outsole component is a first material, and the second outsole component is a second material different from the first material. For example, the first outsole component may be thermoplastic polyurethane, and the second outsole component may be rubber. The second material may be selected to provide durability to the ground contact surface and reinforce support to modulate the cushioning response of the first outsole component.

In one or more embodiments, the outer surface of the wall of the first outsole component has a recess adjacent to a second portion of the bottom surface of the first outsole component. The wall of the second outsole component can be secured to the outer surface of the wall of the first outsole component within the recess. Therefore, the wall of the second outsole component is nested within the recess, which protects the wall of the second outsole component from forces that could cause delamination. In one embodiment, the wall of the second outsole component has a first thickness, the recess has a first depth, and the first thickness is greater than the first depth, such that the second outsole component protrudes outward from the wall of the first outsole component.

In one or more embodiments, the wall of the first outsole component is the outer wall of the first outsole component, and the wall of the second outsole component is the outer wall of the second outsole component. The first outsole component has an inner wall integral with a first base, and the recess extends upward only along the outer wall of the first outsole component to a midpoint, extends along the bottom surface of the base, and extends upward along the inner wall of the first outsole component. The second outsole component has an inner wall integral with a second base and fixed to the outer surface of the inner wall of the first outsole component. The inner wall of the second outsole component extends upward along the first outsole component further than the outer wall of the second outsole component.

In one or more embodiments, the polymer capsule element is configured such that at least a portion of the fluid-filled internal cavity has a U-shape, the U-shape having an arcuate portion at the outer periphery of the sole structure. A first outsole component has a U-shape corresponding to the U-shape of the fluid-filled internal cavity, wherein the wall of the first outsole component is located at the arcuate portion of the fluid-filled internal cavity.

The second outsole component may also have a tread element included in the ground contact surface. In one or more embodiments, the second outsole component has a plurality of integral second tread elements protruding from the bottom surface of the second outsole component. The first tread element and the second tread element establish the ground contact surface of the sole structure.

Footwear articles may include an upper. A midsole, a first outsole component, and a second outsole component may be configured as a forefoot sole structure attached to a forefoot region of the upper, and the sole structure may further include a heel sole structure attached to a heel region of the upper. The heel sole structure may include: a midsole having a polymer capsule element that forms a separate fluid-filled internal cavity isolated from the fluid-filled internal cavity of the polymer capsule element of the forefoot sole structure; a first outsole component attached to the bottom surface of the capsule element of the heel sole structure; and a second outsole component attached to the first outsole component of the heel sole structure.

A method of manufacturing footwear includes placing a pre-formed first outsole component into a thermoforming mold. The pre-formed first outsole component has a base having an integral tread element projecting from a first portion of the base's bottom surface and a second portion of the bottom surface without any tread element. The first outsole component also has a wall integral with the base and adjacent to the second portion of the bottom surface. The method includes placing a polymer material together with the first outsole component into the thermoforming mold and closing the thermoforming mold to encapsulate a first polymer sheet, a second polymer sheet, and the first outsole component within a mold cavity. A vacuum is applied to conform the first polymer sheet to a first mold surface of the thermoforming mold, and to conform the second polymer sheet to the upper surface of the first outsole component and to a second mold surface of the thermoforming mold, with an internal cavity between the first and second polymer sheets.

The first portion of the polymer material may be a first polymer sheet, and the second portion of the polymer material may be a second polymer sheet. The method may further include: thermally bonding the first polymer sheet to the second polymer sheet to form an internal cavity, thermally bonding the lower surface of the second polymer sheet to the upper surface of the first outsole component, and removing the thermally bonded upper and lower polymer sheets and the first outsole component as a unit from a thermoforming mold after a predetermined cooling cycle.

The second outsole component can be positioned on a second portion of the bottom surface of the first outsole component and bonded to it. For example, the second outsole component can be positioned by nesting it within a recess in the outer surface of the wall of the first outsole component. Nesting the second outsole component in the recess can include placing the upper edge of the second outsole component along the lip of the first outsole component at the upper extent of the recess. This wall can be an outer wall, the first outsole component can include an inner wall integral with the base, and the recess can extend along the bottom surface of the base, upward along the outer wall to a midway point, and upward along the inner wall further than the outer wall.

The method may include attaching a footwear upper to the upper surface of a first polymer sheet. The first and second polymer sheets, the first outsole component, and the second outsole component may be configured as a forefoot sole structure and attached to the forefoot region of the footwear upper, and the method may include attaching a heel sole structure to the heel region of the footwear upper, wherein the front edge of the heel sole structure is adjacent to the rear edge of the forefoot sole structure.

The surface of the second mold may have positioning marks, and placing the first outsole component into the thermoforming mold may include placing a predetermined portion of the first outsole component at the positioning marks, thereby orienting the first outsole component at a predetermined position in the thermoforming mold.

The above-mentioned features and advantages, as well as other features and advantages, of this teaching will become apparent when taken in conjunction with the accompanying drawings and from the detailed description of the model used to implement this teaching.

The terms “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate the presence of at least one item. Multiple such items may exist unless the context clearly indicates otherwise. Unless otherwise explicitly or clearly indicated in the context, all numerical values of parameters (e.g., quantities or conditions) in this specification (including the appended claims) should be understood to be modified in all cases by the term “about,” regardless of whether “about” actually precedes the numerical value. “About” indicates that the stated numerical value allows for some slight imprecision (slightly close to the value; approximately or moderately close to the value; almost close to the value). If the imprecision provided by “about” cannot be understood in this ordinary sense in the art unless otherwise otherwise, then “about” as used herein at least indicates variations that may arise from the measurement parameter and the common methods of using such parameters. Furthermore, the disclosure of a range should be understood to specifically disclose all values within that range and further subdivisions of the range. All references cited are incorporated herein in their entirety.

The terms “comprising,” “including,” and “having” are inclusive and therefore specify the presence of the stated features, steps, operations, elements, or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, or components. The order of steps, processes, and operations may be changed where possible, and alternative or alternative steps may be used. As used in this specification, the term “or” includes any and all combinations of the associated listed items. The term “any of” should be understood to include any possible combination of the referenced items, including “any one of” among the referenced items. The term “any of” should be understood to include any possible combination of the referenced claims in the appended claims, including “any one of” among the referenced claims.

Those skilled in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” “top,” and “bottom” can be used descriptively with respect to the accompanying drawings and are not intended to limit the scope of the invention as defined by the claims.

In this embodiment, the molded article can be a cushioning layer and outsole of a footwear article. Figure 1 illustrates this embodiment. Figure 1 is a cross-sectional view of a footwear article including a co-molded article. Footwear article 100 includes an upper 120 and a sole structure 130. The upper 120 provides comfortable and secure coverage for the wearer's foot. Thus, the foot can be positioned within the upper 120 to effectively secure the foot within the footwear article 100 or otherwise integrate the foot and footwear article 100. The sole structure 130 is attached to the lower region of the upper 120 and extends between the foot and the ground to, for example, attenuate ground reaction forces (i.e., cushion the foot), provide traction friction, enhance stability, and influence foot movement. In effect, the sole structure 130 is located under the foot and supports it.

The upper 120 is depicted as having a generally conventional configuration. The majority of the upper 120 comprises various material elements (e.g., textiles, foam, leather, and synthetic leather) that are stitched or adhesively bonded together to create an internal cavity for securely and comfortably receiving the foot. These material elements can be selected and located within the upper 120 to selectively impart properties such as durability, breathability, abrasion resistance, flexibility, and comfort. The cavity in the upper 120 is shaped to accommodate the foot. Thus, when the foot is within the cavity, the upper 120 extends along the outer side of the foot, along the inner side of the foot, above the foot, around the heel, and below the foot. Laces 122 extend above the tongue 123. The adjustability provided by the laces 122 and the tongue 123 can be used in a conventional manner to modify the size of the internal cavity, thereby securing the foot within the internal cavity and facilitating entry and exit. Insoles 125 can enhance the comfort of footwear 100.

Further configurations of the upper 120 may include one or more of the following: (a) a toe guard located in the forefoot area and formed of abrasion-resistant material; (b) a heel counter located in the heel area for enhanced stability; and (c) one or more of a logo, trademark, and label with care instructions and material information. Given that several aspects of this discussion primarily relate to the sole structure 130, the upper 120 may present the general configurations discussed above or virtually any other conventional or unconventional upper configuration. Accordingly, the structure of the upper 120 may vary significantly.

The sole structure 130 includes an outsole 160 attached to a fluid-filled chamber 140. The outsole 160 has ground-engaging protrusions 135 associated therewith.

Figure 2 illustrates an alternative embodiment of a can-shaped article 200 having a top 210 associated with a can-shaped part 220. The can-shaped part 220 is at least partially surrounded by a shell 230 having protrusions 235 extending therefrom. Figures 2, 5, 6, 12, and 13, along with the accompanying description, explain this alternative embodiment.

Figures 3 and 4 illustrate a method for producing a sole structure (such as, but not limited to, the sole structure 130 of Figure 1). Figures 3 and 4 depict a cross-section of a mold used for co-molding a fluid-filled chamber 140 and an outsole 160 (which has protrusions 135). The outsole 160 may be produced from a plurality of preformed objects or elements assembled in the mold. In some embodiments, the outsole 160 wraps around at least a portion of the edge 143 of the fluid-filled chamber 140. The molded article 131 is an embodiment of an article having the outsole 160, which wraps around a large portion of the edge of the fluid-filled chamber 140. Because these parts are produced from a thermoplastic material, they can be softened to facilitate shaping in the mold.

Figures 3 and 4 are cross-sectional views of the mold 300 used for article 131. As shown in Figures 3 and 4, the fluid filling chamber 140 is co-molded with the outsole 160 present in the mold. An adhesive may also be present on a suitable surface.

Generally, co-molded articles can be produced in a two-piece mold having an upper mold portion and a lower mold portion by placing the outsole element into the lower mold portion and then placing the layer to be formed into the fluid-filled chamber 140 on top of the outsole element. The mold is then closed such that the upper mold portion and the lower mold portion are adjacent to each other. The mold is formed such that closing the mold results in the formation of the chamber. Then, pressurized fluid is introduced into the chamber, such that the filling of the chamber forces the upper surface of the chamber to conform to the lower side of the upper mold portion, and also forces the lower portion of the chamber to conform to the lower outer element. Energy can be applied to the mold in the form of heat, radio frequency, etc., to co-mold the first and second elements together with the filled chamber and push the article against the mold surface and the outsole element. The second element portion, such as a polymer layer, can be provided in the mold as a precursor for the finished product. This precursor can be formed in the mold as part of the co-molding process described herein, or it can be provided as a fully pre-formed chamber ready for filling.

Various manufacturing processes can be used to produce the sole structure 131. In some embodiments, a mold 300 that can be used in the manufacturing process is depicted as including a first mold portion 310 and a second mold portion 320. The mold 300 is used to produce a fluid-filled chamber 140 from a first polymer layer 410 and a second polymer layer 420, which are polymer layers that produce an upper surface 141 and a lower surface 142 of the fluid-filled chamber, respectively. More specifically, the mold 300 facilitates the manufacturing process by (a) shaping the first polymer layer 410 and the second polymer layer 420 in areas corresponding to the edge 143, the flange 146, and the channel between the chambers of the fluid-filled chamber 140, and (b) engaging the first polymer layer 410 and the second polymer layer 420 in areas corresponding to the flange 146 and the web area 1147.

The various surfaces or other areas of mold 300 will now be defined for use in discussing the manufacturing process. A first mold portion 310 includes a first mold portion surface 350 that shapes the top surface of the co-molded article. Parts of a first element (such as an outsole 160) and a second element (such as a fluid-filled chamber 140) are illustrated in Figure 3. A second mold portion 320 is shaped to receive a protrusion 135 that engages tightly with a groove 325 in the second mold portion 320. The outsole 160 is then placed in the mold. The outsole 160 is fitted within an undercut 335. Then, when the article is molded, a second element precursor or a first polymer layer 410 is positioned to become the top surface of the article, and the second element precursor or second polymer layer 420 creates the bottom or lower surface 142 of the second element (hereinafter the fluid-filled chamber).

As the first mold portion 310 and the second mold portion 320 move toward each other, various techniques can be used to draw the first polymer layer 410 and the second polymer layer 420 against the surfaces of the first mold portion 310 and the second mold portion 320, thereby initiating the process of forming the first polymer layer 410 and the second polymer layer 420. For example, air can be partially expelled from (a) the region between the first mold portion 310 and the first polymer layer 410 and (b) the region between the second mold portion 320 and the second polymer layer 420. More specifically, air can be extracted through various vacuum ports in the first mold portion 310 and the second mold portion 320. By removing the air, the first polymer layer 410 is drawn into contact with the surface of the first mold portion 310, and the second polymer layer 420 is drawn into contact with the surface of the second mold portion 320. As another example, fluid can be injected into the region between the first polymer layer 410 and the second polymer layer 420, thereby increasing the pressure between the first polymer layer 410 and the second polymer layer 420. During the preparation phase of this process, an injection needle may be positioned between the first polymer layer 410 and the second polymer layer 420, and a fluid (such as a gas, liquid, gel, or a mixture thereof) may then be ejected from the injection needle, causing the first polymer layer 410 and the second polymer layer 420 to engage the surfaces of the mold 300. Each of these techniques may be used together or independently.

As the first mold portion 310 and the second mold portion 320 continue to move toward each other, the first polymer layer 410 and the second polymer layer 420 are clamped between the first mold portion 310 and the second mold portion 320. More specifically, the first polymer layer 410 and the second polymer layer 420 are compressed between the clamping surface 330 and the clamping edge 360. In addition to the process of initiating the separation of excess portions of the first polymer layer 410 and the second polymer layer 420 from the portion forming the fluid filling chamber 140, the clamping of the first polymer layer 410 and the second polymer layer 420 initiates the process of bonding or joining the first polymer layer 410 and the second polymer layer 420 in the region of the flange 146.

As depicted in Figure 4, after the first polymer layer 410 and the second polymer layer 420 are clamped, the first mold portion 310 and the second mold portion 320 continue to move toward each other and enter a closed configuration. As the mold closes, the clamping surface 330 contacts a portion of the second joint forming surface 370 and slides against a portion of the second joint forming surface 370. The contact between the clamping surface 330 and the second joint forming surface 370 effectively cuts off excess portions of the first polymer layer 410 and the second polymer layer 420 from the portion forming the fluid-filled chamber 140. The material forming the first polymer layer 410 and the second polymer layer 420 is compacted or otherwise aggregated to form the flange 146. In addition to forming the flange 146, the first polymer layer 410 and the second polymer layer 420 are (a) shaped to create the fluid-filled chamber 140, and (b) extruded and joined to create the web region 1147.

Once the fluid filling chamber 140 is complete, the mold 300 is opened. Fluid can then be injected into the fluid filling chamber 140 to pressurize the fluid filling chamber of the forefoot component, thereby completing the manufacture of structure 131. As the final step in the process, structure 131 can be incorporated into the sole structure of the footwear article 100.

Co-molded articles can have many uses. Figure 5 illustrates a can or other container. Figure 5 depicts the molding of a can or other container. Mold 600 includes a first mold portion 610 having a mold surface 650. A second mold portion 620 includes a groove 625 to securely engage a protrusion 535 on a first element 560. A second polymer layer 520 and a first polymer layer 510 are positioned in the open mold. After the first element 560 is inserted into the mold, the second polymer layer 520 forms the layer of the can that contacts the first element 560. The first polymer layer 510 forms the upper surface of the can.

Figure 6 illustrates a mold 600 that is closed to form a can or article 570 within a mold. Surface 650 of the first mold portion 610 forms the upper surface 572 of the top layer 506 of the article. The sealed can is produced by fusing or bonding polymer layers at a flange 546, which may extend around the periphery of the can. Protrusions 535 on the first element 560 fit tightly into grooves 625 in the second portion 620 of the mold.

Given that the methods and molds described above produce satisfactory part forming, skilled practitioners recognize that removing co-molded articles from the mold can be difficult. As long as the co-molded article has sufficient flexibility and elasticity, it can be slightly deformed to remove it from the die. However, protrusions formed in grooves on the outer surface of the co-molded article, and other features that cause the article to extend into the mold, can make removal from the mold very difficult.

Therefore, this disclosure relates to co-molded articles in a mold that minimize contact between protrusions on the article and the surface of the mold. The co-molded article may include a preformed article. In some embodiments, the preformed article is able to substantially retain its shape. In such embodiments, the first element may be a preformed element placed in the mold, wherein the inner surface is substantially not interrupted by grooves and other features in which protrusions may form. Conversely, in such embodiments, the first element is placed in the mold with minimal interference or contact between the protrusion and the mold. The element substantially retains its shape when placed in the mold. In some embodiments, the base surface or end surface of the protrusion may contact the surface of the mold, but the sides of the protrusion substantially do not contact the mold. In this way, the co-molded article can be easily removed from the mold.

In some embodiments, the sole structure for footwear articles can be manufactured according to a method for co-molding first and second elements to produce co-molded articles. Figures 7, 8, and 9 depict the stages of this method for co-molding the sole structure for footwear articles. Mold 700 may have a first mold portion 710 and a second mold portion 720. A shape 750 on the first mold portion 710 can form the top surface 741 of the co-molded article.

The first element 760 may have a top surface 761, an edge surface 762, and a protrusion 735 having a base 737 opposite to the top surface 761. The edge surface 762 may extend any distance away from the top surface 761. The first element 760 may also have a bottom surface 794. The second element 765 may have an edge 743, an upper surface 741, and a lower surface 764.

Any suitable polymeric material can be used to produce the first element, which will be the outsole depicted in Figure 7. Although each feature is illustrated as a single layer in the figure, each such feature may comprise a single-layer material or multiple-layer materials and may be thermoformed or otherwise shaped. Examples of polymeric materials that can be used for such outsole structures include any one of polyurethane, urethane, polyester, polyester polyurethane, polyether, polyether-type polyurethane, latex, polycaprolactone, polyoxypropylene, polycarbonate glycol, and mixtures thereof. These and other polymeric materials, exemplary embodiments, and methods of manufacturing these materials can be found in U.S. Patent No. 9,420,848 to Campos II et al., the entire contents of which are incorporated herein by reference.

Shoe outsoles can typically be made from any durable material. Generally, outsole materials are tough, durable, abrasion-resistant, flexible, and slip-resistant. In some embodiments, polyurethane materials are durable enough for ground contact. Suitable thermoplastic polyurethane elastomer materials include sheet Bayer 285, available from Bayer. SP9339, SP9324, and C705, available from BASF, are also suitable. In some embodiments, polyurethane and other polymers that may not be durable enough for direct ground contact can be used to form part of the outsole. In such embodiments, the rubber outsole can be bonded or adhered to the outsole. In some embodiments, the outsole material is transparent or translucent. In some embodiments, ground-engaging protrusions can be integrally formed as part of the outsole, or they can be formed separately and bonded to the outsole. The outsole can have a textured ground-engaging surface to improve adhesion friction.

As depicted in Figures 7, 8, and 9, the first element 760 may be a shoe outsole. In such an embodiment, according to the method, the shoe outsole 760 is located within a second mold portion 720, wherein the base 737 of the protrusion 735 contacts the surface 780 of the second mold portion 720. The surface 780 of the second mold portion 720 is shaped such that the majority of the protrusion 735, except for the base 737, does not contact the surface. The protrusion 735 can be considered a ground-engaging portion, wherein its end is the base 737 engaging the ground. As specifically depicted in Figures 7 and 8, the shoe outsole 760 may have a slight arc or curve that causes the edge 762 to not contact the edge 862 of the second mold portion 720. Not all of the bases 737 can simultaneously contact the surface 780 before molding with the second element.

The precursor for the second element (fluid-filled chamber) is placed in the mold and the mold is closed. A first polymer layer 810 may form the top surface 741 of the second element 765. A second polymer layer 820 may form the edge 743 of the second element 765 and the lower surface or bottom 764 of the second element or fluid-filled chamber 765.

As depicted in Figure 7, each of the first polymer layer 810 and the second polymer layer 820 is initially located between the first mold portion 710 and the second mold portion 720 in a spaced-out or open configuration. In this position, the first polymer layer 810 is positioned adjacent to or closer to the first mold portion 710, and the second polymer layer 820 is positioned adjacent to or closer to the second mold portion 720. A shuttle frame or other device may be used to properly position the first polymer layer 810 and the second polymer layer 820. As part of the manufacturing process, one or both of the first polymer layer 810 and the second polymer layer 820 are heated to a temperature favorable for forming and bonding. As an example, various radiant heaters or other devices may be used to heat the first polymer layer 810 and the second polymer layer 820, possibly before they are positioned between the first mold portion 710 and the second mold portion 720. As another example, the mold 700 can be heated such that the contact between the mold 700 and the first polymer layer 810 and the second polymer layer 820 in a later part of the manufacturing process raises the temperature to a level conducive to forming and bonding.

Once the first polymer layer 810 and the second polymer layer 820 are properly positioned, the first mold portion 710 and the second mold portion 720 translate toward each other or otherwise move and begin to close on the first polymer layer 810 and the second polymer layer 820. Pressurized fluid can be introduced into the fluid-filled chamber 765 such that the upper surface 741 of the fluid-filled chamber 765 conforms to the shape 750 of the first mold portion 710, the lower surface 764 of the fluid-filled chamber or the second element 765 conforms to the shape of the upper surface 761 of the first element 760, and the edge 743 of the fluid-filled chamber 765 conforms to the edge surface 762 of the first element 760 or the edge 862 of the second mold portion 720.

When fluid is injected into the fluid filling chamber 765, the second polymer layer 820 can be advanced toward the top surface 761 of the outsole 760, the edge 762 of the outsole 760, and the edge 862 of the second mold portion 720. As the pressure in the fluid filling chamber 765 increases, the pressure on the top surface 761 of the outsole can advance the base 737 on the protrusion 735 toward the surface 780 of the second mold portion 720. Similarly, the pressure in the fluid filling chamber 765 can advance the edge 743 of the fluid filling chamber 765 toward the edge 762 of the outsole 760, and both toward the edge 862 of the second mold portion. The edge 743 can also be advanced to contact the edge 862 of the second mold portion 720, wherein contact between the edge 762 of the outsole 760 and the edge 862 of the second mold portion 720 is not excluded.

As can be seen in Figures 8 and 9, the bottom surface 794 of the outsole 760 typically does not contact the bottom surface 780 of the second mold portion 720, even after the fluid filling chamber has been fully molded. Although the outsole 760 remains in place, demolding is performed with less force compared to demolding from a mold (such as those in Figures 3 and 4) that applies force to such protrusions. After demolding of the sole structure, the fluid pressure in the fluid filling chamber 765 can be adjusted.

Figures 10 and 11 illustrate another embodiment of a co-molded article in the process of producing a sole structure for footwear articles, which can be manufactured according to a method for co-molding a first element and a second element to produce a co-molded article. The mold 1100 may have a first mold portion 1110 and a second mold portion 1120. A shape 1150 on the first mold portion 1110 can create a top surface 1041 of the co-molded article.

The outsole 1060 may have a top surface 1061, an edge surface 1062, and a protrusion 1035, the protrusion 1035 having a base 1037 opposite to the top surface 1061. The second element 1065 may have an edge 1043, an upper surface 1041, and a lower surface 1064. As described with respect to Figures 7, 8, and 9, any suitable polymer material can be used to produce the sole structure.

In some embodiments, such as those depicted in Figures 10 and 11, the first element 1060 may be a shoe outsole. In such an embodiment, according to the method, the shoe outsole 1060 is located within a second mold portion 1120, wherein the base 1037 of the protrusion 1035 contacts the surface 1180 of the second mold portion 1120. The surface 1180 of the second mold portion 1120 is shaped such that it does not contact the majority of the protrusion 1035 except for the base 1037. The protrusion 1035 may be a ground engagement portion, wherein its end is the base 1037 engaging the ground. As specifically depicted in Figure 10, the shoe outsole 1060 may have a slight arc or curve that causes the edge 1062 to not contact the edge 1162 of the second mold portion 1120. The shoe outsole 1060 may include a flange 1063 that may provide additional support to the sole structure.

The precursor for the second element (fluid-filled chamber) is placed in the mold and the mold is closed. The first polymer layer 1010 can form the top surface 1041 of the second element 1065. The second polymer layer 1020 can form the edge 1043 and the lower surface or bottom 1064 of the second element or fluid-filled chamber 765.

As depicted in Figures 10 and 11, each of the first polymer layer 1010 and the second polymer layer 1020 is initially located between each of the first mold portion 1010 and the second mold portion 1020 in a spaced-out or open configuration. As described with respect to Figures 7, 8, and 9, the polymer layers are placed and heated.

Fluid under pressure can be introduced into the fluid filling chamber 1065 as it is formed, such that the upper surface 1041 of the fluid filling chamber 1065 conforms to the shape 1150 of the first mold portion, the lower surface 1064 of the fluid filling chamber or the second element 1065 conforms to the shape of the top surface 1041 of the first element or the outsole 1060, and the edge 1043 of the fluid filling chamber 1065 conforms to the edge surface 1062 of the outsole 1060 or the edge 1162 of the second mold portion 1120.

When fluid is injected into the fluid filling chamber 1065, the second polymer layer 1020 can be advanced toward the top surface 1061 of the outsole 1060, the edge 1062 of the outsole 1060, and the edge 1162 of the second mold portion 1120. As the pressure in the fluid filling chamber 1165 increases, the pressure on the top surface 1061 of the outsole can advance the base 1037 on the protrusion 1035 toward the surface 1080 of the second mold portion 1120. Similarly, the pressure in the fluid filling chamber 1065 can advance the edge 1043 of the fluid filling chamber 1065 toward the edge 1062 of the outsole 1060, and both toward the edge 1162 of the second mold portion. The edge 1043 can also be advanced to contact the edge 1162 of the second mold portion 1120, wherein contact between the edge 1062 of the outsole 1060 and the edge 1162 of the second mold portion 1120 is not excluded.

As can be specifically seen in Figure 11, the bottom surface 1094 of the outsole 1060 typically does not contact the bottom surface 1180 of the second mold portion 1120, even after the fluid filling chamber has been fully molded. Although the outsole 1060 is held in place during molding, demolding is performed with less force than demolding from a mold that applies force to such protrusions. The fluid pressure in the fluid filling chamber 1065 can be adjusted after the sole structure has been demolded.

The embodiments disclosed herein can be molded from any moldable sheet material, such as thermoplastic polymers. The embodiments can also have any function and can have any shape that can be molded. After the bottom layer of the object is inserted into the mold, the embodiments adapt to the pressure of the mold, such that the pressure propels the layer to contact the fixed object, the edge of the fixed object or the mold, and propels the fixed object toward the mold.

In some embodiments, the shape of the co-molded article can produce a container. Figures 12 and 13 depict a container with legs. The container may be a first element 1260, which can be characterized as a shell 1260. As depicted in Figure 12, the first element or shell 1260 has been placed in a second mold portion 1320. The shell 1260 may have legs or protrusions 1235, wherein the legs have bottoms 1237. The second mold portion 1320 may include a bottom surface 1280. In some embodiments, the bottom surface 1280 may not contact each bottom 1237 of the legs 1235. The shell 1260 may have a shape including minute arcuate curves. Therefore, whether each bottom 1237 of the legs 1235 contacts the bottom surface 1280 depends on the arrangement of the legs 1235 and whether the shell 1260 can have arcuate curves when placed in the second mold portion 1320. In such embodiments, the arcuate curves may be manifested in the edges 1262 of the object. As depicted in Figure 12, the object edge 1262 exhibits an arc shape such that the object edge 1262 does not contact the mold edge 1362.

As depicted in Figure 13, before closing the mold, a first polymer mesh and a second polymer mesh are placed between the first mold portion 1310 and the second mold portion 1320 in the mold 1300 in a manner substantially the same as that described with respect to Figures 7, 8 and 9.

In some embodiments, the top 1206 of the box-shaped component formed by the first polymer layer may be bonded or otherwise attached to a second polymer layer 1208, which forms the remainder of the box-shaped component at the flange 1246. The top surface of the top 1206 of the box-shaped component is shaped by surface 1350 to form the box-shaped component surface 1212.

Fluid can be injected into the volume formed by the second polymer layer 1208 and the top 1206 of the box-shaped component. The fluid can be a gas, liquid, or gel. Injecting fluid into the box-shaped component 1265 can propel the second polymer layer 1208 toward the top surface 1264 of the shell 1260, the edge 1262 of the shell 1260, and the edge 1362 of the second mold portion 1320. As the pressure in the box-shaped component 1265 increases, the pressure on the bottom surface 1264 of the first element can propel the base 1237 on the protrusion 1235 toward the surface 1280 of the second mold portion 1320. Similarly, the pressure in the shell 1260 can propel the edge 1243 of the second polymer layer toward the edge 1262 of the object 1260, and both toward the edge 1362 of the second mold portion 1320. Edge 1243 may also be pushed to contact edge 1362 of second mold portion 1320, wherein edge 1262 of shell 1260 may contact edge 1362 of second mold portion 1320.

As can be specifically seen in Figure 13, the bottom surface 1294 of the shell 1260 typically does not contact the bottom surface 1390 of the second mold portion 1320, even after the shell has been fully molded. Although the shell 1260 is held in place, demolding is performed with less force than demolding from a mold with force applied to such a protrusion 1235. After demolding of the co-molded article, the fluid pressure in the box-shaped part 1265 can be adjusted.

The embodiments include articles manufactured according to the methods disclosed herein. Embodiments of these articles may be sole structures for footwear articles, as described herein. Such sole structures can be attached to uppers for footwear articles to produce footwear articles. The uppers for footwear articles can be composed of any suitable material elements. For example, such material elements may include, for example, textiles, foam, leather, and synthetic leather. More than one material may be present in the upper. The sole structure can be attached to the upper by adhesive, sewing, or stitching, or by any method well known to those skilled in the art.

Figure 14 illustrates a footwear article 3100 having a sole structure 3130, which is attached to the outer periphery of an upper 3120, also shown in Figure 15, or attached to the upper 120 of Figure 1. The sole structure 3130 can be attached to the bottom surface of the upper 3120, or a strobel, lasting board, or foam layer can be attached to the upper 3120, and the sole structure 3130 can be attached to the bottom surface of the strobel, lasting board, or foam layer. The sole structure 3130 is located under the foot and supports the foot. The main components of the sole structure 3130 are the forefoot sole structure 3131 and the heel sole structure 3132. The sole structure 3130 has a forefoot area 3134, a midfoot area 3133, and a heel area 3136, and extends from the inner side 3137 to the outer side 3138.

The forefoot sole structure 3131 includes a forefoot sole interlayer, which, in the illustrated embodiment, is a polymer capsule element 3140, and is also referred to as a forefoot component, forefoot capsule element, or fluid-filled chamber. The polymer capsule element 3140 is best shown in FIG. 16. The polymer capsule element 3150 is best shown in FIG. 20. The capsule element 3140 surrounds the fluid-filled internal cavity 3142 indicated in FIG. 15 and 16. Similarly, the heel sole structure 3132 includes a heel sole interlayer, which, in the illustrated embodiment, is a polymer capsule element 3150, and is also referred to as a heel component, heel capsule element, or fluid-filled chamber. The capsule element 3150 surrounds the fluid-filled internal cavity 3152 indicated in FIG. 15 and 20. The bladder elements 3140 and 3150 are located between the outsole component and the upper 3120 in the bottom view of FIG14, as best shown in FIG15.

Capsule elements 3140 and 3150 are separate from each other and not in fluid communication. Capsule element 3140 has a plurality of tubular portions having an arcuate shape (e.g., a generally U-shaped shape), such that the fluid-filled internal cavity 3142 has corresponding tubular portions 3142A, 3142B, 3142C, 3142D, and 3142E that are interconnected and in fluid communication with each other through channels 3143, as best shown in FIG16. Capsule element 3150 has a plurality of interconnected portions arranged in a U-shape, such that the fluid-filled internal cavity 3152 has a plurality of portions 3152A, 3152B, 3152C, 3152D, and 3152E that are interconnected and in fluid communication with each other through channels 3153, as best shown in FIG20. The polymer capsule element 3140 is configured such that the arcuate portions of the fluid-filled internal cavity 3142 are located at the outer periphery of the forefoot region 3134 of the sole structure 3131, as shown in FIG15. The bladder element 3140 has an arcuate tubular portion 3149 in the forefoot region of the sole structure, as best shown in Figure 16. The arcuate tubular portion 3149 has an inner curved wall 3151, which has a more compact curvature than the outer wall of the arcuate tubular portion 3149. In other words, the inner curved wall 3151 is located inside the U-shaped arcuate tubular portion 3149. The side surface 3079 of the bladder element 3140 is located at the inner curved wall 3151, to which the first wall of the first outsole component is fixed. Therefore, during flexion in the forefoot region, the inner wall 3099 can support and reinforce both the second wall 3087 and the inner curved wall 3151 of the bladder element 3140 at the arcuate tubular portion. This support and reinforcement should reduce stress on the second wall 3087 to prevent cracking of the second wall 3087.

Capsule elements 3140 and 3150 can each be thermoformed (also referred to as first and second sheets, first and second layers, or upper and lower layers) from the upper sheet 3144 and lower sheet 3146 shown in Figures 24 and 27 and described herein, or alternatively, can be blow-molded. The sheets may have alternating layers of TPU and gas barrier material. In any embodiment, each capsule element 3140 and 3150 is configured to retain fluid within a fluid-filled internal cavity 3142 and 3152. As used herein, “fluid” includes gas, including air, inert gases (such as nitrogen), or another gas. Therefore, “fluid filling” includes “gas filling.” Various materials used for capsule elements 3140 and 3150 can be generally transparent or can have a colored hue. For example, capsule elements 3140 and 3150 can be formed from any of a variety of polymeric materials capable of retaining fluid at a predetermined pressure, including fluids that are gases (such as air, nitrogen, or another gas). For example, capsule elements 3140 and 3150 may be thermoplastic urethane (TPU) materials, urethane, polyurethane, polyester, polyester polyurethane and/or polyether polyurethane.

Furthermore, in one embodiment, capsule elements 3140, 3150 may be formed of one or more sheets with different material layers. The sheets may be laminates formed from thin films having one or more first layers comprising thermoplastic polyurethane layers and alternating with one or more second layers, also referred herein as barrier layers, gas barrier polymers, or gas barrier layers. The second layers may comprise a copolymer of ethylene and vinyl alcohol (EVOH) that is impermeable to pressurized fluids contained therein, as disclosed in U.S. Patent No. 6,082,025 to Bonk et al., which is incorporated herein by reference in its entirety. The first layers may be arranged to form the outer surface of the polymer sheet. That is, the outermost first layer may be the outer surface of capsule element 3140 or 3150. Capsule elements 3140 and 3150 may also be formed of materials comprising alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymers, as disclosed in U.S. Patents 5,713,141 and 5,952,065 to Mitchell et al., which are incorporated herein by reference in their entirety. Alternatively, the layers may comprise ethylene-vinyl alcohol copolymers, thermoplastic polyurethanes, and re-polished materials of ethylene-vinyl alcohol copolymers and thermoplastic polyurethanes. Each sheet may also be a flexible microlayer membrane comprising alternating layers of gas barrier polymer materials (such as a second layer) and elastomeric materials (such as a first layer), as disclosed in U.S. Patents 6,082,025 and 6,127,026 to Bonk et al., which are incorporated herein by reference in their entirety. Further suitable materials for capsule elements 3140 and 3150 are disclosed in U.S. Patents 4,183,156 and 4,219,945 to Rudy, which are incorporated herein by reference in their entirety. Other suitable materials for the capsule elements 3140 and 3150 include thermoplastic films containing crystalline materials, as disclosed in Rudy's U.S. Patents Nos. 4,936,029 and 5,042,176, and polyurethanes comprising polyester polyols, as disclosed in Bonk et al.'s U.S. Patents Nos. 6,013,340, 6,203,868, and 6,321,465, which are incorporated herein by reference in their entirety. In selecting the materials for the capsule elements 3140 and 3150, engineering properties such as tensile strength, tensile properties, fatigue characteristics, dynamic modulus, and loss factor may be considered. When the capsule element 3140 or 3150 is formed from a sheet, the thickness of the sheet used to form the capsule element 3140 or 3150 may be selected to provide these properties.

The forefoot bladder element 3140 and heel bladder element 3150 are formed of a polymeric material surrounding a fluid, which can be a gas, liquid, or gel. For example, during walking and running, the forefoot bladder element 3140 and heel bladder element 3150 can be compressed between the foot and the ground, thereby attenuating ground reaction forces. That is, after thermoforming, the forefoot bladder element 3140 and heel bladder element 3150 are inflated and typically pressurized with fluid to cushion the foot. Figure 14 shows a sealed inflation port 3155 through which fluid is introduced into the internal cavities 3142, 3152 before sealing.

In some configurations, the sole structure 3130 may include a foam layer, for example, extending between the upper 3120 and one or both of the forefoot pocket element 3140 and the heel pocket element 3150, or the foam element may be located within a recess in the lower region of the forefoot pocket element 3140 and the heel pocket element 3150. In other configurations, the forefoot sole structure 3131 may include a plate, adjuster, durable element, or motion control member for further damping force, enhancing stability, or influencing foot movement. The heel sole structure 3132 may also include such a member for further damping force, enhancing stability, or influencing foot movement.

The forefoot sole structure 3131 also includes a first outsole component 3060 fixed to the pouch element 3140, and a plurality of second outsole components 3062 fixed to the first outsole component 3060, as described herein. The first outsole component 3060 is shown separately in Figures 17 and 18. In Figure 14, the second outsole components 3062 are fixed to the first outsole component. The heel sole structure 3132 includes a first outsole component 3070 and second outsole components 3072 fixed to the first outsole component 3070, as described herein. The first outsole component 3070 is shown in Figures 21 and 22. As shown in Figure 14, the second outsole components 3072 are fixed to the first outsole component 3070. Figure 15 shows the first outsole components 3060 and 3070 fixed to the bladder elements 3140 and 3150, wherein the second outsole components 3062 and 3072 are removed.

In addition to providing the wear surface (i.e., the ground contact surface) for footwear articles, the forefoot outsole component 3060 and the heel outsole component 3070 can enhance various properties and characteristics of the sole structure 3130. The properties and characteristics of the outsole (such as thickness, flexibility, the properties and characteristics of the materials used to manufacture the outsole, and tensile strength) can be altered or selected to modify or otherwise adjust the cushioning response, compressibility, flexibility, and other properties and characteristics of the sole structure 3130. In the illustrated embodiment, the first outsole component is a first material, and the second outsole component is a second material different from the first material. The first outsole components 3060 and 3070 are injection-molded thermoplastic polyurethane (TPU) components, pre-formed in their desired shape and configuration by an injection molding process before being thermally bonded to the corresponding bladder elements 3140 and 3150 by the methods described herein. As described herein, the second outsole components 3062 and 3072 are made of rubber and pre-formed in their desired shape before being attached to the first outsole component 3060 or 3070. The first outsole component 3060 is a single, integral, one-piece component, and the first outsole component 3070 is also a single, integral, one-piece component. Each of the second outsole components 3062 and 3072 is also a single, integral, one-piece component.

The forefoot outsole component 3060 is attached to the lower surface of the forefoot pocket element 3140. In some embodiments, the forefoot sole structure 3131 may extend into the midfoot region. The forefoot outsole component 3060 may also be attached to the lower region of the forefoot pocket element 3140 in the midfoot region. The heel outsole component 3070 is attached to the lower region of the heel pocket element 3150. Both the heel pocket element 3150 and the heel outsole component 3070 may extend into the midfoot region. The forefoot outsole component 3060 and the heel outsole component 3070 may be formed of an abrasion-resistant material. The abrasion-resistant material may be transparent or translucent to provide a visually appealing effect. The abrasion-resistant material may be textured on the ground contact surface to impart adhesion friction, such as by including integral tread elements 3135, 3091 as described herein. Any or all of the components of the forefoot sole structure 3131 and the heel sole structure 3132 may be translucent or transparent, and may be colored or patterned for aesthetic purposes.

Figures 14, 17, and 18 also illustrate gas venting openings 2069 in the first outsole component 3060 of the forefoot sole structure 3131, and Figures 14, 21, and 22 illustrate gas venting openings 2079 in the first outsole component 3070 of the heel sole structure 3132, with only some indicated by reference numerals. These gas venting openings allow air or other gases trapped between the bladder element and the corresponding outsole component to escape during manufacturing. The inner surface of the outsole component can be shaped in a manner that allows trapped gas to accumulate and be directed to the gas venting openings. For example, small, interconnected grooves 2071 can be formed on the inner surface of the outsole component 3060 during injection molding, or can be provided in the surface by removing material after molding. As shown in Figure 19, the gas venting openings 2069 are at the bottom of the grooves 2071. As shown in Figure 22, the second outsole component 3070 also has a groove 2071 on its inner surface, which guides the trapped gas to the gas escaping opening 2079. The gas escaping opening 2079 is in fluid communication with the groove 3071.

The reinforcements of the outsole (e.g., including structural elements such as ribs), perforations, the height of the outsole walls, the number and location of the outsole walls and the walls of overlapping bladder elements (also referred to as the edges of the bladder elements), or other features of the outsole can be used to adjust the response of the sole structure. In particular, the overlap of the walls of outsole components with the sidewalls of the forefoot or heel bladder elements, or with the sidewalls of the underlying outsole components, as described and illustrated at least in Figures 14-28, can be used to adjust the elastic and cushioning response of the composite sole structure. Using the guidance provided herein, these and other properties and characteristics of the outsole, combined with the properties and characteristics of the fluid-filled bladder elements, can be selected and constructed to provide a desired cushioning response.

In the embodiments shown in Figures 14 to 28 and manufactured according to the descriptions of Figures 25 to 28, the configuration of the first outsole components 3060 and 3070 supports the corresponding pouch elements 3140 and 3150, and allows the second outsole component 3062 or 3072 to be received and partially nested within a recess 4050 in the first outsole component 3060 or a recess 4150 in the first outsole component 3070. Recesses 4050 and 4150 provide positioning guidance during assembly and, as discussed herein, protect the second outsole components 3062 and 3072 from delamination during wear. Furthermore, both the first outsole components 3060 and 3070 and the second outsole components 3062 and 3072 have tread elements 3135 and 3091, respectively. Tread elements 3135 and 3091 establish the ground contact surface of the sole structure (contacting the ground G in FIG. 24). By using tread elements 3135 and 3091 of different shapes and sizes and/or by using different materials for the first outsole components 3060 and 3062, different adhesion friction properties can be provided at the locations of the tread elements 3135 and 3091. Tread elements 3135 and 3091 can be protrusions, ridges, ground contact protrusions, or sections that impart adhesion friction. As shown in FIG. 14, tread elements 3135 have different sizes and shapes, including rectangular and trapezoidal. Tread element 3091 is generally larger than tread element 3135. Depending on the material used for the outsole components 3060, 3062, 3070, and 3072, the second outsole components 3062 and 3072 may provide increased or decreased adhesion friction relative to the first outsole components 3060 and 3070.

As best illustrated in Figures 17 and 20, the tread element 3135 of the first outsole components 3060 and 3070 is an integral part of the first outsole component (i.e., the tread element 3135 is formed together with the base and wall by injection molding of the first outsole component), and similarly, the tread element 3091 of the second outsole component 3062 or 3072 is also an integral part of the single-piece second outsole component 3062 or 3072. This configuration of the outsole components simplifies manufacturing and reduces the possibility of the tread element separating from the base of the outsole component during wear.

Figures 17 and 18 show the first outsole component 3060 before it is attached to the second outsole component 3062. Figures 21 and 22 show the first outsole component 3070 before it is attached to the second outsole component 3072. Figures 23 and 24 show the first outsole component 3060 attached to the bottom surface 3080 of the pouch element 3140 and to the side surfaces 3078 and 3079 of the pouch element 3140. More specifically, the first outsole component 3060 has a first base 3083 attached to the bottom surface 3080 of the pouch element 3140, a first wall 3085 integrally fixed to the side surface 3078 of the pouch element 3140 with the first base 3083, and a second wall 3087 integrally fixed to the side surface 3079 of the pouch element 3140 with the first base 3083. As indicated by the positions of the cross-sections in Figures 23 and 24 in Figure 14, and as shown in Figure 18, the first wall 3085 and the second wall 3087 are located at the arcuate portion of the fluid-filled internal cavity 3142. The second wall 3092 of the second outsole component 3062 is also located at the arcuate portion.

The first outsole component 3060 has an integral tread element 3135 at a predetermined portion of the bottom surface 3081 of the first outsole component, while other portions do not have tread elements. Figure 24 shows the base 3083 of the first outsole component 3060, which is attached to the first pouch element 3140 and has an integral tread element 3135 at a first portion 3082 of the bottom surface 3081 of the base 3083. The second portion 3084 of the bottom surface 3081 of the base 3083 does not have any tread element 3135. Another portion of the first outsole component 3060, shown as being attached to the pouch element 3140, also has a base 3083 and walls 3085, 3087 integrally formed with the base 3083, wherein the first portion 3082 of the base 3083 has an integral tread element 3135 and the second portion 3084 does not have any tread element. At least some of the non-tread portions lack tread elements 3135, specifically because the second outsole component 3062, with its own integral tread element, will be attached to the second portion 3084, as shown in Figure 14. This prevents the tread elements of the first outsole component 3060 from interfering with the attachment of the second outsole component 3062.

The second outsole component 3062 has a second base 3090 and optionally includes one or more integral tread elements 3091. The second base 3090 is fixed to a second portion 3084 of the bottom surface 3081 of the first base 3083. The second outsole component 3062 has a second wall 3092 integral with the second base 3090. The second wall 3092 is fixed to the outer surface 3094 of the first wall 3085 of the first outsole component 3060. The outer surface 3094 is adjacent to the second portion 3084 of the bottom surface 3081. With this configuration, the ground contact surface 3098 of the sole structure 3131 includes an integral tread element 3135 of the first outsole component 3060 and an integral tread element 3091 of the second outsole component 3062.

Similarly, as best shown in Figures 21 and 22, the first outsole component 3070 of the heel-sole structure 3132 has an integral tread element 3135 at a predetermined portion (such as at the first region 4004) of the bottom surface 4002 of the first outsole component 3070, and has a second region 4006 without any tread element. The first outsole component 3070 has a first base 4008 and an integral first wall 4010 extending from the first base adjacent to the second region 4006. The first wall 4010 is the outer wall. The first outsole component 3070 also has a second wall, referred to as the inner wall 4011, which is integral with the first base 4008.

The second outsole component 3072 has a second base 4012 fixed to the first base 4008. The second outsole component 3072 has a second wall 4014 (i.e., an outer wall), which is integral with the second base 4012 and fixed to the outer surface 4016 of the first wall 4010. As shown in Figures 14, 15, and 21, the second outsole component 3072 has an inner wall 4015, which is integral with the second base 4012 and fixed to the outer surface 4017 of the second wall 4011.

As best shown in Figure 23, the first outsole component 3060 has an arcuate shape corresponding to the arcuate shape of the fluid-filled internal cavity 3142, wherein the first wall 3085 is located at the outer periphery of the arcuate portion of the fluid-filled internal cavity 3142. The second wall 3092 of the second outsole component 3062 is also located at the arcuate portion. Therefore, the first wall 3085 and the second wall 3092 are outer walls. The second wall 3087 of the first outsole component 3060 is an inner wall located at the inner curve of the arcuate portion. The inner wall 3099 of the second outsole component 3062 is also located at the inner curve of the arcuate portion. The tubular arcuate portion of the bladder element supported by the outer and inner walls of the outsole components 3060 and 3070 provides support to act as a geometric constraint on the bladder element 3140 and provides stiffness to adjust the cushioning response of the bladder element 3140.

The reinforcements (e.g., including structural elements such as ribs) of the outsole components 3060, 3062, 3070, and 3072, the heights of the walls 3085, 3087, 3092, and 3099 of the outsole components 3060, 3062, 3070, and 3072, the number and position of the overlapping walls of the outsole components 3060, 3062, 3070, and 3072 and the overlapping walls of the pocket elements 3140 and 3150 (also referred to as the edges of the pocket elements), or other features of the outsole components 3060, 3062, 3070, and 3072 may also be used to adjust the response of the sole structures 3131 and 3132. Specifically, the overlap of the walls 3085, 3087, 4010, 4011 of the first outsole components 3060, 3070 away from their respective base portions 4008 and upward along the side surfaces 3078, 3079 of the forefoot pocket element 3140 or upward along the side surface of the heel pocket element 3150, and the overlap of the walls 3092, 3099, 4014 of the second outsole components 3062, 3072 away from their respective base portions and upward along the walls 3085, 3087, 4010, 4011 of the respective first outsole components 3060, 3070 (as described and illustrated at least in Figures 15 to 24) can be used to adjust the elastic and cushioning responses of the composite sole structures 3131, 3132. Using the guidance provided in this article, these and other properties and characteristics of the outsole components 3060, 3062, 3070, and 3072, combined with the properties and characteristics of the fluid-filled bladder elements 3140 and 3150, can be selected and constructed to provide the desired cushioning response.

The first outsole component 3060 and the second outsole component 3062 are cooperatively configured to be fitted together to help position the second outsole component 3062 on the first outsole component 3060 and reduce the likelihood of the second outsole component 3062 separating from the first outsole component 3060 during wear. More specifically, and as best shown in FIG24, the outer surface 3094 of the first wall 3085 of the first outsole component 3060 has a recess 4050. When the forefoot sole structure 3131 is thermoformed, the recess 4050 is adjacent to a second portion 3084 of the bottom surface 3081 of the first outsole component 3060, as shown in FIG24. Referring to FIGS. 25 and 26, the recess 4050 is provided due to the shape of the injection mold 5010 for injection molding the first outsole component 3060. In one embodiment, the injection mold 5010 may have an upper mold 5012 and a lower mold 5014, the upper mold 5012 and the lower mold 5014 having mold surfaces 5016 and 5018, respectively. When the first outsole component 3060 is molded to the contours of the mold surfaces 5016 and 5018, TPU material is injected through port 5020. A protrusion 5022 in the lower mold 5014 results in a recess 4050 in the first wall 3085 of the inner side of the first outsole component 3060. A similar protrusion 5022 results in a recess 4050 in the first wall 3085 of the outer side of the first outsole component 3060. The mold surface 5018 also has a recess 5026 for creating the tread element 3135. In addition, the mold surfaces 5016 and 5018 are formed such that the second wall 3087 (i.e., the inner wall) of the first outsole component 3060 has a greater height than the first wall 3085 (i.e., the outer wall) of the first outsole component 3060, and the upper ends 4070 and 4072 of the walls 3085 and 3087 taper.

The second wall 3092 of the second outsole component 3072 is configured such that it can be fitted into and secured to the outer surface of the first wall 3085 of the first outsole component 3060 within the recess 4050. The first outsole component 3070 and the second outsole component 3072 of the heel-sole structure 3132 are constructed cooperatively in the same manner.

Furthermore, as shown in Figure 24, the second wall 3092 has a first thickness T1, and the recess 4050 has a first depth D1. The first thickness T1 is greater than the first depth D1, such that the second outsole component 3062 protrudes outward from the first outsole component 3060 at the first wall 3085. The upper edge 4060 of the second outsole component 3062 abuts against or is located just below the lip 4062 of the first outsole component 3060 in the recess 4050. The lip 4062 protects the upper edge 4060 from directly applied forces during use, thereby reducing the possibility of delamination or other misalignment of the second outsole component 3062.

As best shown in Figure 23, the inner wall 3099 of the second outsole component 3062 extends upward from the second base 3090 of the second outsole component beyond the second wall 3092 (i.e., the outer wall) of the second outsole component. Support for the bladder element 3040 at the inner wall 3099 is desirable to limit inward movement of the bladder element 3040 during compression and deformation. The second outsole component 3072 of the bladder element 3050 can be similarly constructed, wherein the inner wall extends upward along the inner wall of the first outsole component 3070 beyond the outer wall.

In the illustrated embodiment, the recess 4050 extends through the bottom surface of the inner wall 3087 of the first outsole component 3060 and extends upward along the outer surface of the inner wall 3087 of the first outsole component 3060. Thus, as shown in FIG23, only a portion of the thickness T2 of the inner wall 3099 of the second outsole component 3062 protrudes from the outer surface of the inner wall 3087 of the first outsole component 3060. Alternatively, the recess 4050 may terminate at the bottom surface, such that the inner wall 3087 may be configured without a recess. Both the outer wall 3085 and the inner wall 3087 of the first outsole component 3060 have tapered upper ends 4070, 4072 (shown in FIG18) to help prevent the first outsole component 3060 from delamination from the pouch element 3140. The first outsole component 3070 is similarly configured to have a tapered upper end 4073 at the first wall 4010. As indicated in Figures 14 and 22, the upper end 4074 of the first outsole component 3070 extends upward along the inner wall of the tubular portion of the lower polymer sheet 3146 of the pouch element 3050 to the lower surface of the lower polymer sheet 3146 adjacent to the tubular portion, to provide maximum support against the inner wall of the pouch element 3150.

A method of manufacturing a footwear article including sole structure 3131 and/or sole structure 3132 as described above includes placing a pre-formed first outsole component 3160 into thermoforming molds 6012, 6014. In FIG. 27, the thermoforming molds are schematically depicted as including an upper mold 6012 and a lower mold 6014. As described with respect to FIG. 25 and FIG. 26 and shown in FIG. 17 and FIG. 18, the first outsole component 3060 is pre-formed with a base 3083 having an integral tread element 3135 projecting from a first portion 3082 of a bottom surface 3081 of the base; a second portion 3084 of the bottom surface 3081 without any tread element is pre-formed; and a wall 3085 is pre-formed integrally with the base 3083 and adjacent to the bottom surface of the second portion 3084. As used herein, “preformed” means that the first outsole component 3060 has certain features prior to the thermoforming process (i.e., prior to being placed in the thermoforming molds 6012, 6014).

In one embodiment, the lower mold 6014 may have one or more positioning marks to orient the first outsole component 3060. As shown in FIG27, the second mold surface 6018 has positioning marks 6024, and placing the first outsole component 3060 into the lower mold 6014 includes placing a predetermined portion of the first outsole component 3060 at the positioning marks 6024, thereby orienting the first outsole component 3060 at a predetermined position in the thermoforming mold 6014. The positioning marks 6024 are cavities in the second mold surface 6018, and the predetermined portion of the first outsole component 3060 is one of the tread elements 3135. Alternative positioning marks, such as those other than the positioning marks 6024, may be used.

The method also includes placing the polymer material together with the first outsole component 3060 in thermoforming molds 6012, 6014. The polymer material may be a first polymer sheet 3144 and a second polymer sheet 3146, also referred to as an upper polymer sheet and a lower polymer sheet due to their relative positions in the finished footwear article. Alternatively, the polymer material may be a preform (e.g., a polymer material not in sheet form).

The thermoforming molds 6012 and 6014 are then closed by placing the upper mold 6012 and the lower mold 6014 together, as shown in FIG28, to encapsulate the polymer material (i.e., the encapsulated portions of the sheets 3144 and 3146) and the first outsole component 3060 in a mold cavity 6028 defined between the mold surface 6026 of the upper mold 6012 and the mold surface 6018 of the lower mold 6014. The method then includes forming sheets 3144, 3146 by a combined thermoforming and vacuum forming process, which includes applying a vacuum to conform a first portion of polymer material (i.e., the encapsulated portion of the first sheet 3144) to a first mold surface (i.e., surface 6026) of a thermoforming die, and to conform a second portion of polymer material (i.e., the bottom surface 3080 of the encapsulated portion of the second sheet 3146) to the upper surface 3088 of the first outsole component 3060 and to a second mold surface 6018, with an internal cavity 3142 between the first sheet 3144 and the second sheet 3146. In FIG. 28, the lip 4062 of the first outsole component 3060 is not apparent because it is compressed against the mold surface 6018. After the thermoforming process is completed (i.e., after the bladder element 3140 and the first outsole component 3060 are removed from the thermoforming dies 6012, 6014), the internal cavity 3142 can be filled. A gap may exist between the bottom surface of the first outsole component 3060 and the mold surface 6018 to facilitate the removal of the outsole surface after thermoforming.

In an embodiment where the polymer materials are a first polymer sheet 3144 and a second polymer sheet 3146, the method then includes thermally bonding the first polymer sheet 3144 to the second polymer sheet 3146 to form an internal cavity 3142, and thermally bonding the lower surface 3080 of the second polymer sheet 3146 to the upper surface 3088 of the first outsole component.

The first polymer sheet 3144 and the second polymer sheet 3146 are thermally bonded to each other around the peripheral flange 3148 formed between the clamping surface 6030 and the seam forming surface 6070, and at the web region 3147 between the portion of the fluid-filled internal cavity 3142. When the molds 6012 and 6014 are closed, the clamping surface 6030 contacts and slides against a portion of the second seam forming surface 6070. The contact between the clamping surface 6030 and the second seam forming surface 6070 effectively cuts off excess portions 6810 and 6820 of the first polymer sheet 3144 and the second polymer sheet 3146 from the portion forming the capsule element 3140. The material forming the first polymer sheet 3144 and the second polymer sheet 3146 is compacted or otherwise agglomerated to form the flange 3148. In addition to forming the flange 3148, the first polymer sheet 3144 and the second polymer sheet 3146 (a) are shaped to produce the bladder element 3140, and (b) are compressed and joined to produce the web region 3147.

The thermoformed sheets 3144 and 3146 are allowed to cool, and then the molds 6012 and 6014 are opened by separating the upper mold 6012 and the lower mold 6014. After a predetermined cooling cycle, the thermally bonded upper polymer sheet 3144 and lower polymer sheet 3146, along with the first outsole component 3060, are removed from the molds 6012 and 6014 as a unit. If the molds 6012 and 6014 are configured to simultaneously mold multiple outsole structures 3131 and 3132, additional finishing may be necessary around the flange 3148 or between adjacent outsole structures. The bladder element 3140 with the attached first outsole component 3060 can be filled after thermoforming and before the attachment of the second outsole component 3062, or it can be filled after the attachment of the second outsole component 3062.

After the first outsole component 3060 is attached to the pouch element 3140, the second outsole component 3062 is positioned on a second portion 3084 of the bottom surface 3080 of the first outsole component 3060. The second outsole component 3062 is positioned by nesting it within a recess 4050. Nesting involves abutting the upper edge 4060 of the second outsole component 3062 against the lip 4062 of the first outsole component 3060 at the upper extent of the recess 4050, as indicated in FIG15 with respect to one of the outsole components 3062. As shown in FIG15, 23, and 24, the upper edge 4060 of the second outsole component 3062 abuts against the lip 4062 of the first outsole component 3060 within the recess 4050. The second outsole component 3062 is bonded to the first outsole component 3060. As shown in Figure 15, the footwear upper 3120 is then secured to the upper surface 4041 of the first polymer sheet 3144. In Figure 15, a flange 3148 is shown on the outer side of the sole structure 3130 and is bonded to the lower outer side of the upper 3120.

The method has been described with respect to the forefoot sole structure 3131. The method may further include injection molding a first outsole component 3070, a vacuum/thermoforming bladder element 3150, and thermally bonding the first outsole component 3070 to the bladder element 3150 in a thermoforming mold, attaching a second outsole component to the described 3070, and then securing the heel sole structure 3132 to the heel area of the upper 3120, wherein the front edge 3110 of the heel sole structure is adjacent to the rear edge 3112 of the forefoot sole structure, as shown in Figures 14 and 15.

While several models for implementing many aspects of this teaching have been described in detail, those skilled in the art to which these teachings pertain will recognize a variety of alternative aspects for practicing this teaching within the scope of the appended claims. All content contained in the above description or shown in the accompanying drawings is intended to be illustrative only and not restrictive.

Claims (14)

1. A sole structure for footwear articles, the sole structure comprising: A midsole, the midsole comprising a bladder element surrounding a fluid-filled internal cavity; A first outsole component is attached to the pouch element, and the first outsole component has a first tread element protruding from the bottom surface of the first outsole component. A second outsole component is positioned on the bottom surface of the first outsole component, and the second outsole component has a second tread element that protrudes from the bottom surface of the second outsole component. 2. The sole structure according to claim 1, wherein: The first tread element and the first outsole component are an integral, single-piece component. 3. The sole structure according to claim 1, wherein: The ground contact surface of the sole structure includes the first tread element of the first outsole component and the second outsole component. 4. The sole structure according to claim 1, wherein: The bottom surface of the first outsole component has a first portion and a second portion adjacent to the first portion; The first tread element protrudes at the first portion of the bottom surface of the first outsole component; and The second outsole component is attached to the second portion of the bottom surface of the first outsole component. 5. The sole structure of claim 4, wherein at least a portion of the second portion of the bottom surface of the first outsole component extends laterally outward from the first portion of the bottom surface of the first outsole component. 6. The sole structure according to claim 1, wherein: The first tread element and the second tread element establish the ground contact surface of the sole structure. 7. The sole structure according to claim 6, wherein the second tread element and the second outsole component are integral, single-piece components. 8. The sole structure according to claim 1, wherein the first outsole component is a first material, and the second outsole component is a second material different from the first material. 9. The sole structure according to claim 1, wherein: The bladder element is configured such that at least a portion of the fluid-filled internal cavity has a U-shape, the U-shape having an arcuate portion at the outer periphery of the sole structure; and The first outsole component has a U-shaped shape corresponding to the U-shaped shape of the fluid-filled internal cavity. 10. The sole structure according to claim 1, wherein: The footwear includes shoe uppers; and The flange of the bladder element extends upward along the side of the shoe upper. 11. A sole structure for footwear articles, the sole structure comprising: A midsole, the midsole comprising a bladder element surrounding a fluid-filled internal cavity; A first outsole component, the first outsole component having a gas venting opening that allows air or other gases trapped between the bladder element and the first outsole component to escape during manufacturing, the first outsole component having a first tread element that protrudes from the bottom surface of the first outsole component; and A second outsole component is attached to the bottom surface of the first outsole component, and the second outsole component has a second tread element that protrudes from the bottom surface of the second outsole component. 12. The sole structure according to claim 11, wherein: The inner surface of the first outsole component is shaped in a manner that allows trapped gas to accumulate and be guided to the gas escape opening. 13. The sole structure according to claim 11, wherein: A groove is formed on the inner surface of the first outsole component, and the gas escaping opening is at the bottom of the groove. 14. The sole structure according to claim 11, wherein: The second outsole component has a groove on its inner surface.