Cushioning Component for a Wearable Article

This application claims the benefit of priority to U.S. Provisional Application No. 63/632,059, filed Apr. 10, 2024, and to U.S. Provisional Application No. 63/681,951, filed Aug. 12, 2024, both of which are incorporated by reference in their entirety.

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

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

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

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

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

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

In one or more configurations, the at least one bond may have peaks and valleys extending in the fore-aft direction of the core. By utilizing nonlinear bonds and/or bonds having peaks and valleys extending in the fore-aft direction, the fore-aft extent of each such bond may be increased relative to a straight bond of the same width. This may increase the robustness of the bond and its ability to withstand repeated stresses, such as lateral forces, reducing the likelihood of delamination.

In an aspect, the narrowed portion of the at least one bond may be at a middle of the bond in a transverse direction of the core. In the same or in a different implementation, the bond may be symmetrical in a transverse direction of the core about the narrowed portion along a majority of the bond in the transverse direction.

In one or more configurations, each bond of the plurality of bonds may extend continuously from the medial edge of the core to the lateral edge of the core and may be wider in the fore-aft direction of the core at the medial edge and at the lateral edge than at a narrowed portion of the bond between the medial edge and the lateral edge. Configuring the bonds to extend to the medial and lateral edges of the core may further increase the integrity of the connection of the core to the barrier sheets via the bonds.

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

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

In an example, a thickness of each polymeric sheet of the core may be greater than (e.g., is less than or equal to) a thickness of the first barrier sheet and not greater than a thickness of the second barrier sheet.

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

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

In an example, the opposing inner surfaces of the bladder may include a first inner surface of the first barrier sheet and a second inner surface of the second barrier sheet and the core may be a multi-sheet core. The at least one polymeric sheet of the core may include a first polymeric sheet and a second polymeric sheet. The first polymeric sheet may be disposed between the first barrier sheet and the second polymeric sheet, and the second polymeric sheet may be disposed between the first polymeric sheet and the second barrier sheet such that a first side of the first polymeric sheet faces the first inner surface of the first barrier sheet, a second side of the first polymeric sheet faces a first side of the second polymeric sheet, and a second side of the second polymeric sheet faces the second inner surface of the second barrier sheet. The first side of the first polymeric sheet may be directly bonded to the first inner surface of the first barrier sheet at a first set of bonds of the plurality of bonds, the second side of the second polymeric sheet may be directly bonded to the second inner surface of the second barrier sheet at a second set of bonds of the plurality of bonds and the second side of the first polymeric sheet may be directly bonded to the first side of the second polymeric sheet at a third set of bonds of the plurality of bonds. The bonds of the third set may alternate with the bonds of the first set along a length of the core, and the bonds of the third set may alternate with the bonds of the second set along the length of the core.

In one or more configurations of such cores that include both a first and a second polymeric sheet, each of the first set, the second set, and the third set of bonds may include at least one bond that extends continuously from the medial edge of the core to the lateral edge of the core and is wider in the fore-aft direction of the core at the medial edge and at the lateral edge than at a narrowed portion of the bond between the medial edge and the lateral edge.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

show polymeric sheetsandused to form a coreshown in. The coreis included in a cushioning componentshown in. More specifically, the cushioning componentis included in a sole structureof an article of footwearas shown in. As further explained herein, the cushioning componentincludes a bladderincluding barrier sheetsandbonded to one another at a peripheral bond. The coreis disposed in the bladderand bonded to inner surfaces,of barrier sheets,of the bladder, as shown in, to act as a tensile component. Providing a tensile component within a bladder may be useful in restraining the bladder when inflated, preventing it from adopting a ball-like shape. A tensile component such as the coreaccording to the present disclosure enables bonding the polymeric sheets,to the barrier sheets,at bondsand, respectively, having patterns that result in technical advantages both in performance aspects of the cushioning componentand ease of manufacturing the cushioning component.

is a plan view of a bottom side of the polymeric sheetwith anti-weld materialdisposed thereon. The polymeric sheetis referred to herein as a second polymeric sheet. The side of the polymeric sheet shown inis a second sideand is also referred to as a bottom side or distal side as it is disposed further from the foot when the coreis incorporated in the sole structureof the article of footwear. The second sideinterfaces with and is bonded to the inner surfaceof the second barrier sheetas shown inand discussed herein.

is a plan view of an opposing first sideof the second polymeric sheetwith anti-weld materialdisposed thereon in a different pattern than on the second sideshown in. The first sideis also referred to as the top side or as the proximal side of the second polymeric sheetas it is disposed closer to the foot when the coreis incorporated in the sole structureof the article of footwear.

As best shown in, each of the core, the cushioning component, and the article of footwearincludes a forefoot region, a heel region, and a midfoot region. These regions are referred to as a forefoot region, a midfoot region, and a heel regionwith respect to the cushioning component, the sole structure, and the article of footwear. However, because the coreis of a shorter length than each of the cushioning component, the sole structure, and article of footwear, the forefoot region, midfoot region, and heel region of the coreare referred to asA,A, andA, respectively. The forefoot regionandA generally includes portions of the article of footwearor the corecorresponding with the toes and the joints connecting the metatarsals with the phalanges of a wearer's foot. The midfoot regionandA generally includes portions of the article of footwearor the corecorresponding with the arch area of the foot, and the heel regionandA corresponds with rear portions of the foot, including the calcaneus bone. Each of the core, the cushioning component, the sole structure, and the article of footwearinclude a medial sideand a lateral sidethat extend through each of forefoot regionandA, the midfoot regionandA, and the heel regionandA and fall on opposite sides of a longitudinal axis LM of the cushioning componentin. The longitudinal axis LM is also referred to herein as a longitudinal midline. The forefoot regionandA, the midfoot regionandA, the heel regionandA, the medial side, and the lateral sideare not intended to demarcate precise areas of footwear, the core, the cushioning component, or the sole structure, but are instead intended to represent general areas of the article of footwear, the core, the cushioning component, and the sole structureto aid in the following discussion.

is a plan view of a first sideof the first polymeric sheetwith anti-weld materialdisposed thereon. The opposite second sidedoes not have any anti-weld material disposed thereon. The first polymeric sheetis stacked on the second polymeric sheetwhen the coreis assembled such that the second sideinterfaces with and is bonded to the first sideof the second polymeric sheetand the first sideinterfaces with and is bonded to the inner surfaceof the first barrier sheetas shown inand discussed herein.

The anti-weld materialis disposed on the polymeric sheets,of the coreat areas that will be unbonded areas when the coreis thermally processed. By utilizing anti-weld materialdisposed on the polymeric sheets,, the patterns of bonds of the coreto the inner surfaces,of the barrier sheets,(and the bonds of the second sideof the first polymeric sheetto the first sideof the second polymeric sheet) are controlled to determine the final geometry of the completed cushioning component, including height differentials in different regions (e.g., forefoot regionand heel region) of an article of footwear, toe spring, etc. As shown in, portions of one or both of the inner surfaces,that are outward of the outer perimeterof the coreand inward of where the peripheral bondis formed may also be preprinted or otherwise prepared with anti-weld materialor otherwise processed so that these portions of the inner surfaces,will not bond to one another. This enables a peripheral portionA of the interior cavityoutward of the core.

The anti-weld materialmay be disposed on the polymeric sheetsand(and on the portions of the inner surfaces,of the first barrier sheetand/or second barrier sheetshown in) via a computer-controlled printer head or heads (not shown) according to a stored algorithm representing a predetermined printing pattern. As used herein, the anti-weld materialmay be blocker ink, and may also be referred to as anti-weld ink. For example, when the anti-weld material is blocker ink, it may be printed according to a different predetermined programmed pattern for the first sideof the first polymeric sheet, the first sideof the second polymeric sheet, and the second sideof the second polymeric sheetat all selected locations where bonding of the polymeric sheets,of the coreto one another or to the barrier sheets,is not desired. After trimming the sheets,to establish the outer perimetersB,A and when bonded to one another such as by thermal processing, adjacent surfaces of the stacked, flat polymeric sheets,and barrier sheets,are bonded to one another except where the anti-weld materialis disposed. Accordingly, the patterns of anti-weld materialdetermine corresponding patterns of resulting bonds in the finished cushioning component.

The predetermined pattern of anti-weld materialon the second sideof the second polymeric sheetinis referred to as a second predetermined pattern and results in a second set of bondsdiscussed with respect to, and. The predetermined pattern of anti-weld materialon the first sideof the second polymeric sheetinis referred to as a third predetermined pattern and results in a third set of bondsdiscussed with respect to. The predetermined pattern of anti-weld materialon the first sideof the first polymeric sheetis referred to as a first predetermined pattern and results in a first set of bondsdiscussed with respect to.

With reference to, the anti-weld materialis disposed on the second sideof the second polymeric sheetin the second predetermined pattern at spaced regions A, B, C, D, E, F, G, H, I, J, K, L, M, N, and O of deposited anti-weld material. Areas of the second sideof the second polymeric sheetbetween any adjacent two of the spaced regions A, B, C, D, E, F, G, H, I, J, K, L, M, N, and O are free from anti-weld material. More specifically, areaA between adjacent regions A and B is free from anti-weld material, areaB between adjacent spaced regions B and C is free from anti-weld material, areaC between adjacent spaced regions C and D is free from anti-weld material, areaD between adjacent spaced regions D and E is free from anti-weld material, areaE between adjacent spaced regions E and F is free from anti-weld material, areaF between adjacent spaced regions F and G is free from anti-weld material, areaG between adjacent spaced regions G and H is free from anti-weld material, areaH between adjacent spaced regions H and I is free from anti-weld material, areaI between adjacent spaced regions I and J is free from anti-weld material, areaJ between adjacent spaced regions J and K is free from anti-weld material, areaK between adjacent spaced regions K and L is free from anti-weld material, areaL between adjacent spaced regions L and M is free from anti-weld material, areaM between adjacent spaced regions M and N is free from anti-weld material, and areaN between adjacent spaced regions N and O is free from anti-weld material. The areasA,B,C,D,E,F,G,H,I,J,K,L,M, andN will become a second set of bondsshown ineach corresponding with one of the areasA-N.

Each of the areasA-N has a nonlinear shape including linear segments such that the second set of bondsare nonlinear bonds as further described with respect to. The second polymeric sheetis trimmed to an outer perimeterA shown inafter printing the anti-weld materialsuch that the areas A-O of anti-weld materialextend to the perimeterA and the areasA-N and corresponding resulting bondsalso extend to the perimeterA at both the medial and lateral sides,.

With reference to, the anti-weld materialis disposed on the first sideof the second polymeric sheetin the third predetermined pattern at spaced regions P, Q, R, S, T, U, V, W, X, Y, Z, A, B, and Cof deposited anti-weld material. Areas of the first sideof the second polymeric sheetbetween any adjacent two of the spaced regions P, Q, R, S, T, U, V, W, X, Y, Z, A, B, and Care free from anti-weld material. More specifically, areaP between adjacent regions P and Q is free from anti-weld material, areaQ between adjacent spaced regions Q and R is free from anti-weld material, areaR between adjacent spaced regions R and S is free from anti-weld material, areaS between adjacent spaced regions S and T is free from anti-weld material, areaT between adjacent spaced regions T and U is free from anti-weld material, areaU between adjacent spaced regions U and V is free from anti-weld material, areaV between adjacent spaced regions V and W is free from anti-weld material, areaW between adjacent spaced regions W and X is free from anti-weld material, areaX between adjacent spaced regions X and Y is free from anti-weld material, areaY between adjacent spaced regions Y and Z is free from anti-weld material, areaZ between adjacent spaced regions Z and Ais free from anti-weld material, areaAbetween adjacent spaced regions Aand Bis free from anti-weld material, and areaBbetween adjacent spaced regions Band Cis free from anti-weld material. The areasP,Q,R,S,T,U,V,W,X,Y,Z,A, andBwill become a third set of bondsshown in, each corresponding with one of the areasP-B.

Each of the areasP-Bhas a nonlinear shape including linear segments such that the third set of bondsare nonlinear bonds as further described with respect to. The second polymeric sheetis trimmed to an outer perimeterA shown inand after printing the anti-weld materialsuch that the areas P-Cof anti-weld materialextend to the perimeterA and the areasP-Band corresponding resulting bondsalso extend to the perimeterA.

With reference to, the anti-weld materialis disposed on the first sideof the first polymeric sheetin the first predetermined pattern at spaced regions D, E, F, G, H,, J, K, L, M, N, P, Q, R, and Sof deposited anti-weld material. Areas of the first sideof the first polymeric sheetbetween any adjacent two of the spaced regions D, E, F, G, H,, J, K, L, M, N, P, Q, R, and Sare free from anti-weld material. More specifically, areaA between adjacent regions Dand Eis free from anti-weld material, areaB between adjacent spaced regions Eand Fis free from anti-weld material, areaC between adjacent spaced regions Fand Gis free from anti-weld material, areaD between adjacent spaced regions Gand His free from anti-weld material, areaE between adjacent spaced regions Hand Iis free from anti-weld material, areaF between adjacent spaced regions Iand Jis free from anti-weld material, areaG between adjacent spaced regions Jand Kis free from anti-weld material, areaH between adjacent spaced regions Kand Lis free from anti-weld material, areaI between adjacent spaced regions Land Mis free from anti-weld material, areaJ between adjacent spaced regions Mand Nis free from anti-weld material, areaK between adjacent spaced regions Nand Pis free from anti-weld material, areaL between adjacent spaced regions Pand Qis free from anti-weld material, areaM between adjacent spaced regions Qand Ris free from anti-weld material, and areaN between adjacent spaced regions Rand Sis free from anti-weld material. The areasA,B,C,D,E,F,G,H,I,J,K,L,M, andN will become a first set of bondsshown in, each corresponding with one of the areasA-N.

Each of the areasA-N has a nonlinear shape including linear segments such that the first set of bondsare nonlinear bonds as further described with respect to. The first polymeric sheetis trimmed to an outer perimeterB shown inand after printing the anti-weld materialsuch that the regions D-Sof anti-weld materialextend to the outer perimeterB and the areasA-N and corresponding resulting bondsalso extend to the outer perimeterB.