Article of footwear and method of manufacturing an article of footwear

#The present teachings generally include an article of footwear and a method of manufacturing an article of footwear.

#To ensure a proper fit, footwear is typically offered in a range of sizes with relatively small increments between sizes. The footwear typically includes an upper, and a sole structure underlying the upper. Both the sole structure and the upper are manufactured according to a specific size. The need for separate tooling for each size increases production costs. The logistics and floor space required for producing and stocking different sizes of these subcomponents of the article of footwear can increase production costs.

#FIG. 1 is a schematic illustration in bottom view of a first embodiment of an article of footwear.

#FIG. 2 is a schematic illustration in lateral side view of the article of footwear of FIG. 1.

#FIG. 3 is a schematic illustration in bottom view of a forefoot sole structure of the article of footwear of FIG. 1.

#An article of footwear comprises a sole structure that is configured to be used in the manufacturing of multiple different sizes, increasing manufacturing flexibility and reducing manufacturing costs. The sole structure includes a polymeric bladder element enclosing a fluid-filled interior cavity. The bladder element has a peripheral flange that surrounds the fluid-filled interior cavity. The peripheral flange has a transverse edge extending from the lateral side of the bladder element to the medial side of the bladder element. Optionally, the transverse edge may be further forward at the medial side than at the lateral side.

#The bladder element has a surface with a groove that extends generally parallel with the transverse edge from the lateral side to the medial side, and the bladder element has a reduced thickness at the groove. The bladder element has a first length along a longitudinal midline of the bladder element from a longitudinal extremity of the bladder element to the groove. The bladder element has a longer second length along the longitudinal midline of the bladder element from the longitudinal extremity to the transverse edge. The first length corresponds with a first footwear size, and the second length corresponds with a second footwear size larger than the first footwear size.

#Accordingly, by trimming along the groove, the sole structure may be used in the production of articles of footwear of a first size, or may be used in the production of articles of footwear of a larger second size if not trimmed at the groove. The groove is configured to easily and accurately enable the sole structure to be adapted for use with the smaller footwear size when trimmed along the groove. Grading of sole structures with fluid-filled interior cavities, such as with a bladder element, presents unique challenges because the integrity of the sealed fluid-filled interior cavity cannot be compromised. As used herein, “grading” an article of footwear or a method of “grading” footwear refers to the method by which different sizes of footwear are manufactured. The groove is positioned such that it does not interfere with or limit the often complex contoured shape of the fluid-filled cavity in a bladder element.