Articles of footwear comprising a wound component and methods of making the same

Articles of footwear and methods of making articles of footwear including one or more continuous threads wound around anchor points. In some embodiments, thread lines of continuous thread(s) may extend tangential to an opening on a thread pattern or an upper. In some embodiments, thread lines of continuous thread(s) may define a portion of an upper and extend through a sole for an article of footwear. In some embodiments, thread patterns defined by the continuous thread(s) may be bonded to each other around a sheet to form an upper material for an upper.

FIELD

The described embodiments generally relate to articles of footwear and methods of making articles of footwear. In particular, described embodiments relate to articles of footwear with uppers including a component made by winding a continuous thread into a thread pattern.

BACKGROUND

Individuals are often concerned with the durability, weight, and/or comfort of an article of footwear. This is true for articles of footwear worn for non-performance activities, such as a leisurely stroll, and for performance activities, such as running. Durable footwear will properly function for an extended period of time. Lightweight footwear minimizes the weight an individual has to carry on his or her feet and may be comfortable for an individual. Customized footwear may increase comfort for an individual because it is tailored to the individual's foot anatomy.

For some individuals, for example athletes, stability and propulsion may be desired characteristics for an article of footwear. Footwear that facilitates propulsion (for example, forward and/or upward motion) may help an athlete perform at an optimal athletic level. Stability for footwear, and in particular stability in portions supporting the ankles of an individual, may reduce the chance of injury to the individual's feet.

Proper footwear should be durable, comfortable, and provide other beneficial characteristics for an individual. Therefore, a continuing need exists for innovations in footwear and components used to manufacture the footwear.

BRIEF SUMMARY

A first aspect (1) of the present application is directed to an upper for an article of footwear, the upper including an opening comprising a perimeter edge; a plurality of anchor points disposed around the perimeter edge; and a continuous thread wound around the plurality of anchor points, the continuous thread comprising a plurality of thread lines with each thread line extending between two respective anchor points and extending tangential to the perimeter edge of the opening.

In a second aspect (2), the plurality of thread lines extending tangential to the perimeter edge of the opening according to the first aspect (1) are not wound around an anchor point located at the perimeter edge of the opening.

In a third aspect (3), the opening according to the first aspect (1) or the second aspect (2) defines at least a portion of a collar for an article of footwear.

In a fourth aspect (4), the plurality of thread lines according to any one of aspects (1)-(3) comprise one or more thread lines located on the medial side of the perimeter edge and one or more thread lines located on the lateral side of the perimeter edge.

In a fifth aspect (5), the perimeter edge of the opening according to any one of aspects (1)-(4) is surrounded by a plurality of the plurality of thread lines.

In a sixth aspect (6), the plurality of thread lines according to any one of aspects (1)-(5) comprise: a first thread line, and a second thread line, where the first thread line and the second thread line overlap each other at an overlap point, and where the first thread line is disposed at an angle relative to the second thread line.

In a seventh aspect (7), an angle of intersection at the overlap point of the first thread line and the second thread line according to the sixth aspect (6) is greater than 90°.

In an eighth aspect (8), an angle of intersection at the overlap point of the first thread line and the second thread line according to the sixth aspect (6) is greater than 120°.

In a ninth aspect (9), the plurality of anchor points according to any one of aspects (1)-(8) comprise a forefoot anchor point and a rearfoot anchor point, and one of the plurality of thread lines extends from the forefoot anchor point to the rearfoot anchor point.

In a tenth aspect (10), the plurality of anchor points according to any one of aspects (1)-(9) comprise a medial side anchor point and a lateral side anchor point, and one of the plurality of thread lines extends from the medial side anchor point to the lateral side anchor point.

In an eleventh aspect (11), the plurality of thread lines according to any one of aspects (1)-(10) comprise 10 or more thread lines.

In a twelfth aspect (12), the plurality of thread lines according to any one of aspects (1)-(10) comprise 20 or more thread lines.

In a thirteenth aspect (13), the plurality of anchor points according to any one of aspects (1)-(12) comprise: a first rearfoot anchor point, a second rearfoot anchor point adjacent to the first rearfoot anchor point, a first forefoot anchor point, and a second forefoot anchor point, and the plurality of thread lines comprise: a first thread line extending from the first rearfoot anchor point to the first forefoot anchor point, and a second thread line extending from the second rearfoot anchor point to the second forefoot anchor point.

In a fourteenth aspect (14), the first thread line and the second thread line according to the thirteenth aspect (13) overlap each other at an overlap point.

In a fifteenth aspect (15), the first thread line and the second thread line according to the fourteenth aspect (14) are directly bonded to each other at the overlap point.

In a sixteenth aspect (16), the plurality of anchor points according to the thirteenth aspect (13) further comprise: a third rearfoot anchor point adjacent to the second rearfoot anchor point, and a third forefoot anchor point, and the plurality of thread lines further comprise a third thread line extending from the third rearfoot anchor point to the third forefoot anchor point.

In a seventeenth aspect (17), the plurality of anchor points according to any one of aspects (1)-(12) comprise a first rearfoot anchor point and five adjacent forefoot anchor points, where one of the plurality of thread lines extends from the rearfoot anchor point to a first one of the five adjacent forefoot anchor points, and where the continuous thread further comprises a plurality of non-opening-tangential thread lines that are not tangential to the perimeter edge of the opening, the non-opening-tangential thread lines comprising: a first non-opening-tangential thread line extending from the rearfoot anchor point to a second one of the five adjacent forefoot anchor points, a second non-opening-tangential thread line extending from the rearfoot anchor point to a third one of the five adjacent forefoot anchor points, a third non-opening-tangential thread line extending from the rearfoot anchor point to a fourth one of the five adjacent forefoot anchor points, and a fourth non-opening-tangential thread line extending from the rearfoot anchor point to a fifth one of the five adjacent forefoot anchor points.

In an eighteenth aspect (18), the plurality of anchor points according to the seventeenth aspect (17) comprise a second rearfoot anchor point adjacent to the first rearfoot anchor point, and wherein the continuous thread comprises a non-opening-tangential thread line extending from the second rearfoot anchor point to one of the five adjacent forefoot anchor points.

A nineteenth aspect (19) of the present application is directed to an upper for an article of footwear, the upper comprising: an opening comprising a perimeter edge; and a thread pattern defining at least a portion of the perimeter edge of the opening, the thread pattern comprising a first thread line extending tangential to the perimeter edge of the opening and a second thread line extending tangential to the perimeter edge of the opening, where the first thread line and the second thread line overlap each other at an overlap point, and where the first thread line and the second thread line are directly bonded to each other at the overlap point.

In a twentieth aspect (20), the first thread line and the second thread line according to the nineteenth aspect (19) are directly bonded to each other via a polymeric material of at least one of: the first thread line or the second thread line.

In a twenty-first aspect (21), an angle of intersection at the overlap point of the first thread line and the second thread line according to the nineteenth aspect (19) or the twentieth aspect (20) is greater than 90°.

In a twenty-second aspect (22), an angle of intersection at the overlap point of the first thread line and the second thread line according to the nineteenth aspect (19) or the twentieth aspect (20) is greater than 120°.

In a twenty-third aspect (23), the opening according to any one of aspects (19)-(22) defines at least a portion of a collar for an article of footwear.

In a twenty-fourth aspect (24), the upper according to any one of aspects (19)-(23) further comprises a third thread line extending tangential to the perimeter edge of the opening and a fourth thread line extending tangential to the perimeter edge of the opening, where the third thread line and the fourth thread line overlap each other at a second overlap point, and where the third thread line and the fourth thread line are directly bonded to each other at the second overlap point.

In a twenty-fifth aspect (25), the first and second thread lines according to the twenty-fourth aspect (24) extend tangential to a first side of the perimeter edge of the opening, and the third and fourth thread lines extend tangential to a second side of the perimeter edge of the opening.

In a twenty-sixth aspect (26), the upper according to the twenty-fifth aspect (25) is provided and the first side is a medial side of the perimeter edge and the second side is a lateral side of the perimeter edge.

A twenty-seventh aspect (27) of the present application is directed to an upper material for an article of footwear, the upper material comprising: an opening comprising a perimeter edge; a plurality of anchor points disposed around the perimeter edge; and a continuous thread wound around the plurality of anchor points, the continuous thread comprising a plurality of thread lines with each thread line extending between two respective anchor points and extending tangential to the perimeter edge of the opening.

In a twenty-eighth aspect (28), the plurality of thread lines extending tangential to the perimeter edge of the opening according to the twenty-seventh aspect (27) are not wound around an anchor point located at the perimeter edge of the opening.

In a twenty-ninth aspect (29), the opening according to the twenty-seventh aspect (27) or the twenty-eighth aspect (28) defines at least a portion of a collar for an article of footwear.

In a thirtieth aspect (30), plurality of thread lines according to any one of aspects (27)-(29) comprise one or more thread lines located on the medial side of the perimeter edge and one or more thread lines located on the lateral side of the perimeter edge.

In a thirty-first aspect (31), the perimeter edge of the opening according to any one of aspects (27)-(30) is surrounded by a plurality of the plurality of thread lines.

In a thirty-second aspect (32), the plurality of thread lines according to any one od aspects (27)-(31) comprise: a first thread line, and a second thread line, where the first thread line and the second thread line overlap each other at an overlap point, and where the first thread line is disposed at an angle relative to the second thread line.

In a thirty-third aspect (33), an angle of intersection at the overlap point of the first thread line and the second thread line according to the thirty-second aspect (32) is greater than 90°.

In a thirty-fourth aspect (34), an angle of intersection at the overlap point of the first thread line and the second thread line according to the thirty-second aspect (32) is greater than 120°.

In a thirty-fifth aspect (35), the plurality of anchor points according to any one of aspects (27)-(34) comprise a forefoot anchor point and a rearfoot anchor point, and one of the plurality of thread lines extends from the forefoot anchor point to the rearfoot anchor point.

In a thirty-sixth aspect (36), the plurality of anchor points according to any one of aspects (27)-(35) comprise a medial side anchor point and a lateral side anchor point, and one of the plurality of thread lines extends from the medial side anchor point to the lateral side anchor point.

In a thirty-seventh aspect (37), the plurality of thread lines according to any one of aspects (27)-(36) comprise 10 or more thread lines.

In a thirty-eighth aspect (38), the plurality of thread lines according to any one of aspects (27)-(36) comprise 20 or more thread lines.

In a thirty-ninth aspect (39), the plurality of anchor points according to any one of aspects (27)-(34) comprise: a first rearfoot anchor point, a second rearfoot anchor point adjacent to the first rearfoot anchor point, a first forefoot anchor point, and a second forefoot anchor point, and the plurality of thread lines comprise: a first thread line extending from the first rearfoot anchor point to the first forefoot anchor point, and a second thread line extending from the second rearfoot anchor point to the second forefoot anchor point.

In a fortieth aspect (40), the first thread line and the second thread line according to the thirty-ninth aspect (39) overlap each other at an overlap point.

In a forty-first aspect (41), the first thread line and the second thread line according to the fortieth aspect (40) are directly bonded to each other at the overlap point.

In a forty-second aspect (42), the plurality of anchor points according to the thirty-ninth aspect (39) further comprise: a third rearfoot anchor point adjacent to the second rearfoot anchor point, and a third forefoot anchor point, and the plurality of thread lines further comprise a third thread line extending from the third rearfoot anchor point to the third forefoot anchor point.

In a forty-third aspect (43), the plurality of anchor points according to any one of aspects (27)-(34) comprise a first rearfoot anchor point and five adjacent forefoot anchor points, where one of the plurality of thread lines extends from the rearfoot anchor point to a first one of the five adjacent forefoot anchor points, and where the continuous thread further comprises a plurality of non-opening-tangential thread lines that are not tangential to the perimeter edge of the opening, the non-opening-tangential thread lines comprising: a first non-opening-tangential thread line extending from the rearfoot anchor point to a second one of the five adjacent forefoot anchor points, a second non-opening-tangential thread line extending from the rearfoot anchor point to a third one of the five adjacent forefoot anchor points, a third non-opening-tangential thread line extending from the rearfoot anchor point to a fourth one of the five adjacent forefoot anchor points, and a fourth non-opening-tangential thread line extending from the rearfoot anchor point to a fifth one of the five adjacent forefoot anchor points.

In a forty-fourth aspect (44), the plurality of anchor points according to the forty-third aspect (43) comprise a second rearfoot anchor point adjacent to the first rearfoot anchor point, and the continuous thread comprises a non-opening-tangential thread line extending from the second rearfoot anchor point to one of the five adjacent forefoot anchor points.

A forty-fifth aspect (45) of the present application is directed to a method of making an upper for an article of footwear, the method comprising: defining a plurality of anchor points; defining a boundary line; winding a continuous thread around the plurality of anchor points, the continuous thread comprising a set of thread lines with each thread line in the set extending between two respective anchor points and tangential to the boundary line; and bonding the continuous thread at points of intersection between two or more the thread lines.

In a forty-sixth aspect (46), the boundary line according to the forty-fifth aspect (45) comprises a curved shape.

A forty-seventh aspect (47) of the present application is directed to a method of making an upper for an article of footwear, the method comprising: winding a first continuous thread around a plurality of anchor points disposed on a support plate to form a first thread pattern, the first continuous thread comprising a plurality of thread lines with each thread line extending between two respective anchor points; disposing a sheet over the first continuous thread wound around the plurality of anchor points; winding a second continuous thread over the sheet and around the plurality of anchor points disposed on the support plate to form a second thread pattern, the second continuous thread comprising a plurality of thread lines with each thread line extending between two respective anchor points; and bonding the first thread pattern to the second thread pattern to form an upper material.

In a forty-eighth aspect (48), the method according to the forty-seventh aspect (47) further comprises removing the sheet.

In a forty-ninth aspect (49), the method according to the forty-seventh aspect (47) or the forty-eighth aspect (48) further comprises turning the upper material inside-out.

In a fiftieth aspect (50), the first continuous thread and the second continuous thread according to any one of aspects (47)-(49) are portions of a single thread.

In a fifty-first aspect (51), the first continuous thread and the second continuous thread according to any one of aspects (47)-(49) comprise different threads.

In a fifty-second aspect (52), the sheet according to any one of aspects (47)-(51) comprises a polymeric material.

In a fifty-third aspect (53), the sheet according to any one of aspects (47)-(51) comprises a silicone material.

In a fifty-fourth aspect (54), bonding the first thread pattern to the second thread pattern according to any one of aspects (47)-(53) comprises bonding the first thread pattern to the second thread pattern around a perimeter of the sheet.

In a fifty-fifth aspect (55), bonding the first thread pattern to the second thread pattern according to any one of aspects (47)-(54) comprises directly bonding the first continuous thread to the second continuous thread.

In a fifty-sixth aspect (56), the method according to any one of aspects (47)-(55) further comprises cutting the first thread pattern and the second thread pattern around a perimeter of the sheet.

In a fifty-seventh aspect (57), the method according to any one of aspects (47)-(56) further comprises defining an opening in the upper material.

In a fifty-eighth aspect (58), the method according to the fifty-seventh aspect (57) further comprises removing the sheet through the opening.

In a fifty-ninth aspect (59), the opening according to the fifty-seventh aspect (57) or the fifty-eighth aspect (58) defines at least a portion of a collar for an article of footwear.

In a sixtieth aspect (60), the method according to any one of aspects (47)-(59) further comprises directly bonding the thread lines of the first thread pattern to each other and directly bonding the thread lines of the second pattern to each other.

In a sixty-first aspect (61), directly bonding the thread lines of the first thread pattern to each other and directly bonding the thread lines of the second thread pattern to each other according to the sixtieth aspect (60) is performed while the sheet is disposed between the first thread pattern and the second thread pattern.

In a sixty-second aspect (62), directly bonding the thread lines of the first thread pattern to each other and directly bonding the thread lines of the second thread pattern according to the sixtieth aspect (60) is performed while bonding the first thread pattern to the second thread pattern.

A sixty-third aspect (63) of the present application is directed to a method of making an upper for an article of footwear, the method comprising: winding a first continuous thread around a plurality of anchor points disposed on first a support plate to form a first thread pattern, the first continuous thread comprising a plurality of thread lines with each thread line extending between two respective anchor points; winding a second continuous thread around a plurality of anchor points disposed on a second support plate to form a second thread pattern, the second continuous thread comprising a plurality of thread lines with each thread line extending between two respective anchor points; disposing a sheet between the first thread pattern and the second thread pattern; bonding the first thread pattern to the second thread pattern while the sheet is disposed between the first thread pattern and the second thread pattern to form an upper material.

In a sixty-fourth aspect (64), the method according to the sixty-third aspect (63) further comprises removing the sheet.

In a sixty-fifth aspect (65), the method according to the sixty-third aspect (63) or sixty-fourth aspect (64) further comprises turning the upper material inside-out.

In a sixty-sixth aspect (66), the method according to any one of aspects (63)-(65) further comprises directly bonding the thread lines of the first thread pattern to each other and directly bonding the thread lines of the second thread pattern to each other.

A sixty-seventh aspect (67) of the present application is directed to an article of footwear including a sole; and an upper coupled to the sole, the upper comprising: a seam; a plurality of thread lines extending from a first side of the seam, through the sole, and to a second side of the seam.

In a sixty-eighth aspect (68), a portion of each of the plurality of thread lines that extend through the sole according to the sixty-seventh aspect (67) is embedded within the sole.

In a sixty-ninth aspect (69), the plurality of thread lines according to the sixty-seventh aspect (67) or the sixty-eighth aspect (68) are directly bonded to each other at points of intersection between two or more of the thread lines.

In a seventieth aspect (70), the plurality of thread lines according to any one of aspects (67)-(69) define a thread pattern, and wherein a first end of the thread pattern is directly coupled to a second end of the thread pattern at the seam.

In a seventy-first aspect (71), a portion of the first end of the thread pattern according to the seventieth aspect (70) overlaps a portion of the second end of the thread pattern at the seam.

In a seventy-second aspect (72) the plurality of thread lines according to the seventy-first aspect (71) extend from the first side of the seam, over a portion of a first side of the sole, through the sole, over a portion of a second side of the sole, and to the second side of the seam.

In a seventy-third aspect (73), the sole according to any one of aspects (67)-(72) is an injection-molded sole.

In a seventy-fourth aspect (74), the sole according to any one of aspects (67)-(73) comprises a top surface and bottom surface disposed opposite the top surface, and the plurality of thread lines comprise: a first plurality of thread lines extending through the sole at a first distance from the bottom surface of the sole, and a second plurality of thread lines extending through the sole at a second distance from the bottom surface of the sole, the second distance being different from the first distance.

In a seventy-fifth aspect (75), the second distance according to the seventy-fourth aspect (74) is 10% or more different from the first distance.

In a seventy-sixth aspect (76), the plurality of thread lines according to any one of aspects (67)-(75) define a first set of thread lines and the upper comprises a second set of thread lines extending from a first side of a second seam, through the sole, and to a second side of the second seam.

In a seventy-seventh aspect (77), the article of footwear according to the seventy-sixth aspect (76) is provided and the first set of thread lines is disposed in a forefoot portion of the article of footwear and the second set of thread lines is disposed in a heel portion of the article of footwear.

In a seventy-eighth aspect (78), the sole according to the seventy-seventh aspect (77) comprises a top surface and bottom surface disposed opposite the top surface, the first set of thread lines extends through the sole at a first distance from the bottom surface of the sole, the second set of thread lines extends through the sole at a second distance from the bottom surface of the sole, and the second distance is different from the first distance.

An seventy-ninth aspect (79) of the present application is directed to an article of footwear including a sole; and an upper coupled to the sole and comprising a plurality of thread lines defining a thread pattern, wherein the thread pattern comprises a plurality of thread lines that extend from a medial side of the upper, through the sole, and to a lateral side of the upper.

In an eightieth aspect (80), a portion of each of the plurality of thread lines that extend through the sole according to the seventy-ninth aspect (79) is embedded within the sole.

In an eighty-first aspect (81), a first side of the thread pattern according to the seventy-ninth aspect (79) or the eightieth aspect (80) is directly coupled a second side of the thread pattern at a seam.

An eighty-second aspect (82) of the present application is directed to a method of making an article of footwear, the method including defining a plurality of anchor points; winding a continuous thread around the plurality of anchor points to form a thread pattern, the continuous thread comprising a plurality of thread lines with each thread line extending between two respective anchor points; and molding a sole material on the thread pattern such that a least a portion of the thread pattern is embedded within the sole material.

In an eighty-third aspect (83), the method according to the eighty-second aspect (82) further comprises bonding the continuous thread at points of intersection between two or more of the thread lines.

In an eighty-fourth aspect (84), molding the sole material according to the eighty-second aspect (82) or the eighty-third aspect (83) comprises an injection molding process.

In an eighty-fifth aspect (85), the plurality of anchor points according to any one of aspects (82)-(84) are disposed on a mold for molding the sole material on the thread pattern.

In an eighty-sixth aspect (86), the plurality of anchor points according to the eighty-fifth aspect (85) comprise two anchor points separated from each other in a longitudinal direction, a transverse direction, and a vertical direction orthogonal to the longitudinal and transverse directions.

In an eighty-seventh aspect (87), the method according to any one of aspects (82)-(86) further comprises coupling a first side of the thread pattern to a second side of the thread pattern.

In an eighty-eighth aspect (88), coupling the first side of the thread pattern to the second side of the thread pattern according to the eighty-seventh aspect comprises directly coupling the first side to the second side at a seam.

DETAILED DESCRIPTION

An article of footwear has many purposes. Among other things, an article of footwear may serve to provide cushioning for a wearer's foot, support a wearer's foot, and protect a wearer's foot. Each of these purposes, alone or in combination, provides for a comfortable article of footwear suitable for use in a variety of scenarios (for example, exercise and every day activities). The features of an article of footwear (for example, the materials and components used to make footwear, and the way these materials/components are assembled in a manufacturing process) may be altered to produce desired characteristics, for example, durability, support, weight, tackiness, texture, haptics, and/or breathability.

Durable footwear will properly function for an extended period of time and may instill a wearer's trust in a specific manufacturer's footwear, leading to repeat sales. Supportive footwear may protect an individual's feet from injury. For example, an article of footwear configured to provide ankle support may prevent injury to an individual's ankle by inhibiting undue twisting of the ankle. Lightweight footwear may be conformable for an individual, and for individuals competing in an athletic activity, such as running or biking, may provide a competitive edge due to the decreased weight the individual carries on his or her feet. Breathable footwear may increase comfort for an individual by wicking sweat and heat away from an individual's foot. Designing footwear having a high degree of one or more of these characteristics without detrimentally affecting other characteristics of the footwear may be desirable. Additionally, proper fitting footwear that adapts to the wearer's foot or is correctly shaped to the wearer's foot may provide a benefit in comfort and stability, particularly during changes of direction. The proper zoning of areas of support, flexibility, stiffness, and softness may also benefit the wearer by more accurately providing him or her desired characteristics of the footwear for different movements, or different parts of their foot.

Propulsion enabled by an article of footwear may optimize the performance of a wearer's foot by, for example, maximizing the energy transfer from the individual's foot to the surface his or her foot is in contact with (for example, the ground), via the article of footwear. Maximizing the energy transfer between the individual's foot and a surface (i.e., reducing energy lost via and/or absorbed by an article of footwear) may help an athlete, for example, accelerate faster, maintain a higher maximum speed, change directions faster, and jump higher. Designing footwear having a high degree of propulsion without detrimentally affecting other characteristics of the footwear may be desirable. Providing tackiness in specific areas on an upper may tailor an upper to an individual's liking. For example, some soccer players may like a soccer boot that is smooth for ease of dribbling while others may like high friction for control during hard strikes.

An article of footwear, or a portion thereof (for example, an upper), may be configured to provide various degrees of durability, support, weight, breathability, etc. But the cost of manufacturing the article of footwear may also be a consideration. Footwear, or a portion thereof, that may be manufactured at a relatively low cost may be desirable for manufacturers and consumers. Footwear that can be manufactured using a relatively small amount of resources (for example, energy and labor), materials, and time reduces manufacturing costs and may also reduce the environmental impact of manufacturing.

Further, a manufacturing process that facilitates the manufacture of customized footwear without increasing the complexity of the manufacturing process may be desirable. Customizing an article of footwear, or a portion thereof (for example, an upper), for a particular individual or a group of individuals having similar foot anatomies (for example, foot size and shape) may provide proper support and increased comfort for an individual. Also, it may allow an individual to order/buy articles of footwear customized to his or her needs. Moreover, it may allow the individual to order/buy new and/or replacement articles of footwear customized to his or her needs when desired.

The articles of footwear discussed herein include a component, for example an upper or a sole, made by winding one or more continuous threads into a desired thread pattern. In some embodiments, the continuous thread(s) may be wound around and between fixed anchor points. In some embodiments, the continuous thread(s) may be wound around and between moveable anchor points. Winding the continuous thread(s) around the anchor points includes wrapping a continuous thread around a first anchor point, extending that continuous thread to a second anchor point, wrapping that continuous thread around the second anchor point, and so on. The number and position of the anchor points may be utilized to control characteristics of the thread pattern, and therefore the article of footwear component. Also, the number of times a continuous thread is wound from anchor point to anchor point may be utilized to control characteristics of the thread pattern, and therefore the article of footwear component.

Continuous thread(s) of a thread pattern may be bonded within the thread pattern. The bonding of continuous thread(s) of a thread pattern may consolidate the thread pattern and fix thread lines in a wound pattern. In some embodiments, bonding continuous thread(s) of a thread pattern may be utilized to control characteristics of the thread pattern. In some embodiments, a continuous thread may be bonded to itself within a thread pattern. In some embodiments, a continuous thread may be bonded to itself at one or more anchor points of a thread pattern. In some embodiments, a continuous thread may be bonded to itself at points of overlap between different thread lines of the continuous thread (i.e., at thread line intersection points). In some embodiments, different continuous threads of a thread pattern may be bonded together. In some embodiments, different continuous threads may be bonded to each other at one or more anchor points of a thread pattern. In some embodiments, different continuous threads may be bonded to each other at points of overlap between the different continuous threads (i.e., at intersection points between the different continuous threads). The bonding of continuous thread(s) may fix the continuous thread(s) in tension as the thread(s) are wound around anchor points in tension. The bonding of thread(s) in tension allows a thread pattern to contract once removed from anchor points used to wind the thread pattern, which may be utilized to control characteristics of the thread pattern.

In some embodiments, a plurality of different continuous threads may be wound around anchor points to form a thread pattern. In some embodiments, different continuous threads may be wound in the same configuration (i.e., around the same anchor points and along the same paths). In some embodiments, different continuous threads may be wound in different configurations (i.e., around one or more different anchor points and/or along different paths between one or more anchor points). Different continuous threads may define different wound layers for a footwear component. And these different layers may provide different characteristics for a thread pattern, and therefore the footwear component.

Continuous thread(s) may be wound around anchor points in various configurations to provide varying degrees of characteristics for an article of footwear component. The number of anchor points, the position of the anchor points, and/or the way continuous threads are wound around the anchor points may be utilized to produce a footwear component having desired characteristics, such as strength, support, propulsion, breathability, comfort, tackiness, abrasion resistance, fit, texture, haptics, and durability. Characteristics of a footwear component can be varied by changing the arrangement of anchor points and/or the way continuous thread(s) are wound around the anchor points. Characteristics can also be varied by altering the material of continuous thread(s).

In some embodiments, when winding continuous threads for an upper, the anchor points may be peripheral anchor points arranged in positions corresponding to a perimeter of an upper, or a portion of an upper, for an article of footwear. Winding a continuous thread around and between the peripheral anchor points may define the perimeter shape of the upper, or portion of an upper. The way continuous thread(s) are wound between respective peripheral anchor points (i.e., the winding path for the continuous thread(s)) can be leveraged to produce an upper having desired characteristics.

In some embodiments, winding one or more continuous threads for an upper may include winding one or more threads such that thread lines are positioned tangential to a feature of the upper. The feature may be, for example, an opening, an edge, an insert in the upper, or a functional zone of the upper. Threading thread lines tangential to a feature may define a perimeter boundary of the feature. By threading thread lines tangential to a feature, characteristics of an upper at the feature may be tailored as described herein. Threading thread lines tangential to a feature may result in a relatively high density of thread lines at and around the feature. A high density of thread lines may provide an upper with desired characteristics at and around the feature.

In some embodiments, threading thread lines tangential to a feature may also include threading thread lines such that a relatively high density of thread lines are located near a perimeter of the feature. By threading a high density of thread lines nearly tangential to a feature, characteristics of a thread pattern near the feature can be controlled.

In some embodiments, a plurality of thread patterns may be bonded together in a process for forming an upper material that surrounds all or a portion of a wearer's foot during use. The upper material that surrounds all or a portion of a wearer's foot during use may include a portion that extends across and wraps around at least a portion of the bottom of a wearer's foot. In some embodiments, bonding a plurality of thread patterns together may create an upper material having a void configured to receive all or a portion of a wearer's foot. In some embodiments, the process for forming an upper material may include bonding a medial thread pattern to a lateral thread pattern.

In some embodiments, a plurality of thread patterns may be bonded together at a seam and flipped inside-out to form an upper material that surrounds all or a portion of a wearer's foot during use. In some embodiments, the plurality of thread patterns may be bonded to each other about a temporary substrate that is removed after bonding the thread patterns to each other. The temporary substrate may be a sheet that resists bonding to the thread patterns while forming an upper material.

In some embodiments, winding continuous thread(s) for an upper may include forming a thread pattern with a portion incorporated into a sole for an article of footwear. In some embodiments, winding continuous thread(s) for an upper may include forming a thread pattern with a portion that defines a portion of a sole for an article of footwear. In some embodiments, a thread pattern defining a portion of an upper may wrap around a portion of a sole. In some embodiments, a thread pattern defining a portion of an upper may be embedded within a sole.

FIGS.1A and1Bshow an article of footwear100and upper120according to some embodiments. Article of footwear100may include upper120coupled to a sole180. Article of footwear100and upper120, include a forefoot end102, a heel end104, a medial side106, and a lateral side108opposite medial side106. As illustrated inFIG.1B, upper120includes a forefoot portion110, a midfoot portion112, and a heel portion114. Portions110,112, and114are not intended to demarcate precise areas of upper120. Rather, portions110,112, and114are intended to represent general areas of upper120that provide a frame of reference. Although portions110,112, and114are illustrated in connection with upper120inFIG.1B, references to portions110,112, and114also may apply specifically to article of footwear100or sole180, or individual components of article of footwear100or sole180.

Upper120may be formed of one or more components that are stitched, bonded, or otherwise joined together to form a structure for receiving and securing a foot relative to sole180. And upper120includes a least a portion defined by a thread pattern122. Thread pattern122is made by winding one or more continuous threads into a thread pattern as discussed herein. Thread pattern122is not a knitted or woven pattern. Thread pattern122may be referred to as a thread network of adjacent and overlapping thread lines.

In some embodiments, thread pattern122may include a network of individual thread lines that form a substantially continuous material with minimal void space between thread lines. As used herein, “void space” means an opening extending through a thread pattern between thread lines of the thread pattern. In some embodiments, the substantially continuous material may have a ratio (V:T) of void space (V) to thread material (T) of at least 1:1 measured across all or a portion of an outer surface of a thread pattern. In some embodiments, the ratio of void space to thread material may be at least 1:1, 1:2, 1:2.5, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:20, 1:50, or 1:100. In some embodiments, a thread pattern may include a network of thread lines that form a continuous material with no void space between thread lines. A ratio of void space to thread material may be measured for a thread pattern before or after bonding of thread lines. In some embodiments, bonding of thread lines may serve to reduce the amount of void space of a thread pattern. For example, thermally bonding thread lines via a polymer material of the thread lines may reduce the amount of void space by filling in void space with thermally melted polymer material. In some embodiments, melted polymer material(s) of a thread pattern may fill void spaces between thread lines to form a continuous material without void space between thread lines.

Thread pattern122may wrap around all or a portion of the sides, the top, and/or the heel of a wearer's foot. In some embodiments, thread pattern122may wrap around at least a portion of the bottom surface (i.e., the sole) of a wearer's foot when worn. For example, an upper with thread pattern122may wrap the bottom surface of a wearer's foot when worn. As another example, thread pattern122may wrap around the bottom surface of a wearer's foot by wrapping around a sole for an article of footwear. As another example, thread pattern122may wrap around the bottom surface of a wearer's foot by extending through a sole for an article of footwear (see for example,FIGS.13and14).

Upper120may extend along the lateral side of the foot, along the medial side of the foot, over the foot, around a heel of the foot, and/or under the foot when worn. Upper120defines a void155, which is a generally hollow area having the general shape of a foot and is configured to receive the foot. An opening of void155may be defined in whole or in part by a collar156located in at least heel portion114of upper120.

In some embodiments, collar156may be a separate piece attached to the reminder of upper120via, for example, stitching and/or an adhesive. In some embodiments, collar156may be attached to thread pattern122at a seam. In some embodiments, collar156may be a separate piece of material defined in whole or in part by a wound thread pattern as described herein. In some embodiments, collar156may be an integral component of thread pattern122. In other words, collar156may be formed in the same manner as thread pattern122(for example, via a winding process as discussed herein).

In addition, upper120may include a throat area150extending from collar156towards forefoot portion110of upper120. Throat area150extends over a dorsal area of a wearer's foot that corresponds generally to the location of a wearer's cuneiform and metatarsal bones. In some embodiments, throat area150may define a portion of the opening of void155to assist a wearer in inserting and removing his or her foot from void155. In some embodiments, throat area150may define an opening for a tongue154that extends between lateral and medial perimeter sides of throat area150and moveably opens and closes a portion of void155to enhance the adjustability of footwear100. In some embodiments, throat area150may be a “tongue-less” throat area150.

In some embodiments, throat area150may be a separate piece attached to the reminder of upper120via, for example, stitching and/or an adhesive. In some embodiments, throat area150may be attached to thread pattern122at a seam. In some embodiments, throat area150may be a separate piece of material defined in whole or in part by a wound thread pattern as described herein. In some embodiments, throat area150may be an integral component of thread pattern122. In other words, throat area150may be formed in the same manner as thread pattern122(for example, via a winding process as discussed herein).

Upper120may also include one or more eyelets152formed in a perimeter portion of throat area150for securing and tensioning a shoelace. In some embodiments, eyelets152may be integrally formed during formation of upper120. In some embodiments, eyelets152may be separate components coupled to upper120via, for example, stitching or an adhesive. A shoelace may extend through the eyelets152and permits a wearer to adjust dimensions of upper120to accommodate his or her foot. More particularly, the shoelace may allow a wearer to tighten or loosen upper120around his or her foot. In addition to or alternative to eyelets152, upper120may include other lace-receiving elements, such as loops or hooks.

In some embodiments, upper120may include a heel counter158. Heel counter158provides cushioning, support, and/or protection for a wearer's heel and/or Achilles tendon. In some embodiments, heel counter158may be a separate piece attached to the reminder of upper120via, for example, stitching and/or an adhesive. In some embodiments, heel counter158may be a separate piece of material defined in whole or in part by a wound thread pattern as described herein. In some embodiments, heel counter158may be attached to thread pattern122at a seam. In some embodiments, heel counter158may be an integral component of thread pattern122. In other words, heel counter158may be formed in the same manner as thread pattern (for example, via a winding process as discussed herein).

With reference toFIG.1A, for example, upper120is coupled to sole180at a biteline160(i.e., a sole connection area). Together, biteline160, collar156, heel counter158, and a perimeter portion of throat area150may define a perimeter portion162of upper120. Perimeter portion162may include an outer edge defined by biteline160and an inner edge defined by collar156and a perimeter of throat area150. Perimeter portion162may define a frame having a shape corresponding to at least a portion of a perimeter shape of upper120. Portions of upper120within perimeter portion162include the quarter panels, vamp portion, and toe box portion of upper120. Thread pattern122may define all or a portion of perimeter portion162and/or any portion of upper120within perimeter portion162of upper.

In some embodiments, all or part of perimeter portion162may include one or more seams163for attaching thread pattern122, or any other thread pattern described herein, to other footwear components. At seam(s)163, thread pattern122may be attached to another footwear component, such as but not limited to, a sole, a collar element, a heel counter, or a throat element.

As used herein, a “seam” is any attachment region between two components. Exemplary attachment regions include, but are not limited to, stitched attachment regions, adhesive attachment regions, thermally bonded attachment regions, and interlocking attachments. Exemplary seam structures include, but are not limited to, a self-attaching seam, a hem, a butt stich, a Merrow stitch (tight overlock stitch), a gathered edge, a surge stitch, an overlock stitch, and an interlocking seam construction. In some embodiments, a “seam” may include a region where two attached components overlap. For example, a seam can be a region where a first component overlaps and is bonded to a second component.

Seam(s)163may include one or more mechanical attachments, including but not limited to direct bonding attachments, adhesive attachments, interlocking mechanical attachments, and/or stitched attachments. Exemplary stitches for use in a seam construction for seam163include, but are not limited to, a Merrow stitch (tight overlock stitch), a gathered edge, a surge stitch, or an overlock stitch.

In some embodiments, thread pattern122, or any other thread pattern described herein, may be folded at seam163to and attached to another footwear component. In some embodiments, a seam163may include bonding tape.

In some embodiments, folding a thread pattern at a seam163may serve to provide a suitable surface for attaching another footwear component. In some embodiments, folding a thread pattern at a seam163may serve to conceal anchor points of a thread pattern within the seam163.

In some embodiments, thread pattern122, or any other thread pattern described herein, may include cutouts located in or adjacent a seam163. For example,FIG.13illustrates thread pattern1322with a plurality of cutouts1326located adjacent a collar seam1316. Cutouts1326may be voids in a thread pattern for providing flexibility to the thread pattern at a seam. By providing flexibility at a seam, cutouts1326may provide comfort for a wearer. In some embodiments, cutouts1326may be concealed within a seam. In some embodiments, all or a portion of cutouts1326may extend from a seam.

In some embodiments, a seam163may include one or more interlocking features that serve to provide a mechanical attachment between a thread pattern and another footwear component, such as but not limited to, a sole, a collar element, a heel counter, or a throat element. In such embodiments, a thread pattern may include one or more first interlocking features and the footwear component may include one or more second interlocking features. In some embodiments, a thread pattern may include an interlocking female component (for example, an opening or slit) and the footwear component may include a male interlocking component (for example, a tab, loop, or hook). In some embodiments, a thread pattern may include an interlocking male component (for example, a tab, loop, a strap, or hook) and the footwear component may include a female interlocking component (for example, an opening or slit).

FIG.27Aillustrates an exemplary interlocking seam structure2700for a seam163. Interlocking seam structure2700includes a footwear component2710and thread pattern2720. Footwear component2710may be, for example, a sole, a collar element, a heel counter, or a throat element. Thread pattern2720may be any thread pattern described herein.

For interlocking seam structure2700, footwear component2710includes a tab2712inserted through an opening2722in thread pattern2720. Tab2712may include a base2714directly connected to a portion of footwear component2710and a free end2716opposite base2714and configured to be inserted through opening2722. Free end2716of tab2712may include one or more flanges2718. Free end2716with flange(s)2718may have a length greater than the length of opening2722to provide an interlocking mechanical attachment between footwear component2710and thread pattern2720when tab2712is inserted through opening2722.

FIG.27Billustrates another exemplary interlocking seam structure2750for a seam163. Interlocking seam structure2750includes a footwear component2760and thread pattern2770. Footwear component2760may be, for example, a sole, a collar element, a heel counter, or a throat element. Thread pattern2770may be any thread pattern described herein.

For interlocking seam structure2750, footwear component2760includes a strap2762inserted through an opening2772in thread pattern2770. Strap2762may include a base2764directly connected to a portion of footwear component2760and a free end2766opposite base2764. Strap2762may wrap around an edge portion2774of thread pattern2770adjacent opening2772and attach to itself at opening2722. In particular, free end2766of strap2762may attach to base2764of strap2762at an attachment point2768located within opening2772. The attachment at attachment point2768may be, for example, a stitched attachment and/or an adhesive attachment.

In some embodiments, upper120may include a fabric layer172disposed on the outer surface and/or the inner surface of thread pattern122. As used herein, the term “outer surface” or “outer side” refers to the surface of a component that faces away from the foot when worn by a wearer. And “inner surface” or “inner side” refers to the surface of a component that faces toward the foot when worn by a wearer.

In some embodiments, fabric layer172may be a woven, non-woven, or knitted polymeric layer. In some embodiments, fabric layer172may be a woven, non-woven, or layer composed of thermoplastic polyurethane (TPU), polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU) foam, and co-polymers or polymer blends including one or more these polymers. In some embodiments, fabric layer172may be a bioengineered woven, knitted or layered synthetic spider silk, woven, knitted or layered plant based materials, or woven, knit or layered recycled and/or extruded plastics. In some embodiments, fabric layer172may be film or sheet of a polymeric material, such as thermoplastic polyurethane (TPU), polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU) foam, and co-polymers or polymer blends including one or more these polymers. In some embodiments, fabric layer172may include a plurality of layers stacked vertically and/or arranged side-by-side. In some embodiments, the plurality of layers may be laminated. In some embodiments, fabric layer172may be a woven, non-woven, or knitted layer for providing cushion and/or thermal insulation for article of footwear100. In some embodiments, fabric layer172may be a sock bootie. In some embodiments, fabric layer172may be sheet1220. In some embodiments, fabric layer172may be a discontinuous layer formed of individual spaced-apart fabric elements, like padding elements2220.

Upper120and sole180may be configured for a specific type of footwear, including, but not limited to, a running shoe, a hiking shoe, a water shoe, a training shoe, a fitness shoe, a dancing shoe, a biking shoe, a tennis shoe, a cleat (for example, a baseball cleat, a soccer cleat, or a football cleat), a basketball shoe, a boot, a walking shoe, a casual shoe, or a dress shoe. Moreover, sole180may be sized and shaped to provide a desired combination of cushioning, stability, and ride characteristics to article of footwear100. The term “ride” may be used herein in describing some embodiments as an indication of the sense of smoothness or flow occurring during a gait cycle including heel strike, midfoot stance, toe off, and the transitions between these stages. In some embodiments, sole180may provide particular ride features including, but not limited to, appropriate control of pronation and supination, support of natural movement, support of unconstrained or less constrained movement, appropriate management of rates of change and transition, and combinations thereof.

In some embodiments, sole180may include traction elements, such as cleats182or tread. In some embodiments, sole180may include a midsole. In some embodiments, sole180may include an outsole coupled to a midsole. For example, in reference toFIG.13, sole180may be sole including midsole1382and outsole1384. Sole180and portions thereof (for example, midsole1382and outsole1384) may comprise material(s) for providing desired cushioning, ride, and stability. Suitable materials for sole180(midsole1382and/or outsole1384) include, but are not limited to, a foam, a rubber, ethyl vinyl acetate (EVA), expanded thermoplastic polyurethane (eTPU), expandable polyether block amide (ePEBA), thermoplastic rubber (TPR) and a thermoplastic polyurethane (TPU). In some embodiments, the foam may comprise, for example, an EVA-based foam or a PU-based foam and the foam may be an open-cell foam or a closed-cell foam. In some embodiments, midsole1382and/or outsole1384may comprise elastomers, thermoplastic elastomers (TPE), foam-like plastics, and gel-like plastics.

In some embodiments, portions of sole180(for example, midsole1382and outsole1384) may comprise different materials to provide different characteristics to different portions of sole180. In some embodiments, midsole1382and outsole1384may have different hardness characteristics. In some embodiments, the material density of midsole1382and outsole1384may be different. In some embodiments, the elastic moduli of the materials used to make midsole1382and outsole1384may be different. As a non-limiting example, the material of outsole1384may have a higher modulus than the material of midsole1382.

Sole180and portions thereof (for example, midsole1382and outsole1384) may be formed using suitable techniques, including, but not limited to, injection molding, blow molding, compression molding, and rotational molding. In some embodiments, midsole1382and outsole1384may be discrete components that are formed separately and attached. In some embodiments, midsole1382may be attached to outsole1384via, for example, but not limited to, adhesive bonding, stitching, welding, or a combination thereof. In some embodiments, midsole1382may be attached to outsole1384via an adhesive disposed between midsole1382and outsole1384.

As shown inFIGS.1A and1B, upper120includes thread pattern122. All or a portion of upper120may include thread pattern122. In some embodiments, thread pattern122may be a single thread structure defining at least a portion of upper120. In some embodiments, thread pattern122may include a plurality of thread structures coupled together to define at least a portion of upper120.

In some embodiments, thread pattern122may include a plurality of anchor points134and a continuous thread130fixed at a plurality of anchor points134. In some embodiments, anchor points134may be disposed along a perimeter of upper120(for example, in perimeter portion162). Such anchor points134may be referred to as “peripheral anchor points.”

As used herein, “thread” means a material having a length that is substantially larger than its width. A “thread” may be a filament, a fiber, a yarn, a knitted element, a cable, a cord, a fiber tow, a tape, a ribbon, a monofilament, a braid, a string, a plied thread, and other forms of materials which can be spooled and laid down in a thread pattern as described herein.

As used herein, “anchor point” means a location to which a thread or group of thread lines is fixedly attached. A thread or thread line may be wrapped, wound, bonded, or otherwise attached at an anchor point. An anchor point may be a location on an upper (for example, anchor points134). For example, an anchor point may be a hole or opening left behind by a structure (for example, pin, projection, or nub) used to wind continuous thread(s) of a thread pattern. In some embodiments, a thread pattern for an upper may not include any anchor point locations because all the anchor point locations present during winding of the thread pattern have been removed (for example, cut off the thread pattern). An anchor point may also be a structure (for example, pin, projection, or nub) used to wind continuous thread(s) of a thread pattern. And the anchor point structure may or may not form a portion of a thread pattern for an upper. For example, a thread pattern for an upper may be removed from anchor points defined by metal pins, but anchor points defined by pins composed of a meltable material may be present in a thread pattern for an upper (after being melted and re-solidified).

Continuous thread130may be wrapped around a plurality of anchor points134and includes a plurality of thread lines132. Each thread line132extends between two respective anchor points134. Continuous thread(s)130may be wrapped around a plurality of anchor points134in tension such that individual thread lines132are in tension when wrapped around anchor points134. In some embodiments, different continuous threads130and/or thread lines132may be wrapped around anchor points134at different tensions to impart desired characteristics to thread pattern122. By winding continuous(s) threads130in tension, thread pattern122may be bonded while thread lines132are under tension such that thread lines132are in tension in a bonded thread pattern122. Bonding thread lines132while thread lines132are under tension fixes the thread lines132in tension within thread pattern122. Fixing thread lines132in tension will result in thread lines132wanting to contract when removed from anchor points used to wind thread pattern122. In cases where a portion of a thread line132is not bonded in a fully fixed position, the thread line132may contract when removed anchor points. In such embodiments, the portion(s) of the thread line132that is/are fixed during a bonding process will be under tension while the other portion(s) will be free to contract, and thus will not be under tension in thread pattern122.

In embodiments where different thread lines132were wound at different tensions, different thread lines132of thread pattern122will be under different values of tension in thread pattern122. The tension of thread lines132may be utilized to control characteristics of thread pattern122, and therefore upper120.

The number of thread lines132fixed at an anchor point134is defined by the “thread line communication number” of an anchor point134. As used herein, “thread line communication number” means the number of thread lines extending from an anchor point to different anchor points. Two thread lines extending between the same two anchor points (i.e., overlaying thread lines) only counts as “1” for purposes of calculating a thread line communication number for the anchor points. For example, a thread line communication number of five means that an anchor point has five thread lines extending from it with each of the five thread lines leading to another, different anchor point. As another example, a thread line communication number of six means that an anchor point has six thread lines extending from it with each of the six thread lines leading to another, different anchor point.

Anchor points134may have a thread line communication number of “X” or more for continuous thread130. In some embodiments, two or more respective anchor points134may have a thread line communication number of “X” or more. In some embodiments, all the anchor points134of thread pattern122may have a thread line communication number of “X” or more. “X” may be, for example, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, or 30, within a range having any two of these values as end points. For example, in some embodiments “X” may be in a range of 2 to 30, 3 to 30, 4 to 30, 5 to 30, 6 to 30, 7 to 30, 8 to 30, 9 to 30, 10 to 30, 11 to 30, 12 to 30, 13 to 30, 14 to 30, 15 to 30, 16 to 30, 17 to 30, 18 to 30, 19 to 30, 20 to 30, or 25 to 30. In some embodiments, “X” may be greater than 30. As a non-limiting example, as show inFIG.1B, anchor point134(a) has a thread line communication number of six and anchor point134(b) has a thread line communication number of seven.

Thread lines132may be bonded at anchor points134. Thread lines132may be bonded at anchor points134via an adhesive, a bonding layer, thermal (conductive or convective) heat (for example, in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, a mechanical fastener (for example, a clip), hook and loop fasters, needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement, felting, knotting, chemical bonding with a catalyst of biomaterial, adhesive spraying (for example, CNC adhesive spray deposition), or by pushing one thread line through the other thread line(s).

In some embodiments, thread lines132may be directly bonded together at anchor points134. In some embodiments, thread lines132may be directly bonded together at anchor points134via the polymeric material of continuous thread130). For example, heat and/or pressure may be applied to an anchor point134to directly bond thread lines132at any peripheral anchor points134. In some embodiments, thread lines132may be directly bonded together at perimeter portion162via the polymeric material(s) of continuous thread130. For example, heat and/or pressure may be applied to perimeter portion162of upper120to directly bond thread lines132in perimeter portion, and at any peripheral anchor points134within perimeter portion162. In embodiments where heat and/or pressure is utilized to directly bond the polymeric material of thread lines132, the thread lines132may be thermally fused together at one or more anchor points134. In embodiments including direct bonding of thread lines132at a perimeter portion and/or anchor points, thread lines132are directly bonded at the perimeter portion and/or anchor points without the use of an adhesive or bonding layer.

In some embodiments, thread lines132may be bonded together via a bonding layer. In some embodiments, thread lines132may be bonded together at anchor points134(for example, peripheral anchor points) via a bonding layer. In such embodiments, the bonding layer is attached to one or more anchor points134and mechanically couples the anchor point(s)134to each other. The bonding layer may be, for example, a laminated layer, an adhesive layer, a stitched layer, a cured layer, or a screen-printed layer. In some embodiments, the lamination layer, adhesive layer, cured layer, or screen-printed layer may serve to encase anchor points134in a bonding layer. The bonding layer may bond thread lines132via any suitable mechanical bonding technique.

In some embodiments, thread lines132may be bonded together without the use of a bonding layer. For example, in some embodiments, thread lines132may be directly bonded together via, for example, but not limited to, local bonding via an adhesive, direct local bonding via material(s) of thread lines132, needle punching, hydro-entanglement, and ultrasonic/vibratory entanglement.

In some embodiments, thread lines132may be bonded at points where two or more thread lines132overlap in thread pattern (i.e., intersection points136). Thread lines132may be bonded at intersection points136via an adhesive, a bonding layer, thermal (conductive or convective) heat (for example, in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, a mechanical fastener (for example, a clip), hook and loop fasters, needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement, felting, knotting, chemical bonding with a catalyst of biomaterial, adhesive spraying (for example, CNC adhesive spray deposition), or by pushing one thread line through the other thread line(s). Intersection points for thread lines may be referred to as “overlap points.”

In some embodiments, thread lines132may be directly bonded together at intersection points136. In some embodiments, thread lines132may be directly bonded together at intersection points136via the polymeric material of continuous thread130. In embodiments including direct bonding of thread lines132at intersection points136, thread lines132are bonded at intersection points136without the use of an adhesive or bonding layer. For example, heat and/or pressure may be applied to a thread pattern to directly bond thread lines132at any intersection points136. In embodiments where heat and/or pressure is utilized to directly bond the polymeric material of thread lines132, the thread lines132may be thermally fused together at one or more intersection points136.

In some embodiments, a bonding layer may bond thread lines132together at a plurality of intersection points136within thread pattern122. In embodiments including multiple continuous threads, thread lines of respective continuous threads may be bonded at intersection points between the thread lines, either directly or via a bonding layer.

In some embodiments, continuous thread130includes overlaying thread lines132. As used herein, “overlaying thread lines” means two or more thread lines that follow the same path between two respective anchor points. Overlaying thread lines need not be overlaid directly over each other. Two or more thread lines are considered overlaying as long as they extend between the same two anchor points.

Thread pattern122may include one or more continuous threads130with thread lines132crossing over underlying thread line(s)132in various directions. The thread lines132of thread pattern122may not be woven or knitted together. In such embodiments, thread lines132may be referred to as “non-woven” and “non-knitted” thread lines. The thread lines132of thread pattern122may not be embroidered threads stitched to a base layer. In such embodiments, thread lines132may be referred to as “non-embroidered” thread lines. Thread lines132may be threaded over each other to form a thread network defining a patterned layer for an article of footwear component.

In some embodiments, continuous thread130may be a polymer thread. As used herein “polymer thread” means a thread composed at least in part of a polymeric material. In some embodiments, a polymer thread may be composed entirely of one or more polymeric materials. In some embodiments, a polymer thread may include a polymeric material coated around a core (which may or may not be composed of a polymeric material). In such embodiments, the core may be encapsulated by the coating material. In some embodiments, a polymer thread may include a non-polymer core coated, covered, or encapsulated with a polymeric material. In some embodiments, a polymer thread may include a polymer core coated, covered, or encapsulated with a non-polymeric material. In some embodiments, a polymer thread may be a braided thread with one or more braids composed of a polymeric material. In some embodiments, the polymeric material(s) of a polymer thread may be thermoplastic material(s). In some embodiments, continuous thread130may be a thread coated with an activatable agent, for example a heat activated adhesive or a UV-activated adhesive. In some embodiments, a CNC machine for winding a continuous thread130with an activatable agent coating may include a robotic arm for activing the coating as continuous thread130is being wound into a thread pattern.

Suitable polymeric materials for polymer threads discussed herein include, but are not limited to, thermoplastic polyurethane (TPU), a rubber, and silicone. In some embodiments, the TPU may be recycled TPU. In some embodiments, the polymeric material may be a photo-reactive (infrared or ultraviolet light reactive) polymeric material, such as a photo-reactive TPU. In some embodiments, the polymeric material may be soluble (for example, water-soluble). In embodiments including polymer threads with a coated core, suitable materials for the core include, but are not limited to, polyester, nylon, ultra-high molecular weight polyethylene (for example, DYNEEMA® (a type of ultra-high molecular weight polyethylene)), carbon fiber, KEVLAR® (a type of para-aramid), bioengineered woven, knit or layered materials (for example, synthetic spider silk), woven, knit or layered plant based materials, knit or layered recycled and/or extruded plastics, cotton, wool, and natural or artificial silk. In some embodiments, polymer threads may be thermoplastic polyurethane coated polyester threads. In some embodiments, continuous thread130may be a non-polymer thread composed of non-polymer materials, such as carbon fiber, cotton, wool, or silk. In some embodiments, continuous thread130may be a thread composed of a biomaterial, such as mango yarn or bio-silk. In some embodiments, polymer threads may be a thermoplastic melt yarn, polymer yarn with non-melt core, and other similar types of yarn.

In some embodiments, continuous thread130may be a plied thread. In some embodiments, the plied thread130may be plied while winding thread130. For example, a winding assembly used to wind thread130may ply the thread using thread from a plurality of thread spools (see for example, winding assembly2900). In some embodiments, the plied thread may be a pre-plied thread spooled around a thread spool.

In some embodiments, a plied thread may include a plurality of different types of threads. For example, a plied thread may include one or more polymer threads and one or more non-polymer threads. As another example, a plied thread may include one or more polymer threads including a first polymer material and one or more threads including a second, different, polymer material.

In some embodiments, continuous thread130may be a composite co-extruded thread. In such embodiments, different portions of the composite co-extruded thread are formed of different materials. In such embodiments, the different materials of the composite co-extruded thread may provide varying mechanical characteristics to a thread pattern.

In some embodiments, continuous thread130may be a foamable thread. In such embodiments, a foaming agent in the foamable thread may be activated to expand the thread after the thread is wound in a thread pattern. The foaming agent in a foamable thread may be activated by, for example, heat. In such embodiments, continuous thread130may be wound in a thread pattern to provide areas of increase padding for a wearer's comfort.

In some embodiments, continuous thread130may be a dissolvable thread. Dissolvable threads may be dissolved after being wound in a thread pattern by a solvent. In such embodiments, a portion of a thread pattern may be removed by dissolving the dissolvable thread.

In some embodiments, continuous thread130may be an “active thread.” As used herein, an “active thread” is a thread that changes in length when activated by an activating agent. An active thread may expand or contract in length when activated by an activating agent. Exemplary activating agents include, but are not limited to, heat, water, and electrical current. In embodiments including an active thread, dimensional characteristics of a thread pattern may be altered after winding the thread pattern. For example, in some embodiments, the dimensional characteristics of a thread pattern may be altered while heating a thread pattern within a mold or heat press as described herein.

In some embodiments, continuous thread130may include one or more threads disposed within a hollow tube.

In some embodiments, continuous thread130may be a composed of a viscoelastic shear thickening (dilatant) material. The elastic modulus of a dilatant material is dependent on the rate of strain applied to the material. By incorporating a thread composed of a dilatant material in a thread pattern, the stiffness of the thread pattern can change depending on the degree of stain applied to the thread pattern during use. For example, a thread pattern may remain relatively compliant during a low stress activity, for example walking, but increase in stiffness when high stress levels are applied during a high stress activity, such as running.

In some embodiments, upper120, and thread pattern122, includes more than one continuous thread. For example, as shown inFIGS.1A and1B, thread pattern122may include a second continuous thread170. Second continuous thread170has the same or different characteristics as first continuous thread130. And second continuous thread170may be incorporated into thread pattern122in the same manner as first continuous thread130.

Like continuous thread130, continuous thread170may include a plurality of thread lines wound around and extending between two respective peripheral anchor points134. Anchor points134may have a thread line communication number of “Y” or more for second continuous thread170. The thread line communication number for second continuous thread170may be the same as or similar to the thread line communication number for continuous thread130. “Y” may be less than “X”, more than “X”, or the same as “X”.

In some embodiments, first continuous thread130may be composed of the same material(s) as second continuous thread170. In some embodiments, first continuous thread130may be composed of different material(s) than second continuous thread170. The material(s) of different continuous threads in a thread pattern may be selected to provide targeted characteristics to areas of a thread pattern, and therefore an upper. In embodiments including polymer thread(s) having a core coated with a polymeric material, the material of the core for different continuous threads may be different or the same. And the material of the core for different continuous threads may be selected to provide targeted characteristics to different areas of a thread pattern, and therefore an upper. Similarly, for braided threads, the material(s) of the braided thread(s) may be selected to provide targeted characteristics to different areas of a thread pattern, and therefore an upper.

In some embodiments, continuous threads of a thread pattern may have a denier in the range of 1 denier to 3000 denier, including subranges. For example, continuous threads may have a denier of 1, 10, 50, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2500, or 3000 denier, or within any range having any two of these values as endpoints. For example, in some embodiments, continuous threads of a thread pattern may have a denier in the range of 10 denier to 2500 denier, 50 denier to 2000 denier, 100 denier to 1900 denier, 200 denier to 1800 denier, 300 denier to 1700 denier, 400 denier to 1600 denier, 500 denier to 1500 denier, 600 denier to 1400 denier, 700 denier to 1300 denier, 800 denier to 1200 denier, 900 denier to 1100 denier, or 900 denier to 1000 denier.

In some embodiments, the denier of continuous thread(s) in a thread pattern may be selected to provide varying degrees of a characteristic (for example, strength or stretchability) to different areas of the thread pattern. In embodiments including coated threads, the denier of the core material and/or the overall denier of the continuous thread(s) may be selected to provide varying degrees of a characteristic (for example, strength or stretchability) to different areas of a thread pattern. As a non-limiting example, a larger overall diameter or a larger core diameter for a given continuous thread may increase the degree of directional strength imparted by the given continuous thread within a thread pattern.

WhileFIGS.1A and1Bshow thread pattern122including two continuous threads (130and170), thread pattern122may include any suitable number of continuous threads, such as for example, three or more, four or more, five or more, six or more, seven or more, eight or more, nine or more, ten or more, fifteen or more, or twenty or more continuous threads. Additional continuous threads may be the same as or different from continuous threads130and170. And additional continuous threads may be incorporated into thread pattern122in the same manner as continuous threads130and170. Additional continuous threads may be wound around and extended between anchor points134in the same fashion as continuous threads130and170.

In embodiments including a plurality of continuous threads, each wound continuous thread may define a layer of thread pattern122. For example, a layer defined by wound continuous thread130may define a first layer of thread pattern122and a layer defined by wound continuous thread170may define a second layer of thread pattern122. And different layers of a thread pattern may be disposed over each other in areas of overlap between the two layers. For example, a first layer defined by continuous thread130may be disposed over a second layer defined by continuous thread170, or vice versa, in areas of overlap between the two layers. Different layers defined by different continuous wound threads may provide different characteristics to different areas of upper120.

In some embodiments, one or more of the layers of thread pattern122defined by a wound continuous thread may serve to bond other layers of thread pattern122together. In such embodiments, these one or more layers may be wound using a polymeric thread, which when heated, bonds other layers of thread pattern122together at anchor points and other intersection points between continuous threads. For example, in a thread pattern122including three layers, each defined by a continuous thread, one of the three continuous threads (for example, the middle continuous thread) may be a polymeric thread that serves to bond all three threads together. In some embodiments, one or more of the layers of thread pattern122may be defined by a wound continuous thread coated or impregnated with an adhesive. In some embodiments, the adhesive may be activated with the application of heat. In some embodiments, the adhesive may be a dissolvable adhesive that, when contacted with a solvent, such as water, fully or partially dissolves to bond continuous threads. In some embodiments, one or more layers of thread pattern122may be defined by a wound continuous thread that is a braided or twisted thread including a polymeric and/or adhesive thread braided or twisted with a non-polymeric or non-adhesive thread. In such embodiments, the braided or twisted polymeric and/or adhesive thread may serve to bond thread lines132at anchor points134and/or intersection points136.

In some embodiments, thread pattern122may define at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% of a component of upper120. In some embodiments, thread pattern122may occupy at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% of the outer surface area of upper120. In some embodiments, thread pattern122may be visibly exposed on the outer surface of upper120. In some embodiments, no lamination layer or supporting textile layer is disposed over thread pattern122on the outer surface of upper120. In some embodiments, thread pattern122may be devoid of a lamination layer.

Thread pattern122may provide targeted characteristics (for example, strength, support, propulsion, breathability, comfort (stretchability), tackiness, abrasion resistance, texture, haptics, and durability) to areas of upper120. In some embodiments, thread pattern122, or a portion thereof, may provide a first degree of a characteristic in one area of upper120and a second degree of that characteristic in a second area of upper120.

In some embodiments, different layers of thread pattern122may provide a first degree of a characteristic in one area of upper120and a second degree of that characteristic in a second area of upper120. In some embodiments, different layers of thread pattern122may include different thread patterns to provide targeted characteristics to different areas of upper120. In some embodiments, different layers of thread pattern122may include thread patterns with thread lines oriented in different directions to provide targeted characteristics to different areas of upper120.

FIG.2shows a method200of making an upper (for example, upper120), and an article of footwear (for example, article of footwear100) according to some embodiments. In step210, a plurality of anchor points (for example, anchor points134) may be defined. In some embodiments, the anchor points may include peripheral anchor points. In some embodiments, the anchor points may include interior anchor points disposed interior of peripheral anchor points.

In step220, one or more continuous threads (for example, continuous thread130) may be wound (wrapped) around the defined anchor points such that individual thread lines (for example, thread lines132) of the continuous thread(s) extend between two respective anchor points. Winding continuous thread(s) in step220forms a desired thread pattern (for example, thread pattern122). During winding step220, anchor points are defined by fixed or moveable members, such as pins, projections, nubs, or shafts coupled to a support structure, or any other similar fixed anchor point discussed herein. These fixed members serve to support continuous thread(s) during winding step220. For example, thread(s) may be wound around anchor points on a plate, a three-dimensional object (for example, a last), or a frame as discussed herein. For example, the anchor points may be pins304coupled to support plate300. As another example, the anchor points may be projections606extending from support plate600. As another example, the anchor points may be anchor points1540extending from a mold plate1510/1520. As another example, the anchor points may be anchor points1906extending form three-dimensional object1900.

In some embodiments, the anchor points may be defined by pins coupled to and extending from a supporting structure, such as a plate, platform, or three-dimensional object. In some embodiments, the three-dimensional object may be a last or other three-dimensional object having a volumetric shape corresponding to the shape of a human foot. In operation, the pins defining the anchor points are configured to support the continuous thread(s) during winding in step220.

In some embodiments, the plate, object, or frame may be held stationary and a winding device may wind thread(s) around stationary anchor points. In some embodiments, the plate, object, or frame may move relative to a stationary thread source during winding.

In some embodiments, the anchor point locations about which one or more continuous threads are wound (wrapped) in step220may be temporary structures that are removed from a thread pattern defining an upper, or may be present in a thread pattern defining an upper. Portions of a thread pattern having one or more temporary anchor point locations may be cut from, or otherwise removed from, a thread pattern when shaping a thread pattern into an upper. In such embodiments, a thread pattern for a finished upper will have a fewer number of anchor point locations than the number of anchor point locations used in winding the thread pattern.

In some embodiments, all or a portion of the anchor point locations about which one or more continuous threads are wound (wrapped) in step220may be present on an upper formed using the thread pattern wound in step220. For example, in some embodiments, anchor point locations may be located around an opening for an upper, for example a collar or a throat.FIG.25illustrates an exemplary upper2500having a thread pattern2510with anchor points2520located at a collar2530of upper2500. In some embodiments, anchor points2520may provide collar2530, or other opening in an upper, with a desired aesthetic look. In some embodiments, anchor points2520may serve to provide cushioning at collar2530, or other opening in an upper, for wearer comfort.

As another example, in some embodiments, anchor point locations may be folded or otherwise concealed on an upper. In some embodiments, anchor point locations may be concealed within a seam located on upper. In some embodiments, anchor point locations may be folded in area used for stitching or bonding a footwear component to an upper.

In some embodiments, all or a portion of the anchor point locations about which one or more continuous threads are wound (wrapped) in step220may be utilized in a lasting process for making an upper using the thread pattern wound in step220.FIGS.26A and26Billustrate an exemplary upper lasting process according to some embodiments. In such embodiments, after winding a thread pattern2600, a string2620may be fed through openings defined by all or a portion of anchor point locations2610. Once string2620is fed through the openings and thread pattern2600is placed around a last2630, string2620may be tightened so that thread pattern2600is positioned and cinched around last2630. After cinching thread pattern2600around last, thread pattern2600may be bonded on last2630herein to form a portion of an upper. Bonding thread pattern2600on last2630may including bonding continuous thread(s) and/or thread lines as described herein.

In step230, the continuous thread(s) are bonded within the thread pattern. In some embodiments, continuous thread(s) may be bonded at points of intersection between thread lines via, for example, an adhesive, a bonding layer, thermal (conductive or convective) heat (for example, in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, a mechanical fastener (for example, a clip), hook and loop fasters, needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement, felting, knotting, chemical bonding with a catalyst of biomaterial, adhesive spraying (for example, CNC adhesive spray deposition), or by pushing one thread line through the other thread line(s). In some embodiments, continuous thread(s) may be directly bonded at points of intersection between thread lines.

In some embodiments, continuous thread(s) may be bonded at the anchor points via, for example, an adhesive, a bonding layer, thermal (conductive or convective) heat (for example, in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, a mechanical fastener (for example, a clip), hook and loop fasters, needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement, felting, knotting, chemical bonding with a catalyst of biomaterial, adhesive spraying (for example, CNC adhesive spray deposition), or by pushing one thread line through the other thread line(s). In some embodiments, continuous thread(s) may be directly bonded at the anchor points.

In some embodiments, step230includes the formation of a bonding layer for bonding thread lines together.

In some embodiments, method200may include multiple winding steps220and multiple bonding steps230. For example, a portion of a thread pattern may be wound in a first winding step220and then that portion may be bonded in a first bonding step230. Then a second portion of a thread pattern may be wound in a second winding step220and then that portion may be bonded in a second bonding step230. In some embodiments, bonding step230may include a preliminary bonding step to hold the pattern of a thread pattern until a final bonding step is performed. For example, a preliminary bonding step may allow a thread pattern to be removed from anchor points and be finally bonded after removal.

In some embodiments, steps220and230are performed in the absence of a base layer disposed between the thread pattern and a support structure (for example, support plate300or600). As used herein “base layer” means a layer of material employed to facilitate the placement or arrangement of threads when winding and/or bonding a thread pattern. A base layer may be a layer to which threads are bonded, stitched, woven into, printed on, deposited on, or otherwise in contact with during manufacturing of a thread pattern. A layer attached to a thread pattern after formation of the thread pattern is complete is not considered a base layer.

In some embodiments, a support layer may be attached to a thread pattern in step240. In some embodiments, the support layer attached in step240may be a fabric layer172discussed herein. In some embodiments, method200does not include step240.

In some embodiments, the thread pattern may be attached to a sole in step250to form an article of footwear. In some embodiments, continuous thread(s) of the thread pattern may be directly attached to a sole in step250via, for example, stitching, an adhesive, a lamination process, or a heat pressing process. In some embodiments, the bonding layer of a thread pattern may be attached to a sole in step250via, for example, stitching, an adhesive, a lamination process, or a heat pressing process. In embodiments including a support layer, the support layer may additionally or alternatively be attached to the sole in step250. In some embodiments, step250may include shaping a thread pattern into the shape of an upper (for example, by cutting excess portions of a thread pattern to for a thread pattern with a perimeter shape for an upper). In some embodiments, a sole may be attached to the thread pattern in step250by molding a sole around portion of the thread pattern. In some embodiments, a sole may be attached to the thread pattern in step250by injection molding a sole around portion of the thread pattern (see for example,FIGS.15A and15B).

FIG.3shows continuous threads310and320wound around anchor point pins304coupled to a support plate300to define a thread pattern302according to embodiments. Thread pattern302inFIG.3is a representative exemplary thread pattern. Various thread patterns discussed herein (for example, thread pattern122) may be wound around anchor point pins304coupled support plate300. Anchor point pins304extend from an upper surface308of support plate300and serve to support continuous threads310and320during winding of thread pattern302. Anchor point pins304may be peripheral anchor point pins304arranged in a peripheral area corresponding to a perimeter portion of an upper. In some embodiments, anchor point pins304may include interior anchor point pins.

First continuous thread310may be wound about anchor point pins304with thread lines312extending between two respective anchor point pins304. In other words, first continuous thread310may be wrapped around a first anchor point pin304, threaded to a second anchor point pin304, wrapped around the second anchor point pin304, threaded to a third anchor point pin304, wrapped around the third anchor point pin304, and so on.

Similar to first continuous thread310, second continuous thread320may be wound around anchor point pins304with thread lines322extending between two respective anchor point pins304. A continuous thread wrapped or wound around an anchor point pin (or other anchor point members discussed herein) need not be wrapped or wound completely (i.e., 360 degrees) around a perimeter of the pin. A continuous thread wrapped or wound around an anchor point pin may be wrapped or wound around only a portion of a pin. For example, a continuous thread wrapped or wound around a pin may be wrapped or wound around 25% (90 degrees) of a pin's perimeter, 50% (180 degrees) of a pin's perimeter, 75% (270 degrees) of a pin's perimeter, or 100% (360 degrees) of a pin's perimeter. In some embodiments, a continuous thread may be wrapped or wound around a pin's perimeter more than once before being threaded to the next pin. For example, a continuous thread may be wrapped or wound around a pin's perimeter one and a half times (540 degrees) or twice (720 degrees) before being threaded to the next pin.

Continuous threads310and320may be wrapped around any number of anchor point pins304to define thread pattern302. In some embodiments, continuous thread310and/or continuous thread320may be wrapped or wound around a single anchor point pin304more than once during winding in step220. For example, during winding in step220, first continuous thread310may be wrapped around a first anchor point pin304, threaded to and wrapped around a second anchor point pin304, thread to and wrapped around a third anchor point pin304, and threaded to and wrapped around the first anchor point pin304again. As another example, during winding in step220, first continuous thread310may be wrapped around a first anchor point pin304, threaded to and wrapped around a second anchor point pin304, and threaded to and wrapped around the first anchor point pin304again. In such embodiments, this creates overlaying thread lines312.

During winding in step220, thread lines312of first continuous thread310may overlap each other at intersection points316. Similarly, thread lines322of second continuous thread320may overlap each other at intersection points326. In bonding step230, thread lines312and/or322may be bonded at intersection points316and326, respectively. Each anchor point pin304may have a thread line communication number for first continuous thread310and second continuous thread320as discussed herein.

FIGS.4A and4Bshow continuous thread410wrapped around peripheral anchor point pins404and interior anchor point pins406coupled to a three-dimensional object400to define a thread pattern402. Thread pattern402inFIGS.4A-4Bis a representative exemplary thread pattern. Various thread patterns discussed herein (for example, thread pattern122) may be wound around anchor points pins404/406coupled to three-dimensional object400. Anchor point pins404and406extend from an exterior surface408of three-dimensional object400and serve to support continuous thread(s) during winding of thread pattern402.

Peripheral anchor point pins404may be arranged in a peripheral area corresponding to a perimeter portion of an upper including thread pattern402. Interior anchor point pins406may be disposed in the area between peripheral anchor point pins404(i.e., within perimeter portion162of upper120, including the quarter panels, vamp portion, and toe box portion of upper120including thread pattern402). Interior anchor point pins406may be arranged to provide additional points for fixing thread lines in a thread pattern. These additional points may provide desired characteristics to corresponding areas of a thread pattern, and therefore an upper. Interior anchor points, such as interior anchor point pins406may be utilized in the formation of various thread patterns discussed herein.

Similar to first continuous thread310, continuous thread410may be wound around anchor point pins404and406with thread lines412extending between two respective anchor point pins404/406. For example, continuous thread410may be wrapped around a first anchor point pin404, threaded to a second anchor point pin406, wrapped around the second anchor point pin406, threaded to a third anchor point pin404, wrapped around the third anchor point pin404, and so on.

Also similar to continuous thread310, continuous thread410may be wrapped around any number of anchor point pins404/406to define thread pattern402. In some embodiments, continuous thread410may be wrapped or wound around a single anchor point pin404/406more than once during winding in step220. Further, during winding in step220, thread lines412of continuous thread410may overlap each other at intersection points416. And each anchor point pin404/406may have a thread line communication number for continuous thread410. In bonding step230, thread lines412may be bonded at anchor points404/406and/or intersection points416. Pins404/406may be integrally formed with object400or may be removably coupled to object400. After winding and/or bonding of continuous thread410of thread pattern402, thread pattern402may be removed from pins404/406.

In some embodiments, padding may be incorporated into a thread pattern for providing cushioning, support, and/or protection to areas of an upper. In some embodiments, padding may be incorporated into a thread pattern prior to bonding in step230. Padding may be incorporated into one or more areas of an upper (for example, upper120), such as but not limited to, the throat area150of upper120, collar156of upper120, heel counter158of upper120, biteline160of upper120, quarter panels of upper120, vamp portion of upper120, and toe box portion of upper120.

FIG.5shows an exemplary thread pattern500including padding elements530according to some embodiments. Thread pattern500inFIG.5is a representative exemplary thread pattern. Any thread pattern discussed herein (for example, thread pattern122) may include padding elements530. Thread pattern500may be made using method200and may be used to construct an upper (for example, upper120) as discussed herein.

Similar to other thread patterns discussed herein, thread pattern500includes first and second continuous threads510and520wound around anchor points514with thread lines512and522extending between two respective anchor points514. Thread lines512of first continuous thread510may overlap each other at intersection points. Similarly, thread lines522of second continuous thread520may overlap each other at intersection points.

In some embodiments, padding elements530may be disposed within thread pattern500vertically between thread lines512of first continuous thread510and/or thread lines522of second continuous thread520. In such embodiments, padding elements530may be suspended between thread lines512/522of thread pattern500. For example, in some embodiments, some thread lines512may be disposed above (i.e., on the outer side of) padding elements530and some thread lines512may be disposed below (i.e., on the inner side of) padding elements530to support padding elements within thread pattern500. As another example, in some embodiments, some thread lines522may be disposed above padding elements530and some thread lines522may be disposed below padding elements530to support padding elements within thread pattern500. As another example, in some embodiments, some thread lines512may be disposed above padding elements530and some thread lines522may be disposed below padding elements530.

Padding elements530may be composed of, for example, neoprene, ePEBA, eTPU, EVA, TPU, or a foam, such as polyethylene foam, polyurethane foam, or a urethane foam. In some embodiments, padding elements530may be a knit fabric, a woven fabric, or a non-woven fabric.

In some embodiments, padding elements530may be placed within thread pattern500during winding step220to suspend padding elements530within thread pattern500. In some embodiments, padding elements530may include padded regions2210or padding elements2220(seeFIG.22) disposed on a surface of thread pattern500. In some embodiments, padding elements2220may be disposed on an outer surface and/or an inner surface of thread pattern500.

In some embodiments, winding step220may include winding a thread pattern on a support plate.FIG.6shows a support plate600for winding a thread pattern according to some embodiments. Support plate600includes front side601and a rear side603.

In some embodiments, support plate600may have a frame structure including an interior perimeter wall602and an exterior perimeter wall604. In such embodiments, interior perimeter wall602of support plate600may define a hollow opening608.

In some embodiments, support plate600may not include interior perimeter wall602defining a hollow opening608. In such embodiments, support plate600may include front and rear surfaces defining the area between exterior perimeter wall604.

Exterior perimeter wall604of support plate600includes a plurality of projections606extending laterally from exterior perimeter wall604. Projections606may be integrally formed with support plate600or may be removably coupled to support plate600. Projections606may be, for example, pins, knobs, or studs.

In operation, a thread pattern (for example, thread pattern610) may be wound around projections606of support plate600. Thread pattern610inFIG.6is a representative exemplary thread pattern. Various thread patterns discussed herein (for example, thread pattern122) may be wound around projections606of support plate600.

When winding thread pattern610, one or more continuous threads (for example, continuous threads620and630) are wound around projections606and across front side601and/or rear side603of support plate600. In such embodiments, thread lines622/632of continuous threads620/630extend between respective projections606of support plate600. In some embodiments, one or more continuous threads (for example, continuous threads620and630) may be wound around projections606and across front side601and rear side603of support plate600. In such embodiments, thread lines622/632of continuous threads620/630extend between respective projections606on front side601and rear side603of support plate600, and may wrap around exterior perimeter wall604. For support plate600, projections606define anchor points of thread pattern610.

Once a desired thread pattern610is wound, continuous thread(s) of thread pattern610may be bonded to mechanically set the thread pattern610. In some embodiments, thread lines of continuous thread(s) may be bonded to support plate600around projections606. In some embodiments, thread lines of continuous thread(s) may be directly bonded to each other around projections606. In some embodiments, thread lines of continuous thread(s) may be bonded at together at points of intersection between the thread lines. The thread lines may be bonded at intersection points via an adhesive, a bonding layer, thermal (conductive or convective) heat (for example, in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, a mechanical fastener (for example, a clip), hook and loop fasters, needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement, felting, knotting, chemical bonding with a catalyst of biomaterial, adhesive spraying (for example, CNC adhesive spray deposition), or by pushing one thread line through the other thread line(s). In some embodiments, thread lines of continuous thread(s) may be directly bonded at together at points of intersection between the thread lines. In embodiments including polymeric continuous thread(s), the polymeric material(s) of the continuous thread(s) may directly bond thread lines at projections606and/or at points of intersection between thread lines. In some embodiments, thread lines of continuous thread(s) may alternatively or additionally be bonded with a bonding layer as discussed herein.

Once thread pattern610is mechanically set by bonding continuous thread(s), thread pattern610may be removed from support plate600. In some embodiments, removing thread pattern610from support plate600may include cutting a portion of thread pattern610from support plate600. In some embodiment, the cutting process may include a laser cutting process. In some embodiments, a bonding layer may be applied to thread pattern610after it is cut from support plate600.

In some embodiments, support plate600may be a hand-held plate. In some embodiments, support plate600may be attached to a device configured to rotate the support plate600(for example, a lathe). During rotation of support plate600, continuous thread(s) may be wound around support plate600either manually or with a computer-assisted machine (for example, a CNC machine). In some embodiments, thread may be wound around projections606of support plate600while support plate600is held stationary.

In some embodiments, a support plate may include one or more pads about which thread lines of a thread pattern are threaded. In such embodiments, thread lines of a thread pattern may be diverted around a perimeter of the pad(s) during winding. In some embodiments, by winding thread lines of a thread pattern around pad(s), one or more openings in a thread pattern may be created after the pad(s) are separated from the thread pattern. In some embodiments, by winding thread lines of a thread pattern around pad(s), the pad(s) may be incorporated into a thread pattern.

FIG.28shows a support plate2800including a plurality of pads2810around which thread lines of a thread pattern2820are diverted during winding between anchor points2806of support plate2800. Pad(s)2810may be disposed on and extend above a surface2802of support plate2800between anchor points2806. In some embodiments, the tension in thread lines diverted around pad(s)2810may serve to hold diverted thread lines in contact with pad(s)2810during and after winding.

Thread pattern2820inFIG.28is a representative exemplary thread pattern. Various thread patterns discussed herein (for example, thread pattern122) may be wound around anchor points2806of support plate2800and include thread lines diverted around pads2810.

In some embodiments, pad(s)2810maybe an integral component of support plate2800. In such embodiments, pad(s)2810may be integrally formed with support plate2800. In some embodiments, pad(s)2810may be permanently attached to support plate2800. In some embodiments, pad(s)2810may be removably attached to support plate2800.

In some embodiments, a pad2810may be located on support plate2800for the purpose of creating an opening in thread pattern2820. In such embodiments, thread lines of thread pattern2820may be diverted around a perimeter wall2812of pad2810and set prior to removing thread pattern2820from support plate2800, thereby forming an opening in thread pattern2820. In some embodiments, the thread lines may be locally set around pad2810. For example, thread lines may be locally bonded around pad2810before removing thread pattern2820from support plate2800. In some embodiments, the entire thread pattern2820may be bonded around pad2810. For example, the entire thread pattern2820may be bonded in a heat press or an oven configured to bond thread lines of a thread pattern as described herein. In embodiments where pad(s)2810are for the purpose of creating an opening, the opening may be, for example, an opening for a collar of an upper, an opening for at least a portion of a throat for an upper, an opening for an interlocking seam structure, or an aesthetic opening on an upper.

In some embodiments, a pad2810may be located on support plate2800for the purpose of incorporating the pad2810into thread pattern2820. In such embodiments, thread lines of thread pattern2820may be diverted around a perimeter wall2812of pad2810and bonded to the pad2810, thereby incorporating the pad2810into thread pattern2820. In some embodiments, thread lines may be bonded to the pad2810in a heat press or an oven configured to bond thread lines of a thread pattern as described herein. In some embodiments, thread lines may be bonded to pad2810using an adhesive. In embodiments where pad(s)2810are included for incorporating into thread pattern2820, pad(s)2810may define all or a portion of a footwear component, for example a collar for an upper, a throat for an upper, a heel counter for an upper, or an aesthetic feature on an upper.

In some embodiments, a thread pattern may be wound around anchor points on a support plate (for example, pins304of support plate300or projections606of support plate600) manually. In some embodiments, a thread pattern may be wound around anchor points (for example, pins304of support plate300or projections606of support plate600) using an automated, computer-assisted process.FIG.7illustrates a CNC machine700including a robotic arm705for winding a thread pattern720including thread lines722around pins304on support plate300. Thread pattern720inFIG.7is a representative exemplary thread pattern.

Robotic arm705may include a thread spool710for threading and winding thread lines722of thread pattern720around pins304. In some embodiments, CNC machine700may include a thread tensioner712configured to apply a desired tension to thread(s) that are wound around pins304. CNC machine700may include a controller715configured to wind a desired thread pattern720around pins304using a thread model and input data. In some embodiments, controller715may control tensioner712to wind thread(s) at desired tensions. Controller715may include components of computer system3500discussed herein.

In some embodiments, CNC machine700may include a winding assembly including a plurality of thread spools for threading and winding a plurality of different threads for a thread pattern.FIG.29illustrates a winding assembly2900including a plurality of thread spools2910in connection with a robotic arm2905for winding a thread pattern2920according to some embodiments. Thread pattern2920inFIG.29is a representative exemplary thread pattern. Various thread patterns discussed herein (for example, thread pattern122) may be wound using winding assembly2900.

In some embodiments, winding assembly2900may include a plurality of tensioners2912configured to apply a desired tension to threads from different thread spools2910.

In some embodiments, CNC machine700with winding assembly2900may wind a plurality of threads from a plurality of thread spools2910simultaneously when winding a thread pattern. In some embodiments, winding assembly2900may be used to simultaneously wind “overlaying thread lines” from a plurality of thread spools2910. By simultaneously winding threads from a plurality of thread spools2910, the speed at which a desired thread pattern can be created may be increased.

In some embodiments, CNC machine700may include two or more robotic arms2905for winding a plurality of threads simultaneously. In such embodiments, the two or more robotic arms2905may wind different threads in different regions of a thread pattern simultaneously.

In some embodiments, robotic arm2905of winding assembly2900may ply two or more threads from different thread spools2910. In such embodiments, thread pattern2920will include one or more plied threads. As used herein, “plying” two or more threads means coupling the two or more threads together by twisting at least one of the two or more threads. In some embodiments, plying may include twisting one or more threads around one or more non-twisted threads. In some embodiments, plying may include twisting two or more threads together.

In some embodiments, arm2905of winding assembly2900may be configured to vary how two or more threads are plied as a plied thread is wound into a thread pattern. In such embodiments, arm2905of winding assembly2900may be configured to vary one or more of: (i) the number of threads plied or (ii) how tightly one or more threads is twisted. For example, arm2905may be configured to ply three threads for a first portion of a thread pattern and four threads for a second portion of the thread pattern. As another example, arm2905may be configured to tightly twist one or more threads for a first portion of a thread pattern and loosely twist one or more threads for a second portion of the thread pattern. By varying how two or more threads are plied, characteristics of a thread pattern in different portions and/or regions of the thread pattern may be varied. Exemplary characteristics that may be varied include strength, support, propulsion, breathability, comfort (stretchability), tackiness, abrasion resistance, texture, haptics, or durability.

In some embodiments, tensioners712,2912may be a mechanical tensioning devices with digitally controlled impedance that is used to dynamically control how tight a thread is fed through a winding machine (for example, CNC machine700). In some embodiments, thread may be run through tensioner712,2912before it exits a thread spool, thereby giving an exact tension as it is fed out. In some embodiments, thread may be run through tensioner712,2912after it exits a thread spool to give the thread a desired tension. In some embodiments, the tension value for thread can be changed dynamically by adjusting the voltage in tensioner712,2912. In some embodiments, tensioner712,2912may be a manually adjustable tensioner. In some embodiments, tensioner712,2912may include a spring configured to adjust the amount of tension applied to thread(s). The spring may be manually controlled or digitally controlled.

Adjusting the tension as the thread is wound can provide a number of benefits. With elastic threads, tensioning the threads places a preload on them, allowing them to act as if they have a different stiffness in a thread pattern. By dynamically adjusting the tension, one thread can behave with a range of stiffness, which allows for customized zones of stiffness and compliance without the need for changing thread material. This change in stiffness between different zones may be large or small. For example, high stiffness can be provided in areas where high tensioned threads are bonded together and low stiffness can be provided in areas where stretch is preferred.

In some embodiments, adjusting thread tension within a thread pattern may facilitate customization of an article of footwear for an individual, or group of individuals, by providing desired characteristics to different areas on the footwear. Moreover, tensioning may be used to customize the fit of an article of footwear. For example, when a wound thread pattern is removed from pins304, the thread pattern may contract to an un-stretched shape, which relieves any tension in thread lines that is not fixed by bonding. This may facilitate a customized fit for an individual, or group of individuals, because the un-stretched shape may better conform with the shape of a wearer's foot. In some embodiments, tensioning and un-stretched shapes may be designed based on biometric data, such as foot volume data.

In some embodiments, tensioning of thread lines in a thread pattern may be based on a biometric data profile for an individual. In some embodiments, a biometric data profile may be collected using a physiological and personal characteristic collection and analysis system, such as a Run Genie® system. In some embodiments, the biometric data profile may be collected using the data collection and analysis system described in U.S. patent application Ser. No. 14/579,226, filed on Dec. 22, 2014, and published as US 2016/0180440, which is hereby incorporated by reference in its entirety by reference thereto.

The physiological characteristics collected may include, but are not limited to, gait characteristics, such as foot strike type (e.g. heel, midfoot, forefoot, etc.), rate of pronation or supination, and degree of pronation and supination. In some embodiments, the biometric data profile may include receiving personal information about the individual before or after receiving physiological characteristics data about the individual. Personal information may include information such as their name, prior injury information, height, weight, gender, shoe size, an athletic goal, intended athletic environment or terrain, intended athletic activity duration, intended athletic activity frequency, intended athletic activity distance, quantitative or qualitative preferences about athletic equipment or footwear (such as level of cushion, preference of weight, materials and the like), and current athletic footwear.

In some embodiments, collecting a biometric data profile may include monitoring an individual (e.g., individual3000shown inFIG.30) in real time during an athletic activity, such as jogging, and collecting physiological characteristics using one or more sensor modules (e.g., modules3002). A sensor module may include one or more sensors, and may be physically coupled to an object (e.g., article of footwear3004) during an everyday or athletic activity conducted by an individual. A sensor module may be used to monitor changes in the spatial orientation of an individual's body or a piece of the individual's athletic equipment or article of footwear in some embodiments. A sensor module may be used in combination with predetermined correlation data stored in a data structure to determine a correlation between body or equipment or article of footwear movement data and a characteristic such as a gait characteristic in some embodiments.

In some embodiments, a sensor module is placed and/or built into an article of footwear to measure, for example, a runner's running form and gait cycle (e.g., sensor is placed on, removably attached to, or built into the heel, midsole, or toe of an article of footwear). Additional sensors/motion monitors can also be placed on the runner's knee and hip, for example, to obtain more information about the runner's running form.

A sensor module may include a plurality of sensors, including but not limited to, one or more motion sensors, such as acceleration sensors and magnetic field sensors, or angular momentum sensors. In some embodiments, a sensor module may include one or more temperature sensors, a heart rate monitoring device, a pedometer, and/or an accelerometer-based monitoring device. Sensors of a sensor module may be capable of measuring a variety of athletic performance parameters. The term “performance parameters” may include physical parameters and/or physiological parameters associated with the individual's athletic activity. Physical parameters measured may include, but are not limited to, time, distance, speed, pace, pedal count, wheel rotation count, rotation generally, stride count, stride length, airtime, stride rate, altitude, temperature, strain, impact force, jump force, force generally, and jump height. Physiological parameters measured may include, but are not limited to, heart rate, respiration rate, blood oxygen level, blood lactate level, blood flow, hydration level, calories burned, or body temperature.

An acceleration sensor may be adapted to measure the acceleration of a sensor module. Accordingly, when the sensor module is physically coupled to an object (such as an individual's3000body, article of footwear3004, or other a piece of athletic equipment), the acceleration sensor may be capable of measuring the acceleration of the object, including the acceleration due to the earth's gravitational field. In some embodiments, an acceleration sensor may include a tri-axial accelerometer that is capable of measuring acceleration in three orthogonal directions. In some embodiments one, two, three, or more separate accelerometers may be used.

A magnetic field sensor may be adapted to measure the strength and direction of magnetic fields in the vicinity of a sensor module. Accordingly, when the sensor module is physically coupled to an object (such as an individual's3000body, article of footwear3004, or other a piece of athletic equipment), a magnetic field sensor may be capable of measuring the strength and direction of magnetic fields in the vicinity of the object, including the earth's magnetic field. In some embodiments, a magnetic field sensor may be a vector magnetometer. In some embodiments, a magnetic field sensor may be a tri-axial magnetometer that is capable of measuring the magnitude and direction of a resultant magnetic vector for the total local magnetic field in three dimensions. In some embodiments one, two, three, or more separate magnetometers may be used.

In some embodiments, an acceleration sensor and a magnetic field sensor may be contained within a single accelerometer-magnetometer module.

An angular momentum sensor, which may be, for example, a gyroscope, may be adapted to measure the angular momentum or orientation of a sensor module. Accordingly, when the sensor module is physically coupled to an object (such as an individual's body, an article of footwear, or other athletic equipment), the angular momentum sensor may be capable of measuring the angular momentum or orientation of the object. In some embodiments, an angular momentum sensor may be a tri-axial gyroscope that is capable of measuring angular rotation about three orthogonal axes. In some embodiments one, two, three, or more separate gyroscopes may be used. In some embodiments, angular momentum sensor may be used to calibrate measurements made by one or more of an acceleration sensor and a magnetic field sensor.

A heart rate sensor may be adapted to measure an individual's heart rate. A heart rate sensor may be placed in contact with the individual's skin, such as the skin of the individual's chest, and secured with a strap. A heart rate sensor may be capable of reading the electrical activity the individual's heart.

A temperature sensor may be, for example, a thermometer, a thermistor, or a thermocouple that measures changes in the temperature. In some embodiments, a temperature sensor may primarily be used for calibration other sensors, such as, for example, an acceleration sensor and a magnetic field sensor.

In some embodiments, a sensor module may include a position receiver, such as an electronic satellite position receiver that is capable of determining its location (i.e., longitude, latitude, and altitude) using time signals transmitted along a line-of-sight by radio from satellite position system satellites. Known satellite position systems include the GPS system, the Galileo system, the BeiDou system, and the GLONASS system. In some embodiments, a position receiver may be an antenna that is capable of communicating with local or remote base stations or radio transmission transceivers such that the location of the sensor module may be determined using radio signal triangulation or other similar principles. In some embodiments, position receiver data may allow the sensor module to detect information that may be used to measure and/or calculate position waypoints, time, location, distance traveled, speed, pace, or altitude.

In some embodiments, data collected by a sensor module may classify individuals based on their running style, utilizing data analysis such as an anterior-posterior plot angle vs. time; medial-lateral plot angle vs. time; and the like. Calculations of these characteristics may be used to group individuals into different categories (groups), such as a heel striker, a midfoot striker, a forefoot striker, a pronator, supinator, a neutral individual, or some combination of characteristics. In some embodiments, gait analysis may utilize personal information of an individual, such a gender, shoe size, height, weight, running habits, and prior injuries.

In some embodiments, a regression analysis can be used to determine gait characteristics such as foot strike type, rate of pronation, degree of pronation, and the like based on acceleration data obtained from a sensor module. In some embodiments, the regression analysis can be used to determine gait characteristics such as foot strike type, rate of pronation, degree of pronation, and the like based on other data such as magnetometer data, angular momentum sensor data, or multiple types of data. In some embodiments, the analysis can include other user-input information such as prior injury information, an athletic goal, intended athletic environment or terrain, intended athletic duration, and current athletic footwear.

Athletic goals may be, for example, training for a race, to stay healthy, to lose weight, and training for sports. Other examples of athletic goals may include training for a race, or other sporting event, improving individual fitness, simply enjoy running, or the like. Frequency intervals may include for example about 1 to 2 times per week, about 3 to 4 times per week, about 5 to 7 times per week, or the individual doesn't know. Length intervals may include for example about less than about 5 miles per week, about 5 to 10 miles per week, about 10 to 20 miles per week, greater than about 20 miles per week, or the individual doesn't know. Examples of intended athletic terrain environments may include roads, track, treadmill, trail, gym, or particular athletic fields designed for a specific sport. Examples of athletic equipment preferences may include for example more cushioning, less weight, better fit, strength, durability, intended athletic activity range, balance, weight balance, more color choices, and the like.

In some embodiments, information from sensor module(s) may be used to map areas of an individual's foot subject to different pressures or stresses. And information from sensor module(s) may be used to generate a biometric date profile map. For example, high stress areas may be associated with a heel portion, areas corresponding to the location of the ball of an individual's foot (i.e., at a position corresponding to a location near the anterior end of metatarsals), and a medial most portion of the individual's arch. Mild stress areas may be associated with a medial portion of the individual's arch and areas corresponding to the location of an individual's phalanges. And low stress areas may be associated with a lateral portion of the individual's arch. The size, location, and degree of stress areas for an individual will depend on, among other things, the anatomy of the individual's foot and the individual's gait.

In some embodiments, collecting a biometric data profile may include obtaining previously collected and stored data for an individual. In some embodiments, collecting biometric data may include obtaining a standard biometric data profile for a group of individuals. For example, a standard profile for individuals having a certain shoe size, weight, height, arch shape, stability characteristic, and/or touchdown characteristic may be retrieved. In some embodiments, the standard biometric data profile for a group of individuals may be modified for a particular individual based on personal information about the individual. Personal information may include information such as, prior injury information, height, weight, gender, shoe size, an athletic goal, intended athletic environment or terrain, intended athletic activity duration, intended athletic activity frequency, intended athletic activity distance, quantitative or qualitative preferences about athletic equipment or footwear (such as level of cushion, preference of weight, materials and the like), and current athletic footwear.

FIGS.8A-9illustrate exemplary apparatuses for bonding continuous thread(s) of a thread pattern at locations of anchor points and/or intersection points between thread lines. In some embodiments, bonding of continuous thread(s) for a thread pattern may set the thread pattern such that the pattern forms a portion of an upper for an article of footwear. In some embodiments, bonding of continuous thread(s) for a thread pattern may set the thread pattern so that the pattern can shaped into a structure that forms a portion of an upper for an article of footwear. In some embodiments, after bonding of continuous thread(s) for a thread pattern, the thread pattern may be cut to define a shape utilized to form a portion of an upper for an article of footwear. For example, in some embodiments, a thread pattern may be cut to define a perimeter shape for a portion of an upper for an article of footwear. As another example, in some embodiments, a thread pattern may be cut to define a shape for at least one of a biteline, a collar, or a throat of an upper for an article of footwear.

FIGS.8A-8Cshow an exemplary process and mold for three-dimensionally thermo-molding a thread pattern according to some embodiments according to some embodiments. As shown, inFIGS.8A and8B, a mold800may be assembled around a thread pattern810on an inflatable bladder820. For example, thread pattern810and inflatable bladder820may be inserted into the mold cavity of mold800.

In some embodiments, a connector822may be coupled to inflatable bladder820. Connector822may include a first end coupled to inflatable bladder820and a second end configured to couple with a pressure conduit for delivering pressurized air824from a pressure source. In some embodiments, connector822may include a pressure valve for regulating the pressure of pressurized air824pumped into inflatable bladder820.

In some embodiments, the mold cavity of mold800and/or thread pattern810may be coated with a non-stick material, such as but not limited to a silicone spray, to reduce potential adhesion between thread pattern810and the mold cavity during forming. Before or after thread pattern810and inflatable bladder820are inserted into the mold cavity, mold800may be heated to a predetermined temperature. The temperature of mold800may be such that it softens polymer thread(s) of thread pattern810to allow thread lines of thread pattern810to directly bond to each other. In some embodiments, thread pattern810may take on the shape of an upper for an article of footwear in mold800.

In some embodiments, the predetermined temperature may be equal to or above the melting point of polymeric material(s) of polymer thread(s) of thread pattern810. In some embodiments, the predetermined temperature may be below the melting point of the polymeric material(s), but high enough to cause the polymeric material(s) to bond (fuse) together, or to other materials of thread pattern810. In some embodiments, the predetermined temperature may be 180 degrees C. or less. In some embodiments, the predetermined temperature may be in the range of 80 degrees C. to 180 degrees C. In some embodiments, the predetermined temperature may be 160 degrees C. or less. In some embodiments, the predetermined temperature may be in the range of 65 degrees C. to 160 degrees C. In some embodiments, the predetermined temperature may be selected such that polymeric material(s) of polymer thread(s) of thread pattern810undergo no chemical reactions during thermo-forming.

In some embodiments, the polymer thread(s) of thread pattern810may be bonded at a temperature that creates little to no volatile substances (for example, vapors created by chemical reactions such as those created during curing of a polymer). In some embodiments, the bonding of polymer thread(s) of thread pattern810may not cause a change in the chemical composition of the polymeric material(s) of the polymer thread(s). The use of low processing temperatures may reduce manufacturing cost and may reduce environmental impact of a manufacturing process by reducing the release of volatile substances. Further, a manufacturing process that does not rely on the occurrence of chemical reactions may result in a manufacturing process that is easier to control and reproduce. In some embodiments, the temperature used to bond polymer thread(s) of thread pattern810may be greater than the softening point temperature of the polymeric material(s) of the polymer thread(s). The softening point temperature of a polymer may be measured using a Vicat softening point test.

In some embodiments, the predetermined temperature may be greater than 180 degrees C. In some embodiments, the predetermined temperature may be in a range of 180 degrees C. to 320 degrees C., including subranges. For example, the predetermined temperature may be 200 degrees C. to 300 degrees C., 220 degrees C. to 280 degrees C., 240 degrees C. to 260 degrees C., or within a range having any two of these valves as endpoints. In some embodiments, the predetermined temperature may be in a range of 65 degrees C. to 320 degrees C.

In some embodiments, after heating mold800, inflatable bladder820may be expanded to press thread pattern810against the interior surface of the mold cavity defined by a medial mold plate802and lateral mold plate804of mold800. In some embodiments, inflatable bladder820may be expanded to press thread pattern against the interior surface of the mold cavity defined by a medial mold plate802and lateral mold plate804of mold800, and after expanding inflatable bladder, mold800may be heated. In either case, the combination of pressure and heat can cause thread pattern810to take on the shape of the interior surface of the mold cavity, thereby taking on the shape of an upper for an article of footwear. In some embodiments, inflating inflatable bladder820may press thread pattern810in direct contact with the interior surface of the mold cavity.

Heat may be applied to mold800in one or more ways, such as but not limited to, radio frequency heating, high frequency heating, and infrared heating. Heat transfer between thread pattern810and mold800may be via conduction and/or convection.

In some embodiments, heat may be uniformly applied to thread pattern810within mold800. In such embodiments, the temperature at which thread pattern810is bonded within mold800may be substantially the same across all portions of thread pattern810. For example, heat may be uniformly applied to forefoot, midfoot, and heel portions of thread pattern810in forefoot portion830, midfoot portion832, and heel portion834of mold800.

In some embodiments, heat may be non-uniformly applied to thread pattern810within mold800. In such embodiments, the temperature at which thread pattern810is bonded within mold800may be different for different portions and/or regions of thread pattern810. For example, in some embodiments, heat may be non-uniformly applied to two or more of forefoot, midfoot, and heel portions of thread pattern810in forefoot portion830, midfoot portion832, and heel portion834of mold800. In such embodiments, thread pattern810may be heated to a first temperature in one of the portions and heated to a second temperature in another one of the portions. As another example, in some embodiments, heat may be non-uniformly applied to medial and lateral sides of thread pattern810in medial mold plate802and lateral mold plate804of mold800. In such embodiments, a medial side of thread pattern810may be heated to a first temperature and a lateral side of thread pattern810may heated to a second temperature.

In some embodiments, heat may be non-uniformly applied to two or more of a medial forefoot region, a lateral forefoot region, a medial midfoot region, a lateral midfoot region, a medial heel region, and a lateral heel region of thread pattern810in mold800. For example, thread pattern810may be heated to a first temperature in forefoot portion830of medial mold plate802and heated to a second temperature in forefoot portion830of lateral mold plate804.

By varying the bonding temperature of different portions and/or regions of thread pattern810, characteristics of thread pattern810in different portions and/or regions may be varied. Exemplary characteristics that may be varied include strength, support, propulsion, breathability, comfort (stretchability), tackiness, abrasion resistance, texture, haptics, and durability. Variable heating can control the variation in one or more of these characteristics by controlling one or more of: (i) the degree of melting or softening of a polymeric material in thread pattern810, (ii) the degree of bonding at intersection points between thread lines in thread pattern810, (iii) the activation of activatable agents or coatings and/or active threads in thread pattern810, and (iv) in embodiments including a thread pattern810with a plurality of thread layers, the degree of bonding between layers of thread pattern810.

In some embodiments, a first bonding temperature within mold800may be +/−10 degrees C. or more different from a second bonding temperature.

In some embodiments, the heat applied to thread pattern810may be controlled by controlling heat applied to mold800. In some embodiments, the heat applied to thread pattern810may be additionally or alternatively controlled by one or more inserts840disposed between the interior surface of mold800and thread pattern810. In such embodiments, insert(s)840may control the heat applied to thread pattern810by controlling the heat transfer between mold800and thread pattern810. In some embodiments, insert(s)840may serve to uniformly distribute heat across all or a portion of thread pattern810. In some embodiments, insert(s)840may serve to vary the bonding temperature of different portions and/or regions of thread pattern810.

In some embodiments, insert(s)840may be composed of a polymeric material. In some embodiments, insert(s)840may be composed of a polymeric foam material. Exemplary polymeric and polymeric foam materials include, but are not limited to, silicone, ethyl vinyl acetate (EVA), polyurethane (PU), expanded thermoplastic polyurethane (eTPU), a thermoplastic polyurethane (TPU), an EVA-based foam or a PU-based foam. In some embodiments, insert(s)840may be composed of a ceramic or a metal. In some embodiments, the material of insert(s)840may have a melting temperature higher than the melting temperature of the polymeric material(s) of thread pattern810. In some embodiments, the material of insert(s)840may have a melting temperature higher than the highest temperature applied to mold800during bonding of thread pattern810.

In some embodiments, the material of insert(s)840may additionally or alternatively serve to control the amount of pressure applied to thread pattern810in mold800. In some embodiments, insert(s)840may serve to vary the pressure applied to different portions and/or regions of thread pattern810in mold800. In such embodiments, by varying the pressure applied to different portions and/or regions of thread pattern810, characteristics of thread pattern810in different portions and/or regions may be varied. Variable pressure can control the variation in one or more characteristics of thread pattern810by controlling one or more of: (i) the degree of melting or softening of a polymeric material in thread pattern810, (ii) the degree of bonding at intersection points between thread lines in thread pattern810, and (iii) in embodiments including a thread pattern810with a plurality of thread layers, the degree of bonding between layers of thread pattern810.

In some embodiments, the hardness and/or density of a material for an insert840may be used to tailor the amount of pressure applied to thread pattern810in mold800. In some embodiments, a plurality of inserts840made of materials with different hardness and/or densities may be used to vary the amount of pressure applied to different portions and/or regions of thread pattern810in mold800. In some embodiments, an insert840may include regions with different hardness and/or density for varying the amount of pressure applied to different portions and/or regions of thread pattern810in mold800.

In some embodiments, the interior surface of mold800and/or insert(s)840may include one or more cavities configured to control the amount of heat and/or pressure applied to different portions and/or regions of thread pattern810in mold800. In some embodiments, a cavity may serve to prevent bonding of threads in one or more portions or regions of thread pattern810.

In some embodiments, insert(s)840may be a textured insert including a plurality of regions with different textures and/or elevations. For example, an insert840may include textured regions as described herein for textured sheet1600.

In some embodiments, different amounts of heat may be uniformly or non-uniformly applied to thread pattern810within mold800in separate heating steps. In such embodiments, the separate heating steps may serve to selectively soften, melt, and/or activate particular threads within thread pattern810. For example, a first heating step may soften or melt the polymeric material of a first thread within thread pattern810and a second heating step may soften or melt the polymeric material of a second thread within thread pattern810. As another example, a first heating step may soften or melt the polymeric material of a first thread within thread pattern810and a second heating step may activate an activatable agent of a second thread within thread pattern810.

In some embodiments, after pressing thread pattern810against the interior surface of the mold cavity of mold800and heating thread pattern810, bladder820may be deflated and thread pattern810may be removed from the mold cavity to cool. In some embodiments, after pressing thread pattern810against the interior surface of the mold cavity of mold800and heating thread pattern810, thread pattern810may be cooled while thread pattern810remains in the mold cavity. In some embodiments, mold800may be cooled while thread pattern810remains in the mold cavity, thereby cooling thread pattern810. In some embodiments, thread pattern810may be cooled while thread pattern810is pressed against the interior surface of the mold cavity. In some embodiments, mold800may be cooled while thread pattern810is pressed against the interior surface of the mold cavity, thereby cooling thread pattern810.

In some embodiments, thread pattern810within mold800may be cooled to a temperature below the crystallization temperature of the polymeric material(s) of polymer thread(s) of thread pattern810. Cooling of thread pattern810within mold800, and thus the polymeric material(s) of polymer thread(s), to a temperature below the crystallization temperature of the polymeric material(s) can facilitate bonding of thread lines of thread pattern together at intersection points and/or anchor points.

In some embodiments, the mold cavity of mold800may be sized and shaped for a particular foot type and size (i.e., length and width). In some embodiments, mold800may be a customized mold including a customized interior mold cavity surface. In some embodiments, mold800may be customized for a particular individual. In some embodiments, mold800may include a mold cavity created by digitally scanning a human foot. In some embodiments, mold800may include a customized mold cavity created by digitally scanning an individual's foot. In some embodiments, an individual's foot may be scanned using a CREAFORM Go! SCAN 3D scanner, Serial No: 570489, manufactured by Ametek Ultra Precision Technologies.

When bonding polymer thread(s) of a thread pattern to thermo-form uppers for footwear as discussed herein, only mold(s)800may need to be interchanged to form different sizes, shapes, and/or types of uppers. The interchangeability and modularity of molds may reduce manufacturing costs by reducing the number of parts that need to changed/adjusted when forming uppers for different articles of footwear. Reducing the parts that need to changed/adjusted when forming uppers for different articles of footwear may facilitate the use of an automated process for thermo-forming uppers for articles of footwear. Further, it may facilitate cost-effective manufacturing of customized uppers.

As shown for example inFIG.8C, after polymer thread(s) of thread pattern810are bonded, inflatable bladder820may be deflated and an upper-shaped material defined by thread pattern810may be removed from the mold cavity. In some embodiments, excess material may be removed (for example, cut) from thread pattern810to define edges of an upper. In some embodiments, excess material may be removed after cooling thread pattern810. In some embodiments, edges of bonded thread pattern810may be folded and/or sown at a seam (e.g., a seam163) to define edges of an upper.

FIG.9shows a heat press900according to some embodiments. Heat press900may apply pressure and heat to a thread pattern (for example, thread pattern122) to bond continuous thread(s) of a thread pattern at locations of anchor points and/or intersection points between thread lines. In some embodiments, heat press900may provide heat at a predetermined temperature equal to or above the melting point of polymeric material(s) of polymer thread(s) of a thread pattern. In some embodiments, heat press900may provide heat at a predetermined temperature below the melting point of polymeric material(s) of polymer thread(s) of a thread pattern, but high enough to cause the polymeric material(s) to bond (fuse) together, or to other materials of the thread pattern.

The temperature used to bond continuous thread(s) of a thread pattern with heat press900may be the same as or similar to the temperatures discussed herein for three-dimensionally thermo-molding a thread pattern. In some embodiments, the predetermined temperature may be 180 degrees C. or less. In some embodiments, the predetermined temperature may be in the range of 180 degrees C. to 80 degrees C. In some embodiments, the predetermined temperature may be 160 degrees C. or less. In some embodiments, the predetermined temperature may be in the range of 160 degrees C. to 65 degrees C. In some embodiments, the predetermined temperature may be such that polymeric material(s) of polymer thread(s) of thread pattern810undergo no chemical reactions during heating.

Heat may be applied to a thread pattern in heat press900in one or more ways, such as but not limited to, radio frequency heat sealing (welding), high frequency heat sealing (welding), infra-red welding, and steaming. Heat transfer between a thread pattern and heat press900may be via conduction and/or convection. In some embodiments, heat may be applied to a single outer surface of a thread pattern in heat press900. In some embodiments, heat may be applied to both outer surfaces of a thread pattern in heat press900.

In some embodiments, heat may be uniformly applied a thread pattern within heat press900. In such embodiments, the temperature at which a thread pattern is bonded within heat press900may be substantially the same across all portions of the thread pattern. For example, heat may be uniformly applied to forefoot, midfoot, and heel portions of a thread pattern in forefoot portion930, midfoot portion932, and heel portion934of heat press900.

In some embodiments, heat may be non-uniformly applied to a thread pattern within heat press900. In such embodiments, the temperature at which a thread pattern is bonded within heat press900is different for different portions and/or regions of the thread pattern. For example, in some embodiments, heat may be non-uniformly applied to two or more of forefoot, midfoot, and heel portions of a thread pattern in forefoot portion930, midfoot portion932, and heel portion934of heat press900. In such embodiments, a thread pattern may be heated to a first temperature in one of the portions and heated to a second temperature in another one of the portions. As another example, in some embodiments, heat may be non-uniformly applied to medial and lateral sides of a thread pattern in heat press900. In such embodiments, a medial side of a thread pattern may be heated to a first temperature and a lateral side of the thread pattern may heated to a second temperature.

In some embodiments, heat may be non-uniformly applied to two or more of a medial forefoot region, a lateral forefoot region, a medial midfoot region, a lateral midfoot region, a medial heel region, and a lateral heel region of a thread pattern in heat press900. For example, a thread pattern may be heated to a first temperature in a medial side of forefoot portion930of heat press900and heated to a second temperature in a lateral side of forefoot portion930of heat press900.

By varying the bonding temperature of different portions and/or regions of a thread pattern in heat press900, characteristics of the thread pattern in different portions and/or regions may be varied as described above in connection with thread pattern810and mold800.

In some embodiments, a first bonding temperature within heat press900may be +/−10 degrees C. different from a second bonding temperature.

In some embodiments, the heat applied to a thread pattern may be controlled by controlling heat applied to heat press900. In some embodiments, the heat applied to a thread pattern may be additionally or alternatively controlled by one or more inserts940disposed between an interior surface of heat press900and the thread pattern. In such embodiments, insert(s)940may control the heat applied to a thread pattern by controlling the heat transfer between heat press900and the thread pattern. In some embodiments, insert(s)940may serve to uniformly distribute heat across all or a portion of a thread pattern within heat press900. In some embodiments, insert(s)940may serve to vary the bonding temperature of different portions and/or regions of a thread pattern in heat press900.

Insert(s)940for heat press900may be the same or similar to insert(s)840. In some embodiments, the material of insert(s)940may serve to control the amount of pressure applied to a thread pattern in heat press900. In some embodiments, insert(s)940may serve to vary the pressure applied to different portions and/or regions of a thread pattern in heat press900. In such embodiments, by varying the pressure applied to different portions and/or regions of a thread pattern, characteristics of the thread pattern in different portions and/or regions may be varied as described above in connection with thread pattern810and mold800.

In some embodiments, an interior surface of heat press900and/or insert(s)940may include one or more cavities configured to control the amount of heat and/or pressure applied to different portions and/or regions of a thread pattern in heat press900. In some embodiments, a cavity may serve to prevent bonding of threads in one or more portions or regions of a thread pattern.

In some embodiments, insert(s)940may be a textured insert including a plurality of regions with different textures and/or elevations. For example, an insert940may include textured regions as described herein for textured sheet1600.

In some embodiments, different amounts of heat may be uniformly or non-uniformly applied to a thread pattern within heat press900in separate heating steps. In such embodiments, the separate heating steps may serve to selectively soften, melt, and/or activate particular threads of a thread pattern within heat press900. For example, a first heating step may soften or melt the polymeric material of a first thread within a thread pattern and a second heating step may soften or melt the polymeric material of a second thread within the thread pattern. As another example, a first heating step may soften or melt the polymeric material of a first thread within a thread pattern and a second heating step may activate an activatable agent of a second thread within the thread pattern.

In some embodiments, after applying heat and pressure to the thread pattern in heat press900, the thread pattern may be removed from heat press900to cool. In some embodiments, after applying heat and pressure to the thread pattern in heat press900, the thread pattern may be removed from heat press900and placed in a cold press to cool. In some embodiments, after applying heat and pressure to the thread pattern in heat press900, the thread pattern may be cooled while the thread pattern remains within heat press900. In some embodiments, heat press900may be cooled while the thread pattern remains within heat press900, thereby cooling the thread pattern.

In some embodiments, the thread pattern within heat press900may be cooled to a temperature below the crystallization temperature of the polymeric material(s) of polymer thread(s) of the thread pattern. In some embodiments, the thread pattern within a cold press may be cooled to a temperature below the crystallization temperature of the polymeric material(s) of polymer thread(s) of the thread pattern. Cooling of the thread pattern, and thus the polymeric material(s) of polymer thread(s), to a temperature below the crystallization temperature of the polymeric material(s) can facilitate bonding of thread lines thread pattern together at intersection points and/or anchor points.

In some embodiments, after heat pressing a thread pattern, excess material may be removed (for example, cut) from the patterned material to define the edges of the patterned material. In some embodiments, excess material may be removed after cooling the thread pattern. In some embodiments, edges of a thread pattern bonded in heat press900may be folded and/or sown at a seam (e.g., a seam163) to define edges of an upper.

In some embodiments, continuous thread(s) of a thread pattern may be bonded by pressing a thread pattern against the outer surface of an object configured to provide a desired shape to the thread pattern and heating the thread pattern to impart the desired shape. In some embodiments, the object may be a last.

FIG.31illustrates a method of pressing a thread pattern3110against a last3100such that thread pattern3110conforms to the outer shape of last3100. Thread pattern3110inFIG.31is a representative exemplary thread pattern. Various thread patterns discussed herein (for example, thread pattern122) may bonded by pressing the thread pattern against last3100.

In some embodiments, thread pattern3110may be wound around a hollow support plate3120with anchor points3124so that last3100can be inserted through an opening3122in hollow support plate3120. In such embodiments, inserting last3100through opening3122serves to press thread pattern3110against an outer surface3102of last3100.

After pressing thread pattern3110against last3100, thread pattern3110may be heated while disposed over last3100to bond continuous thread(s) of thread pattern3110. In some embodiments, heat may be applied by placing thread pattern3110and last3100within a heated environment, such as an oven. In some embodiments, heat may be applied to thread pattern3110using a mold plate configured to press thread pattern3110against last3100. In some embodiments, heat may be applied to thread pattern3110by heating last3100.

The temperature(s) at which thread pattern3110is bonded may be the same as those described above in connection with mold800and heat press900. Similarly, heat and/or pressure may be applied to thread pattern3110uniformly or non-uniformly as described above in connection with mold800and heat press900.

In some embodiments, a thread pattern may include one or more continuous threads with a plurality of thread lines extending tangential to an edge of the thread pattern. The edge may be, for example, a perimeter edge of a thread pattern, a perimeter edge of an opening in a thread pattern, and/or a perimeter boundary of a functional zone in a thread pattern.

In some embodiments, a thread pattern may include one or more continuous threads with a plurality of thread lines extending tangential to a perimeter edge of the thread pattern. By threading thread lines tangential to a perimeter edge, the thread pattern can define the perimeter edge. In some embodiments, threading thread lines tangential to a perimeter edge can provide strength at the perimeter edge. In some embodiments, threading thread lines tangential to a perimeter edge can provide stretchability at the perimeter edge. The material(s) of thread lines extending tangential to a perimeter edge can influence the strength and/or stretchability provided at the perimeter edge. In some embodiments, the perimeter edge may define an opening in the thread pattern.

In some embodiments, threading thread lines tangential to a perimeter edge can provide a bonding or attachment surface near the perimeter edge for bonding or attaching another footwear component, such as but not limited to, a sole, a collar element, a throat element, a heel counter, or a toe box element. In some embodiments, the edge may be an edge that defines a part of a seam at which the thread pattern is attached to another footwear component.

In some embodiments, a thread pattern may include one or more continuous threads with a plurality of thread lines extending tangential to a perimeter boundary of a functional zone in the thread pattern. A “functional zone” is a zone of the thread pattern designed to provide one or more zonal characteristics to a particular zone on the thread pattern. Exemplary zonal characteristics include, but are not limited to, strength, breathability, stretchability, texture, tackiness, or abrasion resistance. One or more zonal characteristics of a functional zone are different from the characteristics of the thread pattern adjacent the functional zone. In some embodiments, a functional zone may delineate different features of an upper including the thread pattern. For example, a functional zone may delineate a toe box or a heel counter of an upper including the thread pattern.

In some embodiments, a functional zone may be defined by a region of the thread pattern bounded by the perimeter boundary. In some embodiment, a functional zone may be defined by a region adjacent to the perimeter boundary. In such embodiments, the functional zone may include a region on a thread pattern at perimeter boundary and immediately adjacent to the perimeter boundary where a relatively high density of thread lines is present.

In some embodiments, winding thread lines tangential to a perimeter boundary of a functional zone may be used to create an increased thickness at the perimeter boundary. In some embodiments, the increased thickness may create a bump or similar feature at the perimeter boundary. In some embodiments, the increased thickness may create a bump or similar feature designed to provide desired aesthetics and/or texture. In some embodiments, the increased thickness may create a bump or similar feature designed to provide increased strength at the perimeter boundary. For example, the bump may provide increased strength for an eyestay reinforcement region on the thread pattern. In some embodiments, the increased thickness may create a bump or similar feature designed to provide increased cushioning at the perimeter boundary.

In some embodiments, a thread pattern may include one or more continuous threads with a plurality of thread lines extending tangential to an opening located in the thread pattern. By threading thread lines tangential to an opening, the thread pattern can define the opening. In some embodiments, threading thread lines tangential to an opening can provide strength at a perimeter of the opening. In some embodiments, threading thread lines tangential to an opening can provide stretchability at a perimeter of the opening. In some embodiments, stretchability at an opening may be desirable for an opening defining the throat and/or collar of an article of footwear. In such embodiments, stretchability at the throat and/or collar may increase the ease of entry for a wearer's foot into an upper including the thread pattern. In some embodiments, threading thread lines tangential to an opening can provide a bonding or attachment surface near a perimeter of the opening for bonding or attaching another footwear component. In some embodiments, the opening may define a portion of a seam for bonding or attaching a footwear component to a thread pattern.

In some embodiments, methods of making an upper for an article of footwear may include defining a plurality of anchor points (for example, anchor points1010), defining a boundary line, and winding a continuous thread around the plurality of anchor points such that the continuous thread includes a set of thread lines, with each thread line in the set extending between two respective anchor points and tangential to the boundary line. The boundary line may be a perimeter edge of a thread pattern, a perimeter boundary for a functional zone in a thread pattern, or a perimeter of an opening in a thread pattern. In the examples described below, thread lines extending tangential to the boundary line are described below as “opening-tangential thread lines.” In embodiments including a boundary line defining a perimeter edge for a thread pattern or a perimeter boundary for a functional zone, the thread lines extending tangential to the boundary line may be referred to as “edge-tangential thread lines” or “zone-tangential thread lines.”

In some embodiments, after winding the continuous thread, the method may include bonding the continuous thread at points of intersection between two or more the wound thread lines as discussed herein.

Any of the embodiments of thread pattern1000described herein may be created by winding a continuous thread around anchor points as described herein. In some embodiments, the boundary line to which thread lines extend tangentially may be a perimeter edge of an opening in a thread pattern. In some embodiments, the boundary line to which thread lines extend tangentially may be a perimeter edge of a thread pattern. In some embodiments, the boundary line to which thread lines extend tangentially may be boundary line for a functional zone in a thread pattern. For example, as described below, the boundary line may be perimeter edge1004or secondary perimeter edge1009. In some embodiments, a boundary line may have a curved shape. For example, the boundary line may have circular shape or an elliptical shape. The shape of an opening in a thread pattern, a perimeter edge of a thread pattern, or a functional zone in a thread pattern may be defined by the shape of a boundary line to which thread lines extend tangentially.

FIGS.10A-10Cillustrate a thread pattern1000for an upper for an article of footwear according to some embodiments. In some embodiments, thread pattern1000may define all or a portion of an upper material that is used to form an upper for an article of footwear. Thread pattern1000may be utilized on any article of footwear described herein. For example, thread pattern122may be or may include thread pattern1000.

Thread pattern1000may include one or more openings1002. Each opening1002in thread pattern1000is defined by a perimeter edge1004. In some embodiments, an opening1002may be an opening in an upper for an article of footwear. In some embodiments, an opening1002may define at least a portion of a collar for an upper. For example, opening1002may define at least a portion of collar156for upper120. In some embodiments, an opening1002may define at least a portion of a throat for an upper. For example, opening1002may define at least a portion of throat area150for upper120. In some embodiments, an opening1002may be an aesthetic feature on an upper. For example, opening1002may be define a boundary for a differently colored or patterned region on an upper. In some embodiments, opening1002may be an opening in only a sub-set of thread layers defining thread pattern1000. For example, opening1002may be an opening in only a first thread layer of thread pattern1000. In such embodiments, another thread layer may be wound above or below the first thread layer in thread pattern. In some embodiments, providing an opening in only a sub-set of thread layers defining thread pattern1000may provide one or more functional zones in thread pattern1000.

An opening1002of thread pattern1000may include a medial side1005, a lateral side1006, a forefoot side1007, and a rearfoot side1008. Medial side1005of thread pattern1000or opening1002is defined as the side of thread pattern1000or opening1002on the medial side of a longitudinal line1050extending through the center of opening1002. Lateral side1006of thread pattern1000or opening1002is defined as the side of thread pattern1000or opening on the lateral side of longitudinal line1050extending through the center of opening1002. Forefoot side1007of thread pattern1000or opening1002is defined as the side of thread pattern1000or opening1002on the forefoot side of a transverse line1052extending through the center of opening1002. Rearfoot side1008of thread pattern1000or opening1002is defined as the side of thread pattern1000or opening1002on the rearfoot side of transverse line1052extending through the center of opening1002.

Features of thread pattern1000located on medial side1005may be referred to as medial features of thread pattern1000. Features of thread pattern1000located on lateral side1006may be referred to as lateral features of thread pattern1000. Features of thread pattern1000located on forefoot side1007may be referred to as forefoot features of thread pattern1000. Features of thread pattern1000located on rearfoot side1008may be referred to as rearfoot features of thread pattern1000.

Thread pattern1000may include anchor points1010disposed around perimeter edge1004of an opening1002. In some embodiments, an upper formed using thread pattern1000may include anchor points1010. In some embodiments, after winding one or more continuous threads to form thread pattern1000, portions of thread pattern1000including anchor points1010may be removed from thread pattern1000(for example, perimeter portion1001shown inFIG.10A). In such embodiments, finished thread pattern1000may not include anchor points1010, and similarly, an upper formed using thread pattern1000may not include anchor points1010.

Anchor points1010of thread pattern1000may include a plurality of medial side anchor points1012. For purposes of the present application, medial side anchor points1012are defined as anchor points located on medial side1005of thread pattern1000.

Anchor points1010of thread pattern1000may a plurality of lateral side anchor points1014. For purposes of the present application, lateral side anchor points1014are defined as anchor points located on lateral side1006of thread pattern1000.

Anchor points1010of thread pattern1000may a plurality of forefoot anchor points1016. For purposes of the present application, forefoot anchor points1016are defined as anchor points located on forefoot side1007of thread pattern1000.

Anchor points1010of thread pattern1000may a plurality of rearfoot anchor points1018. For purposes of the present application, rearfoot anchor points1018are defined as anchor points located on rearfoot side1008of thread pattern1000.

Thread pattern1000includes one or more continuous threads wound around anchor points1010to form thread pattern1000. For example, as illustrated inFIG.10A, thread pattern1000includes a first continuous thread1020with thread lines1022extending between respective anchor points1010. In some embodiments, thread pattern1000may include a second continuous thread1040with thread lines1042extending between respective anchor points1010.

Thread lines1022of continuous thread1020may include a plurality of thread lines1022extending between two respective anchor points1010and extending tangential to perimeter edge1004of opening1002. Thread lines1022extending tangential to perimeter edge1004of opening1002may be referred to as “opening-tangential thread lines.”FIGS.10A-10Cshow a plurality of opening-tangential thread lines1024.

Thread lines1022of continuous thread1020may also include a plurality of thread lines1022extending between two respective anchor points1010and not tangential to perimeter edge1004of opening1002. Thread lines1022not extending tangential to perimeter edge1004of opening1002may be referred to as “non-opening-tangential thread lines.”FIGS.10A-10Cshow a plurality of non-opening-tangential thread lines1026.

In some embodiments, thread lines1024extending tangential to perimeter edge1004of opening1002are not wound around an anchor point located at perimeter edge1004of opening1002. In some embodiments, thread pattern1000may include anchor points located at perimeter edge1004of opening1002and no thread lines1024extending tangential to perimeter edge1004of opening1002are wound around the anchor points at perimeter edge1004. In some embodiments, thread pattern1000may be devoid of anchor points located at perimeter edge1004of opening1002.

In some embodiments, opening-tangential thread lines1024may include one or more thread lines1024located on medial side1005of perimeter edge1004. A thread line1024located on medial side1005of perimeter edge1004means that the thread line1024defines a portion of medial side1005of perimeter edge1004. A thread line1024located on medial side1005of perimeter edge1004may extend into lateral side1006of thread pattern1000, but is not considered located on lateral side1006because it does not define a portion of perimeter edge1004on lateral side1006. In some embodiments, opening-tangential thread lines1024may define all of medial side1005of perimeter edge1004.

In some embodiments, opening-tangential thread lines1024may include one or more thread lines1024located on lateral side1006of perimeter edge1004. A thread line1024located on lateral side1006of perimeter edge1004means that the thread line1024defines a portion of lateral side1006of perimeter edge1004. A thread line1024located on lateral side1006of perimeter edge1004may extend into medial side1005of thread pattern1000, but is not considered located on medial side1005because it does not define a portion of perimeter edge1004on medial side1005. In some embodiments, opening-tangential thread lines1024may define all of lateral side1006of perimeter edge1004.

In some embodiments, opening-tangential thread lines1024may include one or more thread lines1024located on medial side1005of perimeter edge1004and one or more thread lines1024located on lateral side1006of perimeter edge1004. In such embodiments, the opening-tangential thread lines1024may define all or a portion of medial side1005and lateral side1006of perimeter edge1004. In some embodiments, perimeter edge1004may be surrounded by opening-tangential thread lines1024such that all of medial side1005and lateral side1006of perimeter edge1004are defined by thread lines1024.

Opening-tangential thread lines1024may include thread lines1024that overlap each other at an overlap point1028in thread pattern1000. Any two thread lines1024of thread pattern1000may overlap each other at an overlap point1028. For example, as shown inFIG.10C, a first opening-tangential thread line1024amay overlap a second opening-tangential thread line1024bat overlap point1028.

Opening-tangential thread lines1024that overlap each other at an overlap point1028may be disposed at an angle relative to each other. The relative angle of the two thread lines1024may be defined by the angle of intersection (θ) at an overlap point1028. Unless specified otherwise, the angle of intersection (θ) is the angle formed by the intersection of two thread lines1024and is measured on the side of the thread lines1024facing opening1002(as shown inFIG.10C).

In some embodiments, the angle of intersection (θ) at an overlap point1028may be in the range of 90° to 179°, including subranges. For example, 0 may be 90°, 100°, 110°, 120°, 130°, 140°, 150°, 160°, 170°, or 179°, or within a range having any two of these values as endpoints, inclusive of the endpoints. In some embodiments, θ may be in a range of 90° to 179°, 100° to 179°, 110° to 179°, 120° to 179°, 130° to 179°, 140° to 179°, 150° to 179°, 160° to 179°, or 170° to 179°. In some embodiments, θ may be greater than 90°, greater than 120°, or greater than 150°.

In some embodiments, thread pattern1000may include one or more opening-tangential thread lines1024extending between a forefoot anchor point1016and a rearfoot anchor point1018. In some embodiments, a thread line1024extending between a forefoot anchor point1016and a rearfoot anchor point1018may be located on medial side1005of perimeter edge1004. In some embodiments, a thread line1024extending between a forefoot anchor point1016and a rearfoot anchor point1018may be located on lateral side1006of perimeter edge1004. In some embodiments, thread pattern1000may include a plurality of opening-tangential thread lines1024, with each thread line1024extending between respective forefoot anchor points1016and rearfoot anchor points1018.

In some embodiments, thread pattern1000may include one or more opening-tangential thread lines1024extending between a medial side anchor point1012and a lateral side anchor point1014. In some embodiments, a thread line1024extending between a medial side anchor point1012and a lateral side anchor point1014may be located on medial side1005of perimeter edge1004. In some embodiments, a thread line1024extending between a medial side anchor point1012and a lateral side anchor point1014may be located on lateral side1006of perimeter edge1004. In some embodiments, thread pattern1000may include a plurality of opening-tangential thread lines1024, with each thread line1024extending between respective medial side anchor points1012and lateral side anchor points1014.

Thread pattern1000may include any suitable number of opening-tangential thread lines1024. In some embodiments, thread pattern1000may include four or more opening-tangential thread lines1024. In some embodiments, thread pattern1000may include 10 or more opening-tangential thread lines1024. In some embodiments, thread pattern1000may include 20 or more opening-tangential thread lines1024. In some embodiments, thread pattern1000may include 30 or more opening-tangential thread lines1024. In some embodiments, thread pattern1000may include a number of opening-tangential thread lines1024in a range of 2 to 50. For example, thread pattern1000may include 2 to 50, 4 to 50, 10 to 50, 20 to 50, or 30 to 50 opening-tangential thread lines1024.

In some embodiments, a higher number of opening-tangential thread lines1024may increase the strength of opening1002at perimeter edge1004. For example, a higher number of opening-tangential thread lines1024may increase the tear strength of opening1002at perimeter edge1004.

In some embodiments, a higher number of opening-tangential thread lines1024may facilitate attachment of another footwear component at perimeter edge1004. For example, opening-tangential thread lines1024may facilitate stitching of a collar element, a throat element, a heel counter, a cushioning element, a padding element, or a liner (for example, a sock liner) at perimeter edge1004. In such embodiments, opening-tangential thread lines1024can serve as attachment points for a stich that attaches the footwear component. And since opening-tangential thread lines1024are tangential to perimeter edge1004, the thread lines1024can provide increased strength for the stitch in directions orthogonal to the perimeter edge1004.

In some embodiments, a plurality of adjacent anchor points1010of thread pattern1000may each include an opening-tangential thread line1024extending therefrom. As used herein, a first anchor point described as “adjacent” to second anchor point means that the second anchor point is the first anchor point's first or second closest anchor point neighbor. An anchor point will typically include two “adjacent” anchor point neighbors, typically located on opposing sides of the anchor point. In embodiments including equally spaced anchor points, an anchor point's first and second closest anchor point neighbors may be located at the same distance from the anchor point. As an example, anchors points1018aand1018care adjacent to anchor point1018binFIG.10A. As another example, anchor points1016dand1016fare adjacent to anchor point1016einFIG.10A.

For example, in some embodiments, the plurality of anchor points1010of thread pattern1000may include a first rearfoot anchor point1018a, a second rearfoot anchor point1018badjacent to first rearfoot anchor point1018a, a first forefoot anchor point1016aand a second forefoot anchor point1016b. In such embodiments, the plurality of thread lines1022of thread pattern1000may include a first opening-tangential thread line1024extending from first rearfoot anchor point1018ato first forefoot anchor point1016aand a second opening-tangential thread line1024extending from second rearfoot anchor point1018bto second forefoot anchor point1016b.

In such embodiments, opening-tangential thread lines1024extending from adjacent rearfoot anchor points1018a,1018bmay overlap at an overlap point1028. For example, as shown inFIG.10C, first open-tangential thread line1024amay overlap second opening-tangential thread line1024bat overlap point1028. Any two opening-tangential thread lines1024may overlap at an overlap point. For example, in some embodiments, thread pattern may include a third opening tangential thread line1024and a fourth opening-tangential thread line1024that overlap each other at a second overlap point1028.

In some embodiments, opening-tangential thread lines1024overlapping at an overlap point1028may be directly bonded to each other at the overlap point1028. In some embodiments, opening-tangential thread lines1024overlapping at an overlap point1028may be directly bonded to each other via a polymeric material of at least one of: the first open-tangential thread line1024or the second open-tangential thread line1024.

Any suitable number of adjacent anchor points1010of thread pattern1000may each include an opening-tangential thread line1024extending therefrom. For example, in some embodiments, anchor points1010of thread pattern1000may further include a third rearfoot anchor point1018cadjacent to second rearfoot anchor point1018band a third forefoot anchor point1016c. In such embodiments, the plurality of thread lines1022of thread pattern1000may include a third opening adjacent thread line1024extending from third rearfoot anchor point1018cto third forefoot anchor point1016c.

In some embodiments, an anchor point1010of thread pattern1000may include an opening-tangential thread line1024extending therefrom and a plurality of non-opening-tangential thread lines1026extending therefrom. Thread lines1022extending between two respective anchor points1010and not tangential to an opening1002are considered “non-opening-tangential thread lines.” In some embodiments, an anchor point1010may have a thread line communication number and at least one of the threads counted in the thread line communication number may be an opening-tangential thread line1024and the remainder of the thread lines are non-opening-tangential thread lines.

For example, in some embodiments, anchor points1010of thread pattern1000may include a first rearfoot anchor point1018aand five adjacent forefoot anchor points1016a,1016d,1016e,1016f, and1016g. In such embodiments, rearfoot anchor point1018amay include the following thread lines extending therefrom: (i) an opening-tangential thread line1024extending from anchor point1018ato anchor point1016a, (ii) a first non-opening-tangential thread line1026extending from anchor point1018ato anchor point1016d, (iii) a second non-opening-tangential thread line1026extending from anchor point1018ato anchor point1016e, (iv) a third non-opening-tangential thread line1026extending from anchor point1018ato anchor point1016f, and (v) a fourth non-opening-tangential thread line1026extending from anchor point1018ato anchor point1016g.

By threading thread lines in this fashion, thread pattern1000can include a high density of thread lines near perimeter edge1004of opening1002and extending nearly tangential to opening1002. By threading a high density of thread lines in this fashion, characteristics of thread pattern1000at opening1002can be controlled. For example, the softness, stretchability, and/or strength of thread pattern1000at opening1002can be controlled by threading thread lines as described above. In some embodiments, the strength of opening1002can be maximized. For example, the tear strength of opening1002can be maximized. In some embodiments, the softness and/or stretchability of thread pattern1000at opening1002can be maximized for a wearer's comfort.

In some embodiments, a high number thread lines extending nearly tangential to perimeter edge1004may facilitate attachment of other footwear components at perimeter edge1004. For example, nearly opening-tangential thread lines may facilitate stitching of a collar element, a throat element, a heel counter, a cushioning element, a padding element, or a liner (for example a sock liner) at perimeter edge1004. In such embodiments, the nearly opening-tangential thread lines can serve as attachment points for a stich that attaches the footwear component. And since the nearly opening-tangential thread lines are almost tangential to perimeter edge1004, the thread lines can provide increased strength for the stitch in directions orthogonal to the perimeter edge1004. Additionally, in some embodiments, a high number thread lines extending nearly tangential to perimeter edge1004may facilitate adhesive bonding of other footwear components at perimeter edge1004. In such embodiments, the high number thread lines extending nearly tangential to perimeter edge1004may create a continuous surface, or substantially continuous surface, near perimeter edge to which a footwear component can be adhesively bonded.

Any suitable number of adjacent anchor points1010of thread pattern1000may each include an opening-tangential thread line1024and a plurality of non-opening-tangential thread lines1026extending therefrom. For example, in some embodiments, anchor points1010of thread pattern1000may include a second rearfoot anchor point1018badjacent to first rearfoot anchor point1018a. In such embodiments, rearfoot anchor point1018bmay include the following thread lines extending therefrom: (i) an opening-tangential thread line1024extending from anchor point1018bto a forefoot anchor point1016and (ii) a non-opening-tangential thread line1026extending from anchor point1018bto one of the five adjacent forefoot anchor points1016a,1016d,1016e,1016f, and1016g.

As another example, in some embodiments, anchor points1010of thread pattern1000may include a second rearfoot anchor point1018dadjacent to first rearfoot anchor point1018a. In such embodiments, rearfoot anchor point1018dmay include the following thread lines extending therefrom: (i) an opening-tangential thread line1024extending from anchor point1018dto one of the five adjacent forefoot anchor points1016a,1016d,1016e,1016f, and1016gand (ii) a non-opening-tangential thread line1026extending from anchor point1018dto a forefoot anchor point1016.

As previously discussed, thread pattern1000, with or without anchor points1010, may be used to form an upper for an article of footwear. In some embodiments, an opening1002of thread pattern1000may not corresponded directly to an opening in an upper. For example, in some embodiments, a portion of thread pattern1000near opening1002may be folded, sown, or otherwise utilized to form a perimeter edge of an opening on an upper. In such embodiments, thread pattern1000may include a secondary perimeter edge1009.

In embodiments including secondary perimeter edge1009, secondary perimeter edge1009may define at least a portion of a collar for an upper. For example, a secondary perimeter edge1009may define at least a portion of collar156for upper120. In some embodiments, a secondary perimeter edge1009may define at least a portion of a throat for an upper. For example, secondary perimeter edge1009may define at least a portion of throat area150for upper120.

In embodiments including secondary perimeter edge1009, thread lines1042of a second continuous thread1040may extend tangential to or nearly tangential to secondary perimeter edge1009in the same fashion as discussed above for perimeter edge1004. In all of the embodiments discussed above, secondary perimeter edge1009can take the place of perimeter edge1004and thread lines1042can take the place of thread lines1022.FIGS.10A and10Billustrate thread lines1042as darker thread lines extending tangential to, nearly tangential to, or not tangential to secondary perimeter edge1009in the same fashion as discussed above for thread lines1022.

While the embodiments described above are described in context with a perimeter edge1004and a secondary perimeter edge1009for an opening1002in a thread pattern, the edges1004and1009may alternatively be edges for a perimeter edge of a thread pattern or a perimeter boundary for a functional zone in a thread pattern. In such embodiments, thread lines may extend tangential to or nearly tangential to edges1004and1009for a perimeter edge of a thread pattern or a perimeter boundary for a functional zone in a thread pattern in the same fashion as discussed above for opening1002. In such embodiments, the thread lines extending tangential to the edges1004and1009may be referred to as “edge-tangential thread lines” or “zone-tangential thread lines.” Also, thread lines not extending tangential to the edges1004and1009may be referred to as “non-edge-tangential thread lines” or “non-zone-tangential thread lines.”

In some embodiments, an upper for an article of footwear may be made by bonding two thread patterns together. In such embodiments, a first thread pattern may be bonded to a second thread pattern to form an upper material with a void shaped to receive a human foot between the first and second thread patterns. For example, a first thread pattern defining a medial portion of an upper material may be bonded to a second thread pattern defining a lateral portion of an upper material to define a void shaped to receive a human foot. By bounding two thread patterns together in this fashion, the stretch and/or stiffness around and underneath a wearer's foot can be controlled.

FIG.11shows a method1100of making an upper (for example, upper120) for an article footwear of (for example, article of footwear100) according to some embodiments.FIGS.12A-12Fillustrate steps of method1100. Unless stated otherwise, the steps of method1100need not be performed in the order set forth inFIG.11. Additionally, unless specified otherwise, the steps of method1100need not be performed sequentially. The steps can be performed simultaneously. Additionally, method1100need not include all the steps described. As one example, method1100need not include the step of removing the sheet. In such embodiments, the sheet may form a part of an upper material. As another example, the sheet may be removed after or during step1170, rather than before step1170as show inFIG.11.

In step1110, a first continuous thread1210may be wound around a plurality of anchor points disposed on a support plate to form a first thread pattern1200as described herein. Accordingly, the first continuous thread1210is wound to include a plurality of thread lines with each thread line extending between two respective anchor points. In some embodiments, first thread pattern1200formed in step1110may include a plurality of continuous threads wound around anchor points on a support plate.

In step1120, a sheet1220may be disposed over first continuous thread1210forming thread pattern1200. In some embodiments, sheet1220may be disposed in direct contact with the thread pattern1200formed with first continuous thread1210. In some embodiments, step1120may be performed after step1130and sheet1220may be disposed between first thread pattern1200and a second thread pattern1230formed in step1130. In such embodiments, sheet1220may be disposed in direct contact with first thread pattern1200and/or second thread pattern1230in step1120.

In some embodiments, sheet1220may be a sock-shaped flat sheet. In some embodiments, sheet1220may be a hollow sock-shaped material. In such embodiments, the hollow sock-shaped material may be capable of being turned inside-out.

In some embodiments, sheet1220may be composed of a polymeric material. In some embodiments, sheet1220may be composed of a silicone material. In some embodiments, sheet may be composed of polytetrafluoroethylene (PTFE). In some embodiments, sheet may be composed of a ceramic material or a metallic material.

In some embodiments, one or more surfaces of sheet1220may include one or more textured regions for imparting a texture to first thread pattern1200and/or second thread pattern1230during step1140. Textured regions of sheet1220may be the same characteristics as textured regions of textured sheet1600described herein.

In some embodiments, sheet1220may be composed of a fabric or textile material. In some embodiments, sheet1220may be formed of a woven, non-woven, or knitted fabric or textile material. For example, sheet1220may be a woven, non-woven, or layer composed of cotton, thermoplastic polyurethane (TPU), polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU) foam, and co-polymers or polymer blends including one or more these polymers.

In step1130, a second continuous thread1240may be wound over sheet1220and around the plurality of anchor points disposed on a support plate to form a second thread pattern1230. Accordingly, second continuous thread1240incudes a plurality of thread lines with each thread line extending between two respective anchor points. In some embodiments, second thread pattern1230formed in step1110may include a plurality of continuous threads wound around anchor points on a support plate.

In some embodiments, step1130may not be performed over sheet1220. Rather, step1130may performed, and after forming second thread pattern1230, sheet1220may be disposed between first thread pattern1200and second thread pattern1230. In such embodiments, step1120may be performed after step1130.

In some embodiments, first continuous thread1210wound in step1110and second continuous thread1240wound in step1130may be portions of a single thread. In some embodiments, first continuous thread1210wound in step1110and second continuous thread1240wound in step1130may include different threads.

After forming first thread pattern1200and second thread pattern1230, and after positioning sheet1220between the thread patterns, first thread pattern1200and second thread pattern1230may be bonded to each other to form an upper material1260in step1140. In some embodiments, bonding first thread pattern1200to second thread pattern1230may include bonding first thread pattern1200to second thread pattern1230around a perimeter1222of sheet1220. Bonding around perimeter1222of sheet1220can create a seam1252around perimeter1222. In some embodiments, first thread pattern1200and second thread pattern1230may be bonded to each other in a heat press (for example, heat press900).

In some embodiments, bonding first thread pattern1200to second thread pattern1230may include directly bonding first thread pattern1200to second thread pattern1230. In such embodiments, first thread pattern1200and second thread pattern1230may be directly bonded to each other via a polymeric material of at least one of: first thread pattern1200or second thread pattern1230. In some embodiments, bonding first thread pattern1200to second thread pattern1230may include indirectly bonding first thread pattern1200to second thread pattern1230via, for example, an adhesive layer.

In some embodiments, bonding first thread pattern1200to second thread pattern1230may include bonding first continuous thread1210to second continuous thread1240. In some embodiments, bonding first thread pattern1200to second thread pattern1230may include directly bonding first continuous thread1210to second continuous thread1240. In such embodiments, first continuous thread1210and second continuous thread1240may be directly bonded to each other via a polymeric material of at least one of: first continuous thread1210or second continuous thread1240.

In some embodiments, the step of bonding first thread pattern1200to second thread pattern1230may include directly bonding thread lines of first thread pattern1200to each other and directly bonding thread lines of second thread pattern1230to each other. In such embodiments, thread lines of first thread pattern1200may be directly bonded to each other at intersection points between thread lines in step1140while sheet1220is disposed between first thread pattern1200and second thread pattern1230. Similarly, in such embodiments, thread lines of second thread pattern1230may be directly bonded to each other at intersection points between thread lines in step1140while sheet1220is disposed between first thread pattern1200and second thread pattern1230.

In some embodiments, bonding step1140may be replaced with a different coupling step configured to attach first thread pattern1200and second thread pattern1230. For example, in some embodiments, step1140may include stitching first thread pattern1200to second thread pattern1230. In any event, a seam for attaching first thread pattern1200and second thread pattern1230may be created in step1140. In some embodiments, bonding step1140may include a plurality of coupling steps. For example, bounding step1140may include a bonding first thread pattern1200to second thread pattern1230and stitching first thread pattern1200to second thread pattern1230.

In step1150, first thread pattern1200and second thread pattern1230may be cut into a shape corresponding to the shape of an upper. For example, first thread pattern1200and second thread pattern1230may be cut to define a perimeter edge1250having a shape corresponding to the shape of an upper. In some embodiments, first thread pattern1200and second thread pattern1230may be cut around perimeter1222of sheet1220. Cutting first thread pattern1200and second thread pattern1230in step1150may include any suitable cutting process, for example a laser cutting process.

In some embodiments, cutting in step1150may include defining an opening1254in upper material1260. In some embodiments, opening1254may define an opening in an upper for an article of footwear. In some embodiments, opening1254may define at least a portion of a collar for an upper. For example, opening1254may define at least a portion of collar156for upper120. In some embodiments, opening1254may define at least a portion of a throat for an upper. For example, opening1254may define at least a portion of throat area150for upper120.

In some embodiments, first thread pattern1200and second thread pattern1230may be cut after bonding the thread patterns in step1140. In such embodiments, first thread pattern1200and second thread pattern1230may be cut at or within seam1252around perimeter1222of sheet1220. When cutting within seam1252, not all of seam1252is cut away so that first thread pattern1200and second thread pattern1230remain attached at seam1252after cutting in step1150. In some embodiments, a portion of seam1252may be cut away entirely to define an opening1254.

In some embodiments, first thread pattern1200and second thread pattern1230may be cut before bonding the thread patterns in step1140. In such embodiments, seam1252may be formed after cutting in step1150. And in such embodiments, seam1252may be formed such that it defines an opening1254.

In some embodiments, method1100may include removing sheet1220from upper material1260in step1160. In such embodiments, an upper formed of upper material1260will not include sheet1220. In some embodiments, removing sheet1220from upper material1260in step1160may be performed after turning upper material1260inside-out in step1170. In some embodiments, sheet1220may be removed through an opening1254defined during cutting and/or bonding first thread pattern1200and second thread pattern1230.

In some embodiments, method1100may not include removing sheet1220. In such embodiments, sheet1220may be attached to upper material1260during method1100. Also, in such embodiments, an upper formed of upper material1260may include sheet1220. For example, sheet1220may define a layer of an upper formed of upper material1260, like fabric layer172of upper120.

In some embodiments, method1100may include turning upper material1260inside-out in step1170(seeFIG.12F). In such embodiments, turning upper material1260inside-out may create a void shaped to receive a human foot (for example, void155of upper120) between first thread pattern1200and second thread pattern1230. In embodiments including step1170, seam1252may be inverted and at least partially concealed within the void. In some embodiments, turning upper material1260inside-out may create a clean edge on the exterior of upper material1260at seam1252. In some embodiments, sheet1220may also be turned inside-out in step1170. In some embodiments, method1100may not include step1170.

In some embodiments, wound thread patterns as described herein may be integrated into a sole for an article of footwear. In some embodiments, wound thread patterns may be integrated into a sole by embedding a wound thread pattern into a sole material. In some embodiments, a wound thread pattern may define a portion of an upper for an article of footwear and extend through a sole material, thereby integrating the wound thread pattern into the sole. Integrating one or more wound thread patterns into a sole may serve to couple thread pattern(s) to a sole.

In some embodiments, a thread pattern defining a portion of an upper and integrated into a sole may facilitate energy transfer from the individual's foot to the surface his or her foot is in contact with (for example, the ground) during use. Such an integrated thread pattern may assist in energy transfer because continuous thread lines of a thread pattern can extend into one side of a sole, through the sole, and out another side of the sole.

FIGS.13and14show articles of footwear1300,1400including one or more thread patterns integrated into a sole according to some embodiments. Article of footwear1300includes a sole1380and an upper1310coupled to sole1380. Sole1380includes a top surface1390and a bottom surface1392opposite top surface1390. Sole1380also includes a forefoot end1370, a heel end1372, a medial side1374, and a lateral side opposite medial side1374. During use, top surface1390is adjacent a wearer's foot and bottom surface1392contacts the ground. Sole1380may include a midsole1382and/or an outsole1384. In some embodiments, all or a portion of sole1380may be injection molded.

Similarly, article of footwear1400includes a sole1480and an upper1410coupled to sole1480. Sole1480includes a top surface1490and a bottom surface1492opposite top surface1490. Sole1480also includes a forefoot end1470, a heel end1472, a medial side1474, and a lateral side opposite medial side1474. During use, top surface1490is adjacent a wearer's foot and bottom surface1492contacts the ground. Sole1480may include a midsole1482and/or an outsole1484. In some embodiments, all or a portion of sole1480may be injection molded.

As shown inFIG.13, upper1310includes a thread pattern1322defining a portion of upper1310. Similarly, as shown inFIG.14, upper1410includes a first thread set1422and a second thread set1426. Thread pattern1322and thread sets1422,1426may have any of the characteristics of thread patterns as described herein. Also, thread pattern1322and thread sets1422,1426may be wound and bonded in the same fashion as described herein. For example, a plurality of thread lines of thread pattern1322and thread sets1422,1426, respectively, may be directly bonded to each other at points of intersection between two or more of the thread lines.

Article of footwear1300may include a seam1340at which two opposing ends of thread pattern1322are attached. In some embodiments, a first end1323of thread pattern1322may be directly coupled to a second end1324of thread pattern1322at seam1340. In some embodiments, a first end1323of thread pattern1322may be directly bonded to a second end1324of thread pattern1322at seam1340.

In some embodiments, a portion of first end1323and a portion of second end1324may overlap at seam1340. At the overlap, first end1323and second end1324may be coupled by, for example, a stich, or via direct bonding of a polymeric material of thread pattern1322.

Thread lines1332of thread pattern1322may be directly or indirectly coupled together at seam1340. In some embodiments, thread lines1332may be stitched together at seam1340. In some embodiments, thread lines1332may be directly bonded at seam1340. In such embodiments, thread lines1332may be directly bonded at seam1340via a polymeric material of the thread lines1332.

In some embodiments, a plurality of thread lines1332of thread pattern1322may extend from a first side1342of seam1340, through sole1380, and to a second side1344of seam1340. In some embodiments, a plurality of thread lines1332of thread pattern1322extending from first side1342of seam1340, through sole1380, and to second side1344of seam1340may be continuous thread lines. For example, one or more thread lines1332may be a continuous thread line extending between anchor points in a thread pattern as described herein. In some embodiments, thread pattern1322may include anchor points. In some embodiments, thread pattern1322may not include anchor points because anchor points have been removed from thread pattern1322.

In some embodiments, thread lines1332of thread pattern1322may extend from a medial side1312of upper1310, through sole1380, and to a lateral side1314of upper1310. In some embodiments, a plurality of thread lines1332of thread pattern1322extending from medial side1312of upper1310, through sole1380, and to lateral side1314of upper1310may be continuous thread lines. Thread lines1332that extend from medial side1312of upper1310, through sole1380, and to lateral side1314of upper1310may or may not be coupled at seam1340. In some embodiments, thread lines1332that extend from medial side1312of upper1310, through sole1380, and to lateral side1314of upper1310may be directly or indirectly coupled to the sides of upper1310. For example, the thread lines1332may be stitched or directly bonded to the sides of upper1310.

In some embodiments, thread lines1332of thread pattern1322may extend from a forefoot end1311of upper1310, through sole1380, and to a heel end1313of upper1310. In some embodiments, a plurality of thread lines1332of thread pattern1322extending from forefoot end1311of upper1310, through sole1380, and to heel end1313of upper1310may be continuous thread lines. Thread lines1332that extend from forefoot end1311of upper1310, through sole1380, and to heel end1313of upper1310may or may not be coupled at a seam.

In some embodiments, thread lines1332that extend from forefoot end1311of upper1310, through sole1380, and to heel end1313of upper1310may be directly or indirectly coupled to the forefoot end1311and heel end1313of upper1310. For example, the thread lines1332may be stitched or directly bonded to forefoot end1311and heel end1313of upper1310. Thread lines1332of thread pattern1322extending from forefoot end1311of upper1310, through sole1380, and to heel end1313of upper1310may serve to provide desired properties for article of footwear1300, for example, bending stiffness and/or torsional stiffness.

In some embodiments, thread lines1332extending through sole1380may extend through midsole1382. In some embodiments, thread lines1332extending through sole1380may extend through outsole1384. In some embodiments, thread lines1332extending through sole1380may extend through an interface between midsole1382and outsole1384.

In some embodiments, a portion of each of the plurality of thread lines1332that extend through sole1380is embedded within sole1380. In some embodiments, a portion of each of the plurality of thread lines1332that extend through sole1380is embedded within midsole1382. In some embodiments, a portion of each of the plurality of thread lines1332that extend through sole1380is embedded within outsole1384.

As described herein, a thread line or thread pattern embedded within a sole material means that all or a portion the previously exposed areas of thread lines or a thread pattern are surrounded on all sides by sole material. In such embodiments, if there are spaces between individual thread lines of a thread pattern, sole material may fill the spaces. A thread line or thread pattern embedded within a sole material means the thread line or thread pattern is in direct contact with the portion of the sole material through which it extends. In some embodiments, a sole may include one or more voids through which thread lines or a thread pattern extend. In such embodiments, thread lines or a thread pattern are not embedded within a sole material at the void(s) because no sole material is present at the void(s).

In some embodiments, a plurality of thread lines1332may extend from first side1342of seam1340, over a portion of a first side (for example, the medial side1386) of sole1380, through sole1380, over a portion of a second side (for example, the lateral side) of sole1380, and to second side1344of seam1340. In some embodiments, a plurality of thread lines1332may extend from medial side1312of upper1310, over a portion of a first side (for example, the medial side1386) of sole1380, through sole1380, over a portion of a second side (for example, the lateral side) of sole1380, and to lateral side1314of upper1310. In such embodiments, thread pattern1322extends from upper1310and covers a portion of the side surfaces of sole1380.

Thread lines1332that extend through sole1380may enter sole1380at an entry point on a side surface of sole1380. For example, as shown inFIG.13, thread lines1332may enter sole1380entry points1394on medial side1386of sole1380. Lateral side of sole1380may have entry points similar to entry points1394. A plurality of entry points1394on sole1380may be referred to as an entry line1395. Entry line1395extends along a side surface of sole1380and is defined by the plurality of entry points1394for each thread line1332extending through sole1380.

In some embodiments, the location of entry line1395for thread lines1332may vary relative to bottom surface1392of sole1380along the length of sole1380. For example, in some embodiments, the plurality of thread lines1332may include a first plurality of thread lines1332extending through sole1380at a first distance1396from bottom surface1392of sole1380and a second plurality of thread lines1332extending through sole at a second distance1398from bottom surface1392of sole1380.

As shown inFIG.13, first distance1396and second distance1398may be defined by the vertical distance between bottom surface1392of sole1380and entry line1395. In embodiments where bottom surface1392includes traction members, such as tread, bottom surface1392is defined by the bottommost surfaces of the traction members. In embodiments wherein distances1396,1398vary along line1395for a plurality of thread lines1332, the average distance along line1495for the plurality of thread lines1332defines distances1396,1398.

First distance1396and second distance1398may be different. In some embodiments, first distance1396may be less than second distance1398. In some embodiments, first distance1396may be greater than second distance1398. In some embodiments, second distance1398may be 10% or more different from first distance1396. By tailoring first distance1396and second distance1398, various characteristics of an article of footwear can be controlled. For example, sole1380can be provided with desired stiffness at different regions of the sole. Such regional stiffness can control how a wearer's foot and/or sole1380deforms during use. For example, a relatively large distance1396/1398can help control the way sole1380deforms when it contacts the ground during use.

In some embodiments, as shown for example, inFIG.14, an upper may include a plurality of different sets of thread lines extending through a sole. Upper1410may include a plurality of thread lines1432defining a first set1422of thread lines extending from a first side1442of a first seam1440, through sole1480, and to a second side1444of first seam1440. Upper1410may also include a plurality of thread lines1436defining a second set1426of thread lines extending from a first side1452of a second seam1450, through sole1480, and to a second side1454of second seam1450.

In some embodiments, first and second sets1422,1426may be portions of the same thread pattern. In some embodiments, first and second sets1422,1426may be separate thread patterns.

In some embodiments, a first end1423of first thread set1422may be directly coupled to a second end1424of first thread set1422at first seam1440. In some embodiments, first end1423of thread set1422may be directly bonded to second end1424of thread set1422at first seam1440.

Similarly, in some embodiments, a first end1427of second thread set1426may be directly coupled to a second end1428of second thread set1426at second seam1450. In some embodiments, first end1427of thread set1426may be directly bonded to second end1428of thread set1426at second seam1450.

In some embodiments, a portion of first end1423of first thread set1422and a portion of second end1424may overlap at first seam1440. At the overlap, first end1423and second end1424may be coupled by, for example, a stich, or via direct bonding of a polymeric material of first thread set1422.

Similarly, in some embodiments, a portion of first end1427of second thread set1426and a portion of second end1428may overlap at second seam1450. At the overlap, first end1427and second end1428may be coupled by, for example, a stich, or via direct bonding of a polymeric material of second thread set1426.

Thread lines1432of first thread set1422may be directly or indirectly coupled together at first seam1440. In some embodiments, thread lines1432may be stitched together at seam1440. In some embodiments, thread lines1432may be directly bonded at seam1440. In such embodiments, thread lines1432may be directly bonded at seam1440via a polymeric material of the thread lines1432.

Similarly, thread lines1436of second thread set1426may be directly or indirectly coupled together at second seam1450. In some embodiments, thread lines1436may be stitched together at seam1450. In some embodiments, thread lines1436may be directly bonded at seam1450. In such embodiments, thread lines1436may be directly bonded at seam1450via a polymeric material of the thread lines1436.

In some embodiments, a plurality of thread lines1432of first thread set1422may extend from a first side1442of first seam1440, through sole1480, and to a second side1444of first seam1440. In some embodiments, a plurality of thread lines1432of first thread set1422extending from first side1442of seam1440, through sole1480, and to second side1444of seam1440may be continuous thread lines. For example, the thread lines1432may be a continuous thread line extending between anchor points in a thread pattern as described herein. In some embodiments, thread set1422may include anchor points. In some embodiments, thread set1422may not include anchor points because anchor points have been removed from thread set1422.

Similarly, in some embodiments, a plurality of thread lines1436of second thread set1426extend from a first side1452of second seam1450, through sole1480, and to a second side1454of second seam1450. In some embodiments, a plurality of thread lines1436of second thread set1426extending from first side1452of seam1450, through sole1480, and to second side1454of seam1450may be continuous thread lines. For example, the thread lines1436may be a continuous thread line extending between anchor points in a thread pattern as described herein. In some embodiments, thread set1426may include anchor points. In some embodiments, thread set1426may not include anchor points because anchor points have been removed from thread set1426.

In some embodiments, thread lines1432of thread set1422may extend from a medial side1412of upper1410, through sole1480, and to a lateral side1414of upper1410. In some embodiments, a plurality of thread lines1432of first thread set1422extending from medial side1412of upper1410, through sole1480, and to lateral side1414of upper1410may be continuous thread lines. Thread lines1432that extend from medial side1412of upper1410, through sole1480, and to lateral side1414of upper1410may or may not be coupled at first seam1440. In some embodiments, thread lines1432that extend from medial side1412of upper1410, through sole1480, and to lateral side1414of upper1410may be directly or indirectly coupled to the sides of upper1410. For example, the thread lines1432may be stitched or directly bonded to the sides of upper1410.

Similarly, in some embodiments, thread lines1436of thread set1426may extend from a medial side1412of upper1410, through sole1480, and to a lateral side1414of upper1410. In some embodiments, a plurality of thread lines1436of second thread set1426extending from medial side1412of upper1410, through sole1480, and to lateral side1414of upper1410may be continuous thread lines. Thread lines1436that extend from medial side1412of upper1410, through sole1480, and to lateral side1414of upper1410may or may not be coupled at second seam1450. In some embodiments, thread lines1436that extend from medial side1412of upper1410, through sole1480, and to lateral side1414of upper1410may be directly or indirectly coupled to the sides of upper1410. For example, the thread lines1436may be stitched or directly bonded to the sides of upper1410.

In some embodiments, thread lines1432extending through sole1480may extend through midsole1482. In some embodiments, thread lines1432extending through sole1480may extend through outsole1484. In some embodiments, thread lines1432extending through sole1480may extend through an interface between midsole1482and outsole1484.

Similarly, in some embodiments, thread lines1436extending through sole1480may extend through midsole1482. In some embodiments, thread lines1436extending through sole1480may extend through outsole1484. In some embodiments, thread lines1436extending through sole1480may extend through an interface between midsole1482and outsole1484.

In some embodiments, a portion of each of the plurality of thread lines1432that extend through sole1480is embedded within sole1480. In some embodiments, a portion of each of the plurality of thread lines1432that extend through sole1480is embedded within midsole1482. In some embodiments, a portion of each of the plurality of thread lines1432that extend through sole1480is embedded within outsole1484.

Similarly, in some embodiments, a portion of each of the plurality of thread lines1436that extend through sole1480is embedded within sole1480. In some embodiments, a portion of each of the plurality of thread lines1436that extend through sole1480is embedded within midsole1482. In some embodiments, a portion of each of the plurality of thread lines1436that extend through sole1480is embedded within outsole1484.

In some embodiments, a plurality of thread lines1432may extend from first side1442of first seam1440, over a portion of a first side (for example, the medial side1486) of sole1480, through sole1480, over a portion of a second side (for example, the lateral side) of sole1480, and to second side1444of first seam1440. In some embodiments, a plurality of thread lines1432may extend from medial side1412of upper1410, over a portion of a first side (for example, the medial side1486) of sole1480, through sole1480, over a portion of a second side (for example, the lateral side) of sole1480, and to lateral side1414of upper1410. In such embodiments, thread set1422extends from upper1410and covers a portion of the side surfaces of sole1480.

Similarly, in some embodiments, a plurality of thread lines1436may extend from first side1452of second seam1450, over a portion of a first side (for example, the medial side1486) of sole1480, through sole1480, over a portion of a second side (for example, the lateral side) of sole1480, and to second side1454of second seam1450. In some embodiments, a plurality of thread lines1436may extend from medial side1412of upper1410, over a portion of a first side (for example, the medial side1486) of sole1480, through sole1480, over a portion of a second side (for example, the lateral side) of sole1480, and to lateral side1414of upper1410. In such embodiments, thread set1426extends from upper1410and covers a portion of the side surfaces of sole1480.

Thread lines1432that extend through sole1480may enter sole1480at an entry point on a side surface of sole1480. For example, as shown inFIG.14, thread lines1422may enter sole1480at entry points1494on medial side1486of sole1480. Lateral side of sole1480may have entry points similar to entry points1494. A plurality of entry points1494on sole1480may be referred to as an entry line1495. Entry line1495extends along a side surface of sole1480and is defined by the plurality of entry points1494for each thread line1432extending through sole1480.

Similarly, thread lines1436that extend through sole1480may enter sole1480at an entry point on a side surface of sole1480. For example, as shown inFIG.14, thread lines1436may enter sole1480at entry points1496on medial side1486of sole1480. Lateral side of sole1480may have entry points similar to entry points1496. A plurality of entry points1496on sole1480may be referred to as an entry line1497. Entry line1497extends along a side surface of sole1480and is defined by the plurality of entry points1496for each thread line1436extending through sole1480.

In some embodiments, first set1422of thread lines1432and second set1426of thread lines1436may be disposed in the same portion of an article of footwear, for example a forefoot portion, a midfoot portion, or a heel portion. In some embodiments, first set1422of thread lines1432and second set1426of thread lines1436may be disposed in different portions of an article of footwear. For example, in some embodiments, first set1422may be disposed in a forefoot portion of an article of footwear and second set1426may be disposed in a heel portion of the article of footwear. As another example, in some embodiments, first set1422may be disposed in a forefoot portion of an article of footwear and second set1426may be disposed in a midfoot portion of the article of footwear.

In some embodiments, first set1422of thread lines1432may at least partially overlap second set1426of thread lines1436on an article of footwear. In some embodiments, first set1422of thread lines1432may not overlap second set1426of thread lines1436. In some embodiments, there may be more than two sets of thread lines. Each set of thread lines may have characteristics as described for first set1422and second set1426.

In some embodiments, first set1422of thread lines1432may extend through sole1480at a first distance1498from bottom surface1492of sole1480, and second set1426of thread lines1436may extend through sole1480at a second distance1499from bottom surface1492of sole1480.

As shown inFIG.14, first distance1498and second distance1499may be defined by the vertical distance between bottom surface1492of sole1480and entry lines1495,1497. In embodiments where bottom surface1492includes traction members, such as tread, bottom surface1492is defined by the bottommost surfaces of the traction members. In embodiments wherein distances1498,1499vary along lines1495,1497, the average distance along lines1495,1497defines distances1498,1499.

First distance1498and second distance1499may be different. In some embodiments, first distance1498may be less than second distance1499. In some embodiments, first distance1498may be greater than second distance1499. In some embodiments, second distance1499may be 10% or more different from first distance1498. By tailoring first distance1498and second distance1499, various characteristics of an article of footwear can be controlled. For example, sole1480can be provided with desired stiffness at different regions of the sole. Such regional stiffness can control how a wearer's foot and/or sole1480deforms during use. For example, a relatively large distance1498/1499can help control the way sole1480deforms when it contacts the ground during use.

Articles of footwear including one or more wound thread patterns integrated into a sole may be made by embedding the one or more wound thread patterns in a sole material. In some embodiments, embedding the one or more wound thread patterns may include directly molding a sole material on the wound thread pattern(s) such that a least a portion of the thread pattern(s) is embedded within the sole material. In some embodiments, a process for directly molding a sole material on the wound thread patterns(s) may include injection molding a sole material around the thread pattern(s).

In some embodiments, one or more wound thread patterns may be wound around a support structure, such as a support plate described herein, and then placed into a mold for molding a sole material on the wound thread pattern(s). In some embodiments, one or more wound thread patterns may be wound on a mold plate for molding a sole material on the wound thread pattern(s). For example, a mold plate may include anchor points for winding a continuous thread into one or more thread patterns. And after winding the thread pattern(s) on the anchor points of the mold plate, sole material may be molded on the wound thread pattern(s) using the mold plate.

FIGS.15A and15Bshow molds1500aand1500bfor molding a sole material on one or more thread patterns according to some embodiments. Mold1500ais described in reference to molding a sole material (sole1380) around thread pattern1322. Mold1500bis described in reference to molding a sole material (sole1480) around thread sets1422and1426.

Mold1500aincludes a first mold plate1510aand a second mold plate1520a. When assembled together first mold plate1510aand second mold plate1520adefine a mold cavity1530. In some embodiments, during use, a sole material may be flowed into mold cavity1530through a port (for example port1550) to mold the sole material around thread pattern1322. In some embodiments, a sole material may be injected into mold cavity1530through port1550. In some embodiments, mold1500amay be a compression mold. In such embodiments, during use, a first sole material piece may be placed into mold1500a, thread pattern1322may be wound or placed over the first sole material piece, a second sole material piece is placed over thread pattern1322, and the two sole material pieces are compression molded around thread pattern1322.

As shown inFIG.15A, thread pattern1322may be disposed between first mold plate1510aand second mold plate1520asuch that at least a portion of thread pattern1322is located within mold cavity1530. In some embodiments, first end1323and second end1324of thread pattern1322may not be located within mold cavity1530so that these ends may remain free of sole material after molding. The portion of thread pattern1322located within mold cavity1530may be embedded within a sole material when the sole material is molded around thread pattern1322in mold cavity1530.

In some embodiments, all of thread pattern1322may be located within mold cavity1530. In such embodiments, first end1323and second end1324may terminate inside a sole molded on thread pattern1322. In some embodiments, one of first end1323and second end1324may terminate inside a sole molded on thread pattern1322. In such embodiments, the end not terminating inside the sole may be directly or indirectly coupled to a side of upper1310. In some embodiments, the end directly or indirectly coupled to a side of upper1310may define all or a portion of a structural element on upper, for example a lace reinforcement.

In some embodiments, mold1500amay include anchor points1540for winding thread pattern1322on mold1500a. Anchor points1540may be located on first mold plate1510aor second mold plate1520a. Anchor points1540may be, for example, pins or projections extending from first mold plate1510aor second mold plate1520a. In such embodiments, thread pattern1322may be wound around anchors points1540, first mold plate1510aand second mold plate1520aare assembled to form mold cavity1530, and then sole material is molded on thread pattern1322in mold cavity1530.

Mold1500bincludes first mold plate1510band second mold plate1520b. Like first mold plate1510aand second mold plate1520a, when assembled together, first mold plate1510band second mold plate1520bdefine mold cavity1530.

As shown inFIG.15B, first thread set1422and second thread set1426may be disposed between first mold plate1510band second mold plate1520bsuch that a portion of both thread sets is located within mold cavity1530. First end1423and second end1424of first thread set1422are not located within mold cavity1530so that these ends may remain free of sole material after molding. Similarly, first end1427and second end1428of second thread set1426are not located within mold cavity1530so that these ends may remain free of sole material after molding. The portions of thread sets1422,1426located within mold cavity1530may be embedded within a sole material when the sole material is molded around thread sets1422,1426in mold cavity1530.

In some embodiments, mold1500bmay include anchor points1540for winding first thread set1422and second thread set1426on mold1500b. Anchor points1540may be located on first mold plate1510bor second mold plate1520b. Anchor points1540may be, for example, pins or projections extending from first mold plate1510bor second mold plate1520b. In such embodiments, thread sets1422,1426may be wound around anchors points1540, first mold plate1510band second mold plate1520bare assembled to form mold cavity1530, and then sole material is molded on thread sets1422,1426in mold cavity1530.

In some embodiments, anchor points1540of mold1500bmay include two or more anchor points1540separated from each other in a longitudinal direction1560(into the page), a transverse direction1562, and/or a vertical direction1564orthogonal to longitudinal direction1560and transverse direction1562. For example, compared to anchor points1540b, anchor points1540amay be forwardly located in longitudinal direction1560, inwardly located in transverse direction1562, and/or upwardly located in vertical direction1564. By separating anchor points1540in this fashion, thread sets1422,1426may be wound at desired locations and to have desired dimensions relative to a sole. For example, by separating anchor points1540in vertical direction1564, first and second thread sets1422,1426may extend through sole1480at different distances1498,1499, as illustrated inFIG.14

In some embodiments, a surface of a thread pattern as described herein may be textured. In some embodiments, a surface of thread pattern may be textured using one or more of the following techniques.

In some embodiments, a textured sheet may be utilized to impart texture to a surface of a thread pattern.FIG.16illustrates a textured sheet1600according to some embodiments. Textured sheet1600includes a plurality of regions with different textures and/or elevations. For example, textured sheet1600may include a first region1610having a first texture and/or elevation, a second region1620having a second texture and/or elevation, and a third region1630having a third texture and/or elevation. In some embodiments, one or more regions of textured sheet1600may have a smooth surface texture. Different elevations of textured sheet1600may impart differently raised areas on a thread pattern. Different elevations of textured sheet1600may be created by varying the thickness of textured sheet1600.

During use, a thread pattern may be placed on textured sheet1600, in for example the outlined area1640shown inFIG.16. After being placed on textured sheet1600, the thread pattern may be pressed onto sheet1600to impart the textured surface of sheet1600onto a surface of the thread pattern. In some embodiments, heat and pressure may be applied to impart the textured surface of sheet1600onto a surface of the thread pattern. In some embodiments, textured sheet1600and a thread pattern may be pressed in a heat press (for example, heat press900) to impart the textured surface of sheet1600onto a surface of the thread pattern.

In some embodiments, textured sheet1600maybe a polymeric sheet. Suitable materials for textured sheet1600include, but are not limited to, silicone, polyether ether ketone (PEEK), a polymeric foam, a metal, or a ceramic.

In some embodiments, a textured support plate1700may be utilized to impart texture to a surface of a thread pattern.FIG.17illustrates a textured support plate1700with projections1706according to some embodiments. Textured support plate1700may include a plurality of regions with different textures and/or elevations. For example, textured support plate1700may include two first regions1710having a first texture and/or elevation, a second region1720having a second texture and/or elevation, and a third region1730having a third texture and/or elevation. Textured regions on support plate1700may be formed on a front side1701of support plate1700. In some embodiments, one or more regions of textured support plate1700may have a smooth surface texture. Different elevations of textured support plate1700may impart differently raised areas on a thread pattern. Different elevations of textured support plate1700may be created by varying the thickness of support plate1700.

During use, a thread pattern may be wound over front side1701of textured support plate1700using projections1706. After winding the thread pattern, the thread pattern may be pressed onto front side1701of support plate1700to impart the textured surface of plate1700onto a surface of the thread pattern. In some embodiments, heat and pressure may be applied to impart the textured surface of support plate1700onto a surface of the thread pattern. In some embodiments, textured support plate1700and a thread pattern may be pressed in a heat press (for example, heat press900) to impart the textured surface of plate1700onto a surface of the thread pattern.

In some embodiments, texture may be imparted on a thread pattern by depositing a material on the thread pattern or physically manipulating the thread pattern. Suitable deposition processes for imparting texture to a thread pattern include, but are not limited to, a coating process, fused deposition modeling, and flocking. Suitable processes for physically manipulating a thread pattern to impart texture include, but are not limited to, brushing.

A fused deposition modeling process includes 3D printing a material onto a surface of a thread pattern. A coating process may include coating one or more materials on a surface of a thread pattern. In some embodiments, a coating process may include spraying one or more materials on a surface of a thread pattern. A flocking process may include two steps. First, an adhesive material is zonally coated on a thread pattern. Second, small fiber particles are deposited in areas coated with the adhesive. A brushing process can include raising up threads of a bonded thread pattern. In some embodiments, a brushing process may include passing one or more bristle-covered rollers over a thread pattern.

FIG.18shows an exemplary thread pattern1800including a plurality of regions with texture imparted to thread pattern1800by depositing a material on thread pattern1800or physically manipulating thread pattern1800. Thread pattern1800includes a plurality of first regions1810having a first texture and a second region1820having a second texture. By varying the process parameters of the processes described above, regions1810,1820may be imparted with different textures.

In some embodiments, a thread pattern may be wound around anchor points to define a portion of a sole. For example, in some embodiments, a thread pattern may be wound around anchor points to define cleats for a sole. As another example, a thread pattern may be wound around anchor points to define a support member for a sole. Exemplary support members include, but are not limited to, torsion plates or stiffening plates. In some embodiments, support members defined by a thread pattern may extend between cleats defined by a thread pattern. As another example, a thread pattern may be wound around anchor points to define an outsole.

FIG.19illustrates a three-dimensional object1900for winding a thread pattern around anchor points1906to define a portion of a sole. In some embodiments, three-dimensional object1900may be a last.

Three-dimensional object1900includes a sole surface1902and an upper surface1904. Sole surface1902includes anchor points1906for winding thread lines1912of a thread pattern1910to define a portion of a sole for an article of footwear. Upper surface1904includes anchor points1906for winding thread lines1912of thread pattern1910to define a portion of an upper for an article of footwear.

In some embodiments, three-dimensional object1900may be used to simultaneously wind a thread pattern1910that defines a portion of a sole and a portion of an upper for an article of footwear. In such embodiments, thread pattern1910may include a plurality of thread lines extending from a sole feature (for example, a cleat or support member) to an upper.

In some embodiments, anchor points1906may be integrally formed with object1900. In some embodiments, anchor points1906may be removably coupled to object1900. Anchor points1906may be projections, pins, knobs, or studs. In some embodiments, anchor points1906may be posts2030for a forming a cleat.

Thread lines1912of thread pattern1910may be bonded to each other at anchor points1906and/or intersection points as described herein. Thread pattern1910may be removed from object1900before or after bonding thread lines1912. In some embodiments, thread lines1912of thread pattern1910may be bonded to each other at anchor points1906and/or intersection points while thread pattern1910is disposed on object1900. In some embodiments, thread lines1912of thread pattern1910may be bonded to each other at anchor points1906and/or intersection points after thread pattern1910is removed from object1900.

In some embodiments, anchor points1906may be incorporated into thread pattern1910and define a portion of thread pattern1910after thread pattern1910is bonded. For example, removable anchor points1906may be bonded to thread pattern1910and removed from object1900when thread pattern1910is removed from object1900. One example of this is when anchor points are posts2030for a forming a cleat. In such embodiments, thread lines1912may be wound around posts2030. Then, when bonding the thread lines1912at posts2030, posts2030are also bonded to thread lines1912. In some embodiments, posts2030may be directly bonded to thread lines1912, for example, via a polymeric material of thread lines1912and/or posts2030.

In some embodiments, a sole material may be molded over thread lines defining a portion of a sole. For example, a sole material may be molded over thread lines1912on object1900defining cleats and/or a support member. In such embodiments, object1900may be mold plate or a portion of a mold plate. For example, object1900may be mold plate2020and sole surface1902may be mold surface2022.

FIG.20shows a mold2000for molding a sole (for example, sole180) according to some embodiments. Mold2000includes a first mold plate2010and a second mold plate2020. Second mold plate2020includes a mold surface2022over which a sole material is molded. When assembled, first mold plate2010and second mold plate2020form a mold cavity having an interior shape corresponding to the shape of a sole for an article of footwear.

Mold surface2022includes anchor points for winding a thread pattern. In some embodiments, the anchor points may be posts2030for forming traction elements, such as cleats. In some embodiments, the anchor points may be posts2030for winding a support member, and some embodiments, the supper member may include posts2030.

In operation, thread lines2032of one or more continuous threads may be wound around posts2030in a similar fashion as discussed herein for winding continuous thread(s) around other anchor points. In other words, posts2030may define anchor points for thread lines2032.

In some embodiments, as shown for example inFIG.20B, posts2130may be removably attached to mold surface2022. Removable posts2030may be attached to mold surface2022via a removable mechanical attachment, such as but not limited to, a friction fit, a magnetic force, and/or via a recess in mold surface2022. In some embodiments, removable posts2030may be removably attached to studs2024formed on mold surface2022. In such embodiments, studs2024may be arranged in a pattern for cleats of an article of footwear. In some embodiments, posts2030may include ridges2031to help hold threads during winding.

In some embodiments, posts2030may be irremovably fixed on mold surface2022. In such embodiments, posts2030do not form a portion of a sole. Rather, a finished sole or sole component is removed from posts2030after winding and/or molding.

In some embodiments, after winding thread lines2032around posts2030, thread lines2032may be bonded to each other at posts2030and/or at intersection points to form a sole, or a portion of a sole. In some embodiments, mold2000may be utilized to bond thread lines2032by applying heat and pressure to thread lines2032and posts2030.

In some embodiments, after winding thread lines2032around posts2030, sole material may be molded around thread lines2032and/or posts2030within mold2000. In other words, thread lines2032may be embedded with a sole material defining at least a portion of a sole (for example, sole180). In some embodiments, thread lines2032may be bonded to each other at posts2030and/or at intersection points before molding a sole material around thread lines2032and/or posts2030in mold2000.

In some embodiments, mold2000may be an injection-molding mold. In some embodiments, mold2000may be used to partially consolidate a sole or sole component and the sole or sole component may be cured to fully solidify it after it is removed from mold2000.

FIG.21illustrates a thread pattern2110wound around anchor points2102over a bottom surface2101of a midsole2100to form an outsole according to some embodiments. In some embodiments, anchor points2102may be formed on midsole2100. In other words, anchor points2102may define a portion of midsole2100. In such embodiments, anchor points2102may be an integral part of midsole2100. In some embodiments, anchor points2102may be pins, or other similar projecting elements, extending from an object2120and through midsole2100. In some embodiments, three-dimensional object2120may be a last or a mold plate.

After winding thread lines2112of thread pattern2110, thread lines2112may be may be bonded to each other at anchor points2102and/or at intersection points to form an outsole on bottom surface2101of midsole2100. In some embodiments, anchor points2102may be bonded to thread pattern2110when bonding thread lines2112to each other at anchor points2102and/or at intersection points. In some embodiments, anchor points2102may be directly bonded to thread lines2112, for example, via a polymeric material of thread lines2112and/or anchor points2102.

In some anchor points2102may be removed from midsole2100and thread pattern2110after bonding thread lines2112. In such embodiments, anchor points2102are not present in a finalized sole including midsole2100and an outsole formed using thread pattern2110.

In some embodiments, a thread pattern as described herein may including padding or lining for enhancing the comfort and/or aesthetics of an upper formed using the thread pattern. In some embodiments, a plurality of padding or lining elements may be disposed on a thread pattern.

FIG.22illustrates a padded thread pattern2200according to some embodiments. Thread pattern2200includes two padded regions2210including a plurality of padding elements2220. Padding elements2220may be individual elements separated from each other on thread pattern2200. Padding elements2220may be made of, for example, padding material, liner material, or foam material. Exemplary materials for padding elements include, but are not limited to, a foam, ethyl vinyl acetate (EVA), polyurethane (PU), expanded thermoplastic polyurethane (eTPU), a thermoplastic polyurethane (TPU), a knit fabric, a woven fabric, a non-woven fabric, Spandex, a suede, or a polymeric mesh (for example, a TPU mesh). In some embodiments, the foam may comprise, for example, an EVA-based foam or a PU-based foam and the foam may be an open-cell foam or a closed-cell foam.

In some embodiments, padding elements2220may be disposed in one or more discrete padded regions2210on a surface of thread pattern2200. In some embodiments, padding elements2220may be disposed over an entire surface of thread pattern2200. In some embodiments, different padding elements2220may have different heights to provide a three-dimensional effect for one or more padded regions2210.

FIG.23shows a method2300of disposing padding material on a thread pattern according to some embodiments.FIGS.24A-24Fillustrate steps of method2300. Unless stated otherwise, the steps of method2300need not be performed in the order set forth inFIG.23. Additionally, unless specified otherwise, the steps of method2300need not be performed sequentially. The steps can be performed simultaneously.

In step2310, a pattern is cut in a padding material2410. The cut pattern may define individual padding elements2420to be applied to thread pattern2400. Cutting padding material2410in step2310may include any suitable cutting process, for example a laser cutting process.

In step2320, a transfer sheet2430is applied to the cut padding material2410. Suitable transfer sheets, include, but are not limited to, MYLAR® (a biaxially-oriented polyethylene terephthalate silicone), cellophane, wax paper, and PTFE.

In step2330, transfer sheet2430with padding elements2420attached is disposed on thread pattern2400such that padding elements2420are in contact with a surface of thread pattern2400.

In step2340, padding elements2420of padding material2410are attached to thread pattern2400. In some embodiments, heat and pressure may be applied to attach padding elements2420to thread pattern2400. In some embodiments, padding elements2420and thread pattern2400may be pressed in a heat press (for example, heat press900) to attach padding elements2420to thread pattern2400in step2340.

After attaching padding elements2420to thread pattern2400in step2340, transfer sheet2430is removed in step2350. Removing transfer sheet2430leaves behind padding elements2420attached to thread pattern2400.

FIG.32shows an upper3200including a thread pattern3210according to some embodiments. In some embodiments, upper3200may include a medial flap3220. In some embodiments, upper3200may include a lateral flap3222. In some embodiments, upper3200may include medial flap3220and lateral flap3222.

In some embodiments, medial flap3220and/or lateral flap3222may be an integral part of thread pattern3210. In other words, medial flap3220and/or lateral flap3222may be wound using one or more continuous threads that define the rest of thread pattern3210.

In some embodiments, medial flap3220and/or lateral flap3222may be a separate piece attached to thread pattern3210at a seam. In particular, medial flap3220may be attached to thread pattern3210at a seam3224and lateral flap3222may be attached to thread pattern at a seam3226. In some embodiments, medial flap3220and/or lateral flap3222may be a material including a thread pattern as described herein. In some embodiments, medial flap3220and/or lateral flap3222may not be a material including a thread pattern as described herein. For example, in such embodiments, medial flap3220and/or lateral flap3222may be a woven or knit material.

In embodiments including medial flap3220, medial flap3220may be folded over a medial portion of upper3200and attached to a medial side upper3200. In some embodiments, folded medial flap3220may encapsulate one or more padding elements3230between flap3220and the medial portion of upper3200. Padding element(s)3230may be composed of, for example, neoprene, ePEBA, eTPU, EVA, TPU, or a foam, such as polyethylene foam, polyurethane foam, or a urethane foam.

In embodiments including lateral flap3222, lateral flap3222may be folded over a lateral portion of upper3200and attached to a lateral side upper3200. In some embodiments, folded lateral flap3222may encapsulate a padding element3230between flap3222and the lateral portion of upper3200.

FIG.33shows an article of footwear3300including a sole3310coupled to upper3200with medial flap3220folded over a medial portion of upper3200and encapsulating a padding element3230between flap3220and the medial portion of upper3200.

FIG.34shows an upper3400according to some embodiments with a lining3420attached to a thread pattern3410. Lining3420is disposed interior of thread pattern3410on upper3400. In some embodiments, lining3420may be located in a heel portion of upper3400and wrap around a heel end of upper3400.

In some embodiments, upper3400may include a collar3430. In some embodiments, collar3430may include a portion defining a throat for upper3400.

In some embodiments, a top end3422of lining3420may be attached to thread pattern3410at a seam3424. In some embodiments, top end3422of lining3420may be attached to collar3430at seam3424. In some embodiments, top end3422of lining3420may be attached to thread pattern3410and/or collar3430at seam3424and the rest of lining3420may not be directly attached to upper3400. In such embodiments, a bottom end3426of lining3420may be a free end of lining3420not directly attached to upper3400. In some embodiments, top end3422of lining3420may be attached to thread pattern3410and/or collar3430at seam3424and the rest of lining3420may not be directly attached to upper3400or any component of an article of footwear including upper3400. In such embodiments, bottom end3426of lining3420may be a free end of lining3420not directly attached to upper3400or any component of an article of footwear including upper3400.

In some embodiments, bottom end3426of lining3420may be attached to thread pattern3410at a seam3428. In some embodiments, bottom end3426of lining3420may be attached to a bottom cushioning element3440at seam3428. Bottom cushioning element3440may be, for example, a strobel board or a sock liner. In some embodiments, bottom end3426of lining3420may be attached to thread pattern3410and/or bottom cushioning element3440at seam3428and the rest of lining3420may not be directly attached to upper3400. In such embodiments, top end3422of lining3420may be a free end of lining3420not directly attached to upper3400. In some embodiments, bottom end3426of lining3420may be attached to thread pattern3410and/or cushioning element3440at seam3428and the rest of lining3420may not be directly attached to upper3400or any component of an article of footwear including upper3400. In such embodiments, top end3422of lining3420may be a free end of lining3420not directly attached to upper3400or any component of an article of footwear including upper3400.

While various embodiments have been discussed herein in the context of footwear, and in particular embodiments, uppers for articles of footwear, other articles of apparel may be manufactured using the winding processes discussed herein. Other articles of apparel include, but are not limited to, a strobel board, a sock liner, pants, shorts, leggings, a sock, a jacket, a coat, a hat, a sleeve, a shoe, a sweater, a shirt, a jersey, a bra, a bootie, and a glove. In some embodiments, when making these articles of apparel, and others, a thread pattern may be wound around anchor points to form a thread pattern defining all of a portion of these articles. In some embodiments, when making these articles of apparel, and others, a thread pattern may be wound around anchor points to form a thread pattern as discussed herein and all or a portion of these articles may be cut from the thread pattern. For example, a strobel board may be cut from a thread pattern.

One or more aspects of the methods of manufacturing an article of footwear discussed herein, or any part(s) or function(s) thereof (for example, defining a boundary line and winding continuous threads with a CNC machine), may be implemented using hardware, software modules, firmware, tangible computer readable media having instructions stored thereon, or a combination thereof and may be implemented in one or more computer systems or other processing systems.

FIG.35illustrates an exemplary computer system3500in which embodiments, or portions thereof, may be implemented as computer-readable code. For example, aspects of the methods discussed herein may be implemented in computer system3500using hardware, software, firmware, tangible computer readable media having instructions stored thereon, or a combination thereof and may be implemented in one or more computer systems or other processing systems.

If programmable logic is used, such logic may execute on a commercially available processing platform or a special purpose device. One of ordinary skill in the art may appreciate that embodiments of the disclosed subject matter can be practiced with various computer system configurations, including multi-core multiprocessor systems, minicomputers, and mainframe computers, computer linked or clustered with distributed functions, as well as pervasive or miniature computers that may be embedded into virtually any device.

For instance, at least one processor device and a memory may be used to implement the above-described embodiments. A processor device may be a single processor, a plurality of processors, or combinations thereof. Processor devices may have one or more processor “cores.”

Various embodiments described herein may be implemented in terms of this example computer system3500. After reading this description, it will become apparent to a person skilled in the relevant art how to implement one or more of the embodiments using other computer systems and/or computer architectures. Although operations may be described as a sequential process, some of the operations may in fact be performed in parallel, concurrently, and/or in a distributed environment, and with program code stored locally or remotely for access by single or multi-processor machines. In addition, in some embodiments the order of operations may be rearranged without departing from the spirit of the disclosed subject matter.

Processor device3504may be a special purpose or a general-purpose processor device. As will be appreciated by persons skilled in the relevant art, processor device3504may also be a single processor in a multi-core/multiprocessor system, such system operating alone, or in a cluster of computing devices operating in a cluster or server farm. Processor device3504is connected to a communication infrastructure3506, for example, a bus, message queue, network, or multi-core message-passing scheme.

Computer system3500also includes a main memory3508, for example, random access memory (RAM), and may also include a secondary memory3510. Secondary memory3510may include, for example, a hard disk drive3512, or removable storage drive3514. Removable storage drive3514may include a floppy disk drive, a magnetic tape drive, an optical disk drive, a flash memory, a Universal Serial Bus (USB) drive, or the like. The removable storage drive3514reads from and/or writes to a removable storage unit3518in a well-known manner. Removable storage unit3518may include a floppy disk, magnetic tape, optical disk, etc. which is read by and written to by removable storage drive3514. As will be appreciated by persons skilled in the relevant art, removable storage unit3518includes a computer usable storage medium having stored therein computer software and/or data.

Computer system3500(optionally) includes a display interface3502(which can include input and output devices such as keyboards, mice, etc.) that forwards graphics, text, and other data from communication infrastructure3506(or from a frame buffer not shown) for display on display unit3530.

In additional and/or alternative implementations, secondary memory3510may include other similar means for allowing computer programs or other instructions to be loaded into computer system3500. Such means may include, for example, a removable storage unit3522and an interface3520. Examples of such means may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units3522and interfaces3520which allow software and data to be transferred from the removable storage unit3522to computer system3500.

Computer system3500may also include a communication interface3524. Communication interface3524allows software and data to be transferred between computer system3500and external devices. Communication interface3524may include a modem, a network interface (such as an Ethernet card), a communication port, a PCMCIA slot and card, or the like. Software and data transferred via communication interface3524may be in the form of signals, which may be electronic, electromagnetic, optical, or other signals capable of being received by communication interface3524. These signals may be provided to communication interface3524via a communication path3526. Communication path3526carries signals and may be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, an RF link or other communication channels.

In this document, the terms “computer program medium” and “computer usable medium” are used to generally refer to media such as removable storage unit3518, removable storage unit3522, and a hard disk installed in hard disk drive3512. Computer program medium and computer usable medium may also refer to memories, such as main memory3508and secondary memory3510, which may be memory semiconductors (for example, DRAMs, etc.).

Computer programs (also called computer control logic) are stored in main memory3508and/or secondary memory3510. Computer programs may also be received via communication interface3524. Such computer programs, when executed, enable computer system3500to implement the embodiments as discussed herein. In particular, the computer programs, when executed, enable processor device3504to implement the processes of the embodiments discussed here. Accordingly, such computer programs represent controllers of the computer system3500. Where the embodiments are implemented using software, the software may be stored in a computer program product and loaded into computer system3500using removable storage drive3514, interface3520, and hard disk drive3512, or communication interface3524.