Method of forming an article of apparel

An article of apparel includes a composite material. The composite material includes a pliable first layer and a resilient second layer, where the first and second layers are secured to each other via a patterned strand network. In forming the composite material, the second layer is stretched and maintained under tension while the first layer is secured to the second layer via the patterned strand network. The tension on the second layer is then released, resulting in contraction of the second layer in relation to the first layer and an outward buckling or protrusion of the first layer in relation to the second layer to form protruding cells along the composite material that are bounded by portions of the patterned strand network. The patterned strand network can be formed using embroidery with one or more auxetic patterns in the stitching.

FIELD OF THE INVENTION

The present invention relates to a method of forming an article of apparel.

BACKGROUND

Apparel such an article of footwear can be designed to provide a variety of features in the upper and sole structure depending upon a particular application. Some features that are desirable are comfort, breathability, durability, stretchability and sufficient support and protection for the user's foot when the shoe is worn for a particular application. For certain applications, it may also be desirable to control a degree of stretch in one or more directions along the upper during use. Controlling a degree of stretch and providing a comfortable fit is also important for other textile articles, including articles of apparel.

It would be desirable to provide a textile article that is lightweight, breathable, and durable, and further provides enhanced levels of stretchability at different locations of the textile article depending upon a particular application of use.

SUMMARY OF THE INVENTION

In example embodiments, an article of apparel comprising a composite material is formed by orienting a first layer with a second layer such that a second stretch value of the second layer is greater than a first stretch value of the first layer in a stretch direction. Tension is applied to stretch the second layer in the stretch direction from an original dimension to a stretched dimension, and the first layer is secured to the second layer via a stitch network while the second layer is under tension. The stitch network forms a plurality of enclosed cells located between the first and second layers, with each enclosed cell being defined by a perimeter of stitches of the stitch network. The applied tension is then released, allowing the second layer to retract from its stretched dimension so as to form a composite material. The composite material is incorporated into an article of apparel.

In a further embodiment, the composite material is a multilayered textile comprising a non-resilient first layer (i.e., a fabric with limited stretch and recovery properties) and a resilient second layer (i.e., a fabric possessing stretch and recovery properties). The first layer is secured to second layer via stitching formed of a plurality of strand segments, each strand segment including a first thread positioned on the surface of the first layer and a second thread positioned on the surface of the second layer. The first and second threads extend through the multilayered textile at predetermined locations to interlock with each other. The stitches are organized in a predetermined pattern within the multilayer textile to form a plurality of cells, each cell being enclosed by stitching. The multilayered textile is dynamic, being configured to move from a normal, unstretched or unloaded position to an expanded, stretched or loaded position. In the normal position, the first layer is separated from the second layer within one or more of the cells. In the expanded position, the first layer contacts the second layer within one or more of the cells.

In certain embodiments, the dynamic composite material comprises a pliable first layer (e.g., the first layer having a two-way stretch) and a resilient second layer (e.g., the second layer having a four way stretch), where the first and second layers are secured to each other via a patterned stitch or strand network to define a plurality of dynamic cells. In forming the composite material, the second layer is stretched and maintained under tension while the first layer is secured to the second layer via the stitch network. After securing the first and second layers together, the tension on the second layer is released, resulting in contraction of the second layer in relation to the first layer and an outward buckling or protrusion of the first layer in relation to the second layer. Specifically, each cell is driven upward (along the z-axis) from a first position, in which the first layer is in contact with the second layer within the confines of the stitched cell, to a second position, in which the first layer is separated from the second layer within the cell confines (as defined by the stitching). With this configuration, an array of protruding cells is formed along the composite material in a dynamic state, with each cell being bounded by portions of the patterned strand network. When the formed composite material is stretched in use, the cells collapse or flatten toward the second layer to a static state. The patterned strand network, as described herein, can comprise an embroidered network that is formed with one or more auxetic patterns in the stitching, where the auxetic patterns enhance the stretchability of the composite material when integrated within the upper. Alternatively, the stitch network can also be any suitable stitching that facilitates the formation of individual cells based upon the pattern of stitches formed along the layers forming the composite material.

In other embodiments, the dynamic composite material formed with a patterned strand network and including dynamic cells can be used to form other textile articles, such as other articles of apparel (e.g., a brassiere, a shirt, shorts, pants, etc.).

Methods of forming the composite material are also described herein.

The above and still further features and advantages of the present invention will become apparent upon consideration of the following detailed description of specific embodiments thereof.

DETAILED DESCRIPTION

The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous.

A composite material as described herein is a textile construction including multiple layers (e.g., at least two layers) that cooperate to form a plurality of discrete, dynamic cells operable to control the expansion pattern of the composite material. The material is resilient—when load or tension is applied, the material moves from a normal, unstretched configuration to an expanded, stretched configuration. The cells, moreover, move from a protruded configuration to a flattened configuration. When the load is released, the material (including the cells) recovers, returning to its normal configuration.

Referring toFIG. 1A, the composite material100includes a first or outer layer110(also called a pliable layer) and a second or base layer120(also called a resilient layer). In other embodiments shown inFIGS. 1B-1D, the composite material100B,100C,100D includes further layers (as described in further detail herein). The specific number and/or types of layers that are used to form a composite material may depend upon a particular application of use for the composite material (e.g., integration of the composite material within a particular article of apparel, such as an article of footwear or shoe, a brassiere, shirts, shorts or pants, or other textile structures).

In an embodiment, the outer layer110is a pliable or flexible layer with low, moderate or no stretch and/or recovery properties. For example, the first layer (as well as other layers except for the second layer) can have a recovery of less than 50%. By way of example, the first layer110is a synthetic fabric including a substrate and a polymer coating. The substrate can be a nonwoven web or a knit textile. A nonwoven web is an assembly of textile fibers held together by mechanical interlocking in a random web or mat, e.g., by fusing of the fibers (in the case of thermoplastic fibers) or by bonding with a polymer. The fibers may be oriented in one direction or be deposited in a random manner. In an embodiment, the first layer110is a spun-bonded or spunbond web of entangled strands or fibers impregnated with a polymer to form a substantially continuous, porous structure. The polymer may include polymers such as polyurethane, acrylonitrile-butadiene copolymer, styrene-butadiene copolymer, copolymer of acrylic ester or methacrylic ester, and silicone rubber. In a further embodiment, the first layer110can include ultra-fine fibers or microfibers which are impregnated and/or coated with polyurethane. By way of example, the first layer110can comprise by weight about 55% polyester microfibers and about 45% polyurethane.

The thickness of the first layer may be any suitable for its described purpose (to buckle or bend upon recovery of the second layer120). In an embodiment, the thickness of the pliable layer110is generally less than 2 mm. By way of example, the thickness can be from about 0.5 mm to about 1.5 mm (e.g., about 0.8 mm) so as to facilitate certain properties for the composite material as described herein. In example embodiments, the first layer110forms an outer layer of a textile structure (e.g., an upper for an article of footwear) in which the composite material is integrated.

The second or base layer120is a resilient fabric possessing a second stretch and/or recovery value that is greater than that of the first layer110and, preferably, better than one or more of any other layers forming the composite material100,100A,100B100C,100D. Elongation or stretch is the deformation in the direction of load caused by a tensile force. Elongation may be measured in units of length (e.g., millimeters, inches) or calculated as a percentage of the original length (e.g., a fabric that stretches 100% expands to twice its original length). In particular, an elongation value (also referred to as a stretch value) refers to an amount of elongation of a material in a dimension (length or width) that is defined with the formula: [(elongated dimension-original dimension)/(original dimension)]×100. Recovery (elastic recovery or elasticity) is the ability of a material under load to recover its original size or near original size and shape immediately after removal of the stress that causes deformation. For example, a recovery percentage refers to a percentage of an original dimension to which the material relaxes (i.e., no longer under the load or tension) after being stretched along such dimension (e.g., a recovery percentage of at least 90% of a material indicates that the dimension of the material in the stretch direction after the load is removed will be at least 90% of the original dimension of the material before being stretched).

In an embodiment, the second layer120is a power stretch or elastic fabric having the ability to expand under load and regain its original form once the load is removed. In an embodiment, the second layer has a stretch value of at least 100% and a recovery value of greater than 50% and preferably at least 90%. By way of example, the second layer120is a knit textile. Knitting is a process for constructing fabric with strands by interlocking a series of loops (bights) of one or more strands organized in wales and courses. In general, knitting includes warp knitting and weft knitting. In warp knitting, a plurality of strands run lengthwise in the fabric to make all the loops. In weft knitting, one continuous strand runs crosswise in the fabric, making all the loops in one course. Weft knitting includes fabrics formed on both circular knitting and flat knitting machines.

The strands forming the second layer may be of any one or more types suitable for the described purpose (to form a shoe upper). The term strand includes a single fiber, filament, or monofilament, as well as an ordered assemblage of textile fibers having a high ratio of length to diameter and normally used as a unit (e.g., slivers, roving, single yarns, plies yarns, cords, braids, ropes, etc.). In a preferred embodiment a strand is a yarn (a continuous strand of textile fibers, filaments, or material in a form suitable for knitting, weaving, or otherwise intertwining to form a textile fabric). A yarn may include a number of fibers twisted together (spun yarn); a number of filaments laid together without twist (a zero-twist yarn); a number of filaments laid together with a degree of twist; and a single filament with or without twist (a monofilament).

The strands forming the textile can be natural strands (e.g., cotton strands, wool strands, silk strands, etc.) and/or synthetic strands formed of one or more types of polymers, including fibers or filaments having one or more polymer components formed within the fibers or filaments.

By way of example, a strand of the textile includes elastic strands and/or inelastic strands. Elastic strands are strands including elastomeric material (e.g., 100% elastic material). Elastic strands, by virtue of their composition alone, are capable of stretching under stress and recovering to its original size once the stress is released. Accordingly, elastic strands are utilized to provide a textile with stretch properties. An elastic strand is formed of rubber or a synthetic polymer having properties of rubber. A specific example of an elastomeric material suitable for forming an elastic strand is elastane, an elastomeric polyester-polyurethane copolymer.

In general, both elastic and inelastic strands may be used in forming a textile layer, with inelastic strands utilized for ground stitches and the elastic strands being inserted and/or knitted into the structure. Accordingly, elastomeric strands are used in combination with inelastic strands. In an embodiment, the proportion of elastomeric fibers in the fabric may include about 50% or more elastomeric strands to provide desired stretch and recovery properties of the fabric. By way of example, the second layer comprises at least 60% (e.g., 68%-72%) elastomeric strands (e.g., elastane) and no more than 40% (e.g., 28%-32%) inelastic strands (e.g., nylon).

Accordingly, the second layer120is configured to have high elongation and recovery properties. The elastic or stretch fabric may be a mono-elastic fabric, which stretches in a single, longitudinal or horizontal (crosswise) direction (also called a two-way stretch fabric) or bi-elastic fabric, which stretch in both longitudinal and horizontal directions (also called a four-way stretch fabric). In an embodiment, the second layer is a weft-knitted fabric possessing an elongation (stretch) value in the machine (longitudinal) direction of about 60% and an elongation in the width direction of about 220% (ASTM D4964-96 (R2016)).

The layers forming the composite material100may be positioned in a predetermined orientation and, in particular, may be oriented with reference to the dominant stretch axis of the base layer120. InFIG. 1A(as well as inFIGS. 1B-1D) the double sided arrow provided on each material layer110,120(as well as additional layers130,135and140) provides an indication of an orientation of a primary or dominant direction or dimension of stretch (also called the dominant stretch axis), i.e., greatest or maximum elongation/stretch and recovery property for the layer. As illustrated, the arrangement of the layers forming the composite material indicates that certain layers have a dominant direction of stretch that are oriented transverse (e.g., orthogonal) in relation to other material layer(s) that are secured together to form the composite material.

As shown inFIG. 1A, the second layer120has a primary/dominant or greatest degree of stretch (greatest elongation value) oriented in a horizontal or second direction (also called the width or x-axis direction, as shown by the double arrow oriented on layer120). It should be understood that the second layer120can also have a degree of stretch in a vertical or first direction (i.e., a direction transverse the dominant direction of stretch as shown inFIG. 1A, also called the length or y-axis direction), where the degree of stretch (elongation value) in the vertical direction is less than that in the horizontal (dominant) stretch direction for the second layer. As used herein, the horizontal (second) and vertical (first) directions refer to orientations of a dominant degree of stretch for each layer in relation to all the other layers for each composite material depicted inFIGS. 1A-1D.

In an embodiment, the second or base layer120is a power stretch knit textile possessing an elongation value of at least 50% in one or both directions and preferably in a range from about 50% to 200% or greater (e.g., up to about 160% in the dominant elongation or stretch direction (e.g., the width direction), and at least about 50% in the orthogonal direction (the length direction). The second layer120, furthermore, possesses a recovery value of greater than 90% (e.g., 94% or greater), preferably in both directions.

The second layer120can also have any suitable thickness that permits suitable elongation and recovery of the second layer for the intended use of the composite material. In example embodiments, the thickness of the second layer can range from about 0.5 mm to about 2.0 mm.

In an embodiment, the other layers are generally rigid. As explained in greater detail below, in an embodiment, the other layers are firm knits (no/little stretch), moderate knits (less than 25% stretch) or stretch knits (less than 50% stretch). Should these other layers possess a dominant stretch axis that axis may be oriented generally orthogonal to the dominant stretch axis of the base layer120. As indicated by the double arrows inFIG. 1A-FIG. 1D, the first layer possesses a dominant elongation axis; accordingly, the dominant elongation axis is oriented generally orthogonal to the dominant stretch direction of the base layer120.

It is further noted that the first layer110can also have a stretch property in the same (e.g., horizontal or second) direction as the second layer120(e.g., the first layer can have four way stretch properties), but the degree of stretch for the first layer110will be less than the degree of stretch for the second layer120when in the same (e.g., parallel) direction. The orientation and degree of stretch properties for the first layer110in relation to the second layer120can also be applicable for further layers (e.g., layers130,135and140as shown in the composite material embodiments ofFIGS. 1B-1D). Thus, in example embodiments, the layers110,120,130,135,140are secured to each other in a suitable alignment or orientation such that second layer120has the greatest degree of elongation/stretch or greatest stretch property in a particular dimension (e.g., horizontal or second or width direction as shown inFIGS. 1A-1D) in relation to other layers of the formed composite material.

The layers (e.g., layer110and layer120as shown inFIG. 1A, and further layers as shown inFIGS. 1B-1D) of the composite material100are connected to each other via stitching that is patterned to guide the stretching of the composite material, such as the expansion pattern of the material100and/or the extent of material expansion. In an example embodiment, the stitches are formed via an embroidery process. In embroidery, strands are attached to the composite material100in a predetermined pattern. Referring toFIG. 2, a strand205includes a first thread215A (also called a top or needle thread) and a second thread215B (also called a bottom or bobbin thread). The threads215A,215B are generally vertically aligned. In addition, the threads215A,215B are interlocked at spaced locations along the length of the strand. Specifically, the top thread215A is secured to the bobbin thread215B (and vice versa) via a stitch225(i.e., an interlocking structure that locks the strands together). By way of example, a lockstitch (where the one strand wraps the other strand) is utilized. A lockstitch effectively secures the strands to each other, preventing unraveling of crossing yarn205. While a particular lockstitch is illustrated (an over-lock stitch), it should be understood that different means of interlocking may be utilized to provide desired load extension characteristics to the textile structure. For example, other stitches such as a tatami stitch, a triaxial fill stitch, satin stitch, running stitch, chain stitch, etc. may be utilized.

With this configuration, the top thread215A is positioned on a first exposed side of the composite material100(the first layer110), and the second thread215B is positioned on a second exposed side of the composite material (e.g., the base layer120in the package ofFIG. 1A) such that the top thread is generally aligned with the bobbin thread along the length of the strand. Specifically, the top thread215A travels along the exposed (outer/upper) surface of the first layer110(or other topmost layer), while the bobbin thread215B travels along the exposed (inner/lower) surface of the second layer120(or other bottommost layer, such as a lining layer140as described herein and depicted inFIGS. 1B-1D). At predetermined intervals, the strands215A,215B pass through the layers of the composite material100, interlock to form the stitch225, and then travel back to their respective sides of the composite material. The process is then repeated, with a resulting strand205that includes thread segments215A,215B generally aligned on opposite sides of the composite material100(i.e., the top surface pattern is in registry with the bottom surface pattern).

The distance between immediately adjacent stitches225along the length of the strand205is referred to as the stitch length SL. The stitch length SL may be any distance suitable for providing sufficient strength for the patterned stitch network as described herein. For example, the stitch length may range from about 1 mm to about 8 mm and is preferably less than about 5 mm (e.g., about 2 mm to about 2.5 mm). Stitch lengths greater than 8 mm are generally insufficient to secure the layers together, as well as provide the necessary lockout of the composite material100under load.

The strand205(i.e., the threads215A,215B) may be similar to those described above for the strands forming the base layer120, and may include single fiber, filament, or monofilament, as well as an assemblage of textile fibers having a high ratio of length to diameter and normally used as a unit (e.g. includes slivers, roving, single yarns, plies yarns, cords, braids, ropes, etc.).

In an embodiment, the top thread215A and the bobbin thread215B can be formed of the materials selected to achieve a desired strength for the patterned strand network (e.g., each strand may be formed of nylon, polyester, polyacrylic, polypropylene, polyethylene, metal, silk, cellulosic fibers (e.g., cotton), elastomers, etc.). The choice of a particular type of thread can depend upon a number of factors, including thread strength. For example, a thread formed of ultra-high molecular weight (UHMW) polyethylene can be stronger than a thread formed of nylon, which in turn can be stronger than a thread formed of polyester. In an example embodiment, the threads215A,215B comprise nylon. In another example embodiment, the threads215A,215B comprise a polyethylene material, e.g., ultra-high molecular weight polyethylene (UHMWPE). In further embodiments, the strands may be high tenacity nylon (e.g., nylon 6,6) or a polyethylene terephthalate (“PET”). The threads can have a suitable elongation value ranging, e.g., from about 20% to about 30%.

The dimensions (size/shape) of the threads215A,215B may be any suitable for its described purpose. For example, the top thread215A and the bobbin thread215B can range from M40 (70 TEX) to M80 (35 TEX). The top thread215A and the bobbin thread215B can be identical in size and composition. Preferably, the top thread21A and the bobbin thread215B differ in size and/or composition. For example, the bobbin thread215B possesses a higher TEX value and/or is formed of different material than the top thread215A. In an embodiment, the top thread215A is a M60 (45 TEX), continuous filament nylon 6,6, while the bobbin thread215B is and M122, continuous filament nylon (NYLBOND and ECOBOBS, respectively, each available from Coats Industrial (Great Britain)).

The embroidery process is utilized to form a patterned stitch or strand network within the composite material100. The embroidery may be conducted utilizing an embroidery machine available from Shanghai Tajima Embroidery Machinery Co., Ltd. The stitch network is structural, being capable of controlling the expansion pattern of the composite material100. Thus, while it permits expansion, it not only directs the movement of the expansion, as well as can limit the degree of expansion. Referring toFIG. 5(showing the first layer110of composite material100), the stitch network500defines a plurality of discrete cells510, each cell having predetermined dimensions (size and shape) and being formed by an enclosed area EA, which, in turn, is defined by a stitch perimeter or border of stitching lines/stitching rows (i.e., a pattern of straight and/or curved lines or rows formed from a plurality of stitches) for the cell. In the embodiment ofFIG. 5, the stitch network500includes an array of polygonal (e.g., arrow-shaped) cells510defined within the perimeter or boundary of stitch lines or stitch rows. The cells510have uniform size and shape, with the cells510further being organized in columns515and rows520. As shown, the arrowhead cells of one column are inverted compared to the arrowhead cells of an adjacent column. In further embodiments, the cells can have varying sizes and/or varying shapes.

In example embodiments, the stitch network500is configured to control the expansion pattern of the composite material100. In particular, as described herein (with reference toFIGS. 7A-7C), the size(s) and shape(s) of the cells510of the stitch network500may have shapes that expand and contract in a predetermined pattern, cooperating to allow and guide the expansion or contraction of the composite material100(or one or more layers of the composite material) a suitable dimension during stretching/tension of the second layer120as well as contraction of the second layer when the tension on the second layer is released. In an embodiment, the shapes and/or configuration of the cells (as defined by the stitching pattern/stitch network applied to the composite material) may be selected to create a pattern effective to lower the Poisson's ratio of the composite material (compared to the ratio the composite material would have without the array of cells).

In a further embodiment, the stitch network500that forms the cells510may be selected to provide the composite material with a negative Poisson's ratio. In other words, when stretched, the composite material and/or cells of the composite material will move or expand in a direction generally orthogonal or perpendicular to the applied tension or stretching force. This will also cause a change in the shapes of the cells, where the cells collapse along the z-axis in response to such tension or stretching force as described herein (in relation toFIGS. 4B-4D).

Lowering or imparting a negative Poisson's ratio to the composite material100can be achieved by providing a stitch network that forms cells having one or more auxetic shapes (e.g., the auxetic arrowhead shapes of cells510for stitch network500). Further still, the auxetic shapes can be formed as reentrant polygonal shapes. A reentrant polygonal shape has one or more reentrant angles, where a reentrant angle is an internal angle of the polygon that is greater than 180°. Reentrant auxetic shapes can have hinge-like features (e.g., at the reentrant angle locations of the auxetic shapes) that can cause an expansion or compression of the composite material or layer upon which the auxetic shape is formed in a direction orthogonal or perpendicular to a direction of corresponding expansion or compression of the composite material. In the embodiments described herein, hinge-like features are formed by the stitch network defining the cells510, including the strands215A,215B and the stitches225.

Any suitable type or types of auxetic patterns can be formed by the patterned strand network along the exposed sides of the composite material100. Some non-limiting examples of cell arrays formed as auxetic patterns which can be used to form cells of a composite material are depicted inFIGS. 6A-6D. Referring toFIGS. 6A and 6B, stitch networks605,610are shown along a composite material forming cells having an arrowhead auxetic shape that is similar in shape and pattern configuration as the stich network500of cells510depicted inFIG. 5. Other examples of auxetic cell shapes that can be provided for a composite material are shown by the stitch patterns615,620,625inFIGS. 6C, 6D and 6E(e.g., hour glass shaped auxetic cells for stitch patterns615,620, and wavy shaped auxetic cells for stitch pattern625).

It should be understood, however, that other enclosed cell shapes may be utilized in forming the stitch network. For example, non-auxetic polygonal cells may be utilized.

An example method of forming the composite material100is now described with reference to the flow diagram ofFIG. 3and the schematic cross-sectional views ofFIGS. 4A, 4B and 4C. In operation, first layer110and second layer120are obtained. At Step310, the resilient second layer120(also called the base layer) is placed under tension and stretched to a suitable elongation value (e.g., stretched along at least one axis to an elongation value of at least 150%). At step320, the first layer110, which is not tensioned, is then positioned over the tensioned second layer120, as depicted inFIG. 4A. At step330, the layers110,120are then connected, e.g., via embroidery as described herein, with stitch sites425(i.e., locations at where stitches225are to be formed) being defined along the surface areas of layers110,120. SeeFIG. 4B. As noted above, embroidery of the stitches225creates the stitch network500along the composite material100so as to define a pattern of stitched cells510along the composite material. After formation of the stitch network500, at step340, the tension on the second layer120is released, allowing the resilient layer to recover, returning to its normal, unstretched state. SeeFIG. 4C. Once the composite material is in its normal, unstretched state, it may be incorporated into an article of apparel (step350) in a manner similar to other textile structures.

As depicted inFIG. 4C, release of the tension allows the second layer120to recover substantially or entirely, contracting along the x and/or y axes to an original, normal or unstretched position. The first layer110, being non-stretch or a lower stretch (i.e., having a lower elongation value) along the axis on which tension to the second layer was applied, causes one or more of the cells510of the stitch network500to buckle or pucker, moving away (along a Z dimension or axis from the surface area (which defines a generally two dimensional surface area in X and Y dimensions or axes) of the second layer120as the second layer contracts to its relaxed/original state. In particular, in the relaxed state of the second layer120, the first layer110forms a buckled or undulating surface pattern in the Z dimension way from the underlying second layer120, where the pattern of stitches225formed in the composite material100secure the first layer110to the second layer along the stitch network500. Thus, the cells510formed by the process of steps310-350protrude from the surface of the underlying second layer120when the second layer is in a relaxed (unstretched) state. Accordingly, voids470(e.g., air spaces) are defined within pockets of the buckled cells510(i.e., the spacing or volume between the buckling first layer110and the relatively flat or unbuckled second layer120within each cell510).

Thus, the composite material includes a series of protruding pockets formed by the first layer110being separated from the second layer120within each cell510. The overall pattern of the pockets, moreover, is defined by the stitch pattern or network500. Referring again toFIG. 5, the resulting composite fabric material100(in its unstretched state) includes an uneven surface, where layer110forming each cell510is buckled or puckered, extending away from the second layer120along the z axis or direction orthogonal to the surface of the second layer (seeFIG. 4B). Each cell510is defined and bordered by stitching (shown via top thread215A). The area within the border protrudes outward, thereby separating the first layer110from the second layer120within the border. With this configuration, a composite material100including an array of cells510is formed. The shape of the protruding cells or pockets, moreover, matches the shape of the original stitch network cells.

With this configuration, a composite material100provides a dynamic textile that that repeatedly stretches under load and recovers upon removal of the load. In particular, the stretch properties of the second layer120allow for a certain amount of overall stretch for the composite material under load and, upon removal of the load, further drives the entire composite back to its normal, unstretched state. As depicted inFIGS. 7A, 7B and 7C, the composite material100begins in its normal, unstretched configuration.FIG. 7A. Here, the distance (dmax) between the base layer and the highest point of the protruding cell is at its maximum value. Similarly, the void volume of the void470is at its maximum.

Applying a tension or load (e.g., along the dominant stretch direction of the base layer120(the x-axis)) to the composite material100causes stretching of the second layer120in the directions indicated by the arrows.FIG. 7B. This results in a corresponding splaying or collapse of the first layer cells110in the Z direction (indicated by arrow z) toward the second layer120. As the cells510collapse or flatten the distance dintbetween the highest point of the cell510(as defined by outer layer) decreases, as does the void volume of the cell voids470. Continued application of tension or load stretches of the composite material results in further until full or complete collapse and flattening of the cells510results, as seen inFIG. 7C. At this degree of tension, the distance dminis at a minimum, with the outer layer110generally contacting (e.g., nearly contacting or continuously contacting) the base layer120; accordingly, the void volume of each cell void470at its minimal level and the composite material significantly flattens.

This collapse or flattening of the cells510during stretching of the second layer120enhances stretching of the composite material during cell collapse until the cells lock down or lock out (e.g., completely flatten) so as to prevent further expansion of the composite material in the area of the flattened cells. This becomes a lock down or a lock out position or static state at which the composite fabric is prevented from further movement.

As shown, at an original or initial relaxed condition of the composite material (FIG. 7A), the cells510are buckled to their full extent in the “Z” direction (i.e., greatest separation between first layer110and second layer120for each cell510) and are in a dynamic state. As the composite material100is stretched at any location in the indicated direction, the elongation of the base layer120causes the cells510to flatten by collapsing driving the pliable layer110toward the base layer, thereby reducing the volume of the voids470within the cells510(as shown, e.g., inFIGS. 7B and 7C). Similarly, any layers140positioned on the opposite side of the base layer similarly begin buckled and then flatten as load is applied on the composite fabric (e.g., in the direction of the dominant stretch axis of the base layer120) as seen best inFIG. 13.

Upon release of the tension on the composite material100, the composite material contracts back to its relaxed (e.g., original) dimension and the cells510buckle outward and away from the second layer120to their original positions as depicted inFIG. 7A. The cells510therefore exhibit a dynamic or loaded state in which the cells are capable of movement along the z-axis (e.g., as shown inFIGS. 7A and 7B) and a degree of stretching movement of the composite material, and the cells510further exhibit a static state (FIG. 7C) when the cells are fully flattened or collapsed toward the second layer120so as to lock the portion of the composite material100including the fully flattened cells in place and prevent further stretching movement of this portion of the composite material.

Due to the stitching process (e.g., embroidery), the patterned strand network is identical and precisely aligned on each of the exposed sides of the composite material100. Due to its formation, each cell510is further capable of flattening or splaying when subjected to a load force, where each cell can completely flatten independent of other cells due to each cell being independently locked in position in relation to the second layer120due to the stitching that surrounds the cell. Thus, depending upon a localized tension applied to a first portion of the composite material100, an area defined by the first portion can exhibit varying degrees of movement and stretch, with corresponding flattening (e.g., to lockdown) of cells when the tension is applied to the first portion while a second portion of the composite material that is not subjected to the localized tension does not exhibit stretching or collapsing action of the cells within the area defined by the second portion.

The collapse of cells510and stretching of the composite material to lock out can be further enhanced by orienting the auxetic shapes of cells in relation to a dimension of stretch of the second layer120during formation of the composite material. In an example embodiment, a stitched network500of cells510having auxetic polygonal shapes with reentrant angles (e.g., arrowhead auxetic shapes, hourglass auxetic shapes, etc.) is formed (step330) along the layers110,120such that at least one reentrant angle of the auxetic shapes is oriented in a direction that is transverse (e.g., orthogonal) in relation to the dimension of dominant stretch of the tensioned second layer. Such an orientation of auxetic shapes for the cells in relation to the greatest elongation potential for the second layer in the composite material can facilitate a suitable degree of stretch of at least a portion of the composite material and sufficient cell movement until cell lockout is achieved (i.e., full flattening or full collapse of the cells).

An example embodiment for implementing the composite material100within an upper of an article of footwear (i.e., a shoe) is now described with reference toFIGS. 8 and 9. Referring toFIG. 8, an upper for a shoe can be formed with a upper material700that includes at least layers110and120, where layer110forms an outer surface of the upper. The process flow chart described herein and depicted inFIG. 3can be used to form the upper material700, where first (outer) layer110is first cut as a blank to form the shape of the upper when secured with the second layer120. In particular, the first layer110includes a first (e.g., lateral) side705that will form the lateral side of the shoe upper and a second (e.g., medial) side710that will form the medial side of the upper, a front or toe end715and a rear or heel end720that will respectively form the toe and heel ends of the upper when combined with a sole structure to form a shoe (e.g., as depicted inFIGS. 8A, 8B and 8C). A cut-out portion of the heel end720will define the neck opening for the upper when the composite material700is combined with a sole structure. After completing process steps310-350, the composite material700can be cut out along the perimeter/edges of first layer110(thus removing excess portions of layer120) to form the upper material that will combine with a sole structure to form a shoe.

In certain embodiments (e.g., depending upon the material cost of the first layer), it may be desirable to obtain precise dimensions for the first layer110prior to securing to the second layer so as to ensure the first layer is sufficiently sized to fit the final dimensions of the upper. In this case, a material that forms the first layer can be pulled over a shoe last or other structural form to expand slightly under tension and simulate the final dimensions required for the upper, where the first layer110is then cut to the precise dimensions while the material remains pulled over the shoe last (thus defining the shape of first layer110inFIG. 8).

When the composite material100,700is utilized in forming the upper of a shoe (FIG. 9A), the composite material adapts to the dimensions (shape and/or size) of the user's foot. This adaption occurs not only while the user dons or doffs the shoe, but also during active use of the shoe (e.g., during sports or other physical activities), permitting selective expansion of the upper (the composite material100,700) based on load conditions. Under load, the cells510splay out or expand until they flatten, at which point the cell locks out, preventing further expansion of the fabric in that area.

Further, when the shapes of the cells510are aligned in a particular direction of the upper/shoe in relation to the dominant stretch direction of the second layer120(i.e., direction or dimension of the second layer having the greatest or maximum elongation value), further enhancement can be achieved with regard to the expansion and lockout features of the upper imparted by the dynamic movement (flattening/collapsing) of the cells during use of the shoe. For example, the composite material100,700can be integrated as part of the upper so as to align or orient the second layer120such that the dominant stretch dimension for the second layer is aligned in a direction transverse the length or toe-to-heel dimension of the upper and shoe (i.e., in a direction extending the width or medial-to-lateral side dimension of the upper and shoe). In such embodiments, the composite material100,700can also be integrated as part of the upper such that one or more reentrant angles for auxetic shapes of the cells510of the composite material are aligned in the length (toe-to-heel) dimension of the upper and shoe.

In further embodiments, the composite material100,700for the upper may include additional layers depending on the desired end use. Example embodiments of further composite materials are depicted inFIGS. 1B, 1C and 1D. As shown, the composite materials100A,100B,100C,100D are similar to composite material100ofFIG. 1Ain that each comprises the pliable, first or outer layer110and the second or resilient, stretch layer120. As noted above, the first or outer layer110may be formed of any material suitable for its described purpose. For example, the first layer may be knit fabric, a woven fabric, a film or a nonwoven web. The first layer110also has a suitable thickness to facilitate bending or buckling as well as stretch/lockout features for the cells510in the manner described herein. By way of example, the first layer110can have a thickness no greater than about 2 mm (e.g., a thickness of no greater than 1 mm, or less than 1 mm). In an example embodiment, the pliable first layer110can comprise a synthetic leather material having a thickness of about 0.5 mm to about 1.5 mm, such as 0.8 mm. The other layers described herein for the different embodiments of the composite materials (layers120,130,135,140) can have thickness in a similar range (about 0.5 mm to about 2.0 mm). Each layer can further have a suitable basis weight that renders the layer, when combined with one or more other layers to form the composite material, suitable for achieving the features of the stitched network of cells for the composite material. For example, the basis weight for one or more layers can be in the range from about 80 g/m2to about 150 g/m2or greater.

As previously noted, the resilient second layer120may be a four way stretch fabric. A dominant degree of stretch or elongation (elongation value) of the second layer120in one dimension is at least about 50%, and the second layer120can be oriented within the composite material100such that its dominant degree of elongation is in the second (width) direction of the composite material100. The resilient second layer120can be a fabric formed from at least about 50% elastic strands. In an embodiment, the second layer120is a knit layer that includes at least about 50% elastane strands, e.g., at least about 60% elastane strands (e.g., about 68% elastane strands). A fabric with 60+% elastane strands possesses high stretch or elongation properties, such as a maximum elongation of at least 50%. This fabric also exhibits high recovery properties (i.e., ability to recover or contract a length that is some percentage of original length/width after stretch or tension is removed from the fabric), e.g., recovery in both the first and second directions of greater than about 50%, or even about 90% or greater. Thus, the second layer120has a greater degree of elongation in at least the width direction (and, e.g., in the width and length directions) in relation to the first layer110.

In addition, the composite material can include one or more further layers, including one or more intermediate layers that are between the first layer110and the second layer120and/or one or more inner or outer layers that are not between but instead located to one side of the first layer110or the second layer120. In the example embodiment ofFIGS. 1B and 1C, the composite material100B,100C includes an intermediate reinforcement layer130disposed between the first layer110and the second layer120(e.g., along an outer facing side of the second layer120). In addition, an inner or lining layer140may be disposed adjacent the second layer120(on an opposing side of the second layer). The composite material100C may further include a second reinforcement layer130oriented between the second layer120and the first layer110. Alternatively, the composite material100D may include a spacer reinforcement layer135oriented between the second layer120and the reinforcement layer130as shown inFIG. 1D.

In general, the layers (other than the first layer110and the second layer120) can be selected so that, while flexible, they are generally non-stretch and/or non-recovery textiles. By way of example, the layers may be fabrics having a maximum elongation or stretch of less than 30% and preferably less than 10%. Stated another way, while the textile may include small amounts of mechanical stretch, the textile includes no elastic stretch. By way of specific example, the reinforcement layer130may be a rigid tricot knit fabric formed of 100% hard/inelastic yarn such as nylon. The spacer fabric135(which can provide airflow and/or cushioning to the structure) is similarly a low or no stretch material formed completely of a hard yarn such as polyester. Finally, the lining layer140is a knit layer formed entirely of hard yarns such as polyester.

In each composite material package illustrated inFIGS. 1B-1D, the second layer120possesses a dominant stretch or elongation value that is oriented orthogonal to the dominant stretch dimension of the reinforcement layer130, the spacer layer135, the lining layer140, and the first layer110, as indicated by the arrows (i.e., the arrow is aligned in a horizontal or second direction for layer120, and the arrows are aligned in a vertical or first direction for layers110,130,135,140). In addition, to the extent any of layers110,130,135,140has some degree of elongation in the horizontal (second) direction (i.e., the same direction as the dominant stretch direction for the second layer120), the elongation values for these layers in the horizontal direction is significantly less than the elongation value for the second layer120in its dominant stretch dimension.

In still further embodiments, the various layers as depicted in the embodiments ofFIGS. 1A-1Dcan be oriented in relation to each other based upon the warp or weft direction of each textile layer. A warp direction for a textile refers to the orientation of threads or yarns that run the length of a continuous roll of fabric, where the warp direction also refers to the machine direction of the formed textile. The weft direction of the textile is transverse to the warp or machine direction (i.e., the cross direction of the textile). When the composite materials100,100B,100C,100D depicted inFIGS. 1A-1Dare used to form an upper for a shoe using the methods as described herein, the machine direction corresponds with the length (toe-to-heel) dimension of the shoe. The first layer110and the second layer120can each be oriented in the warp (toe-to-heel) direction, the reinforcement layer130and the spacer layer135can be oriented in the weft (lateral to medial side) direction, and the lining layer140can be oriented in the warp (toe-to-heel) direction. In such embodiments, the second layer120preferably has a dominant stretch or elongation value (e.g., an elongation value of greater than 50%, or even greater than 100%, and as great as 160%) that is in the weft direction of the second layer.

As with the composite material100described forFIG. 1A, an embroidery process can be used to connect some or all of the layers together as depicted inFIGS. 1B-1D, as well as form the patterned stitch network. In other words, when forming the composite materials100A,100B,100C, the second or stretch layer120is placed under tension while the remaining layers110,130,135,140are not. The layers can be stitched together via stitches225(e.g., via embroidery) and, after formation of the patterned strand network, the tension on the second layer120can be released according to the process steps as described herein with reference to the flowchart ofFIG. 3. This release in tension on the second layer120allows the second layer120to relax and recover/contract back to (or close to) its original dimension along the first direction of the composite material100A,100B,100C. Since the first layer110and any other further layers have been secured (via stitches225) to the second layer120while the second layer120was stretched, the contraction of the second layer120results in a bending, bowing or buckling outward (i.e., in a “Z” dimension of the composite material) of these layer(s) in relation to the second layer120and further at the areas between enclosed shapes defined by the stitching patterns.

Similar to the cells510of the composite material100, the buckling forms pockets or cells along the exposed sides of the composite materials100A,100B,100C where the cells are defined by at least the first layer110and/or any other layers130,135,140bowing outward or buckling on either side of the second layer120within the areas defined between the stitched shapes. The second layer120remains relatively flat or unbuckled. Voids (e.g., air spaces)470are also defined within the pockets of the buckled cells (i.e., the spacing or volume between the buckling layers and the relatively flat or unbuckled second layer120). Furthermore, each cell is capable of flattening or splaying when subjected to a load force, where each cell can completely flatten independent of other cells due to each cell being independently locked in position in relation to the second layer120due to the stitching that surrounds the cell.

In some embodiments, it may be desirable to add a further layer to the composite material after performing the process steps ofFIG. 3. For example, in an embodiment in which it is desirable to add a lining layer140to an underside of the second layer120, where the lining layer forms an interior surface of the composite material (e.g., for a shoe upper) and may be in contact with the wearer. As seen best inFIG. 13, when the composite material100B is in its normal, unloaded state, the cells510of the lining layer140protrude from the surface of the base layer120, creating a void or pocket470. Under load, moreover, the cells510of the lining layer collapse until lockout (e.g., full, continuous contact with the base layer120).

The different embodiments of component materials100,100B,100C,100D depicted inFIGS. 1A-1Dcan be utilized to obtain different performance characteristics for an intended purpose or specific application (e.g., based upon a particular sport, such as football, soccer, baseball, etc.). For example, providing one or more reinforcement layers130and/or a reinforcement layer130and a spacer layer135to the component material including the first and second layers110,120can enhance the puncture resistance of the component material (e.g., when integrated within a shoe upper) and/or increase the tear strength or other properties of the material.

In a further embodiment, a laminate film can be adhered (e.g., via a heat press method) to the outer surface of layer110so as to provide a thin synthetic “skin” film over the upper outer surface. The laminate film is very thin and can have a thickness that is less than the thickness of layer110(e.g., about 0.2 mm to about 0.3 mm) so as to still permit dynamic movement of the cells510during physical activities when the shoe is worn. The synthetic “skin” film can provide a protection layer over the upper (e.g., to provide moisture barrier or resistance properties, enhanced puncture resistance, etc. for the upper).

Referring toFIGS. 9A, 9B and 9C, an article of footwear or shoe800is depicted including an upper with the composite material700integrated as some or all of the upper (where material can comprise composite material100or any of the other composite materials100B,100C,100D as described herein). The shoe800defines a longitudinal shoe axis LA dividing the shoe into lateral L and medial M sides. The shoe800includes an upper805and a sole structure810spanning heel815A, midfoot815B, and forefoot815C sections of the shoe. The shoe800can be in the form of a running shoe or other type of athletic shoe. The sole structure810of the shoe800can include a midsole and an outsole that are separately formed of any one or more suitable materials and can include any suitable number (one or more) of layers for a particular application of use for the shoe. The medial side M is oriented along the medial or big toe side of the user's foot and the lateral side L is oriented along the lateral or little toe side of the user's foot (the medial and lateral sides being distinguished by a central, longitudinal axis LA). The forefoot section815C includes the toe (i.e., front) end (also referred to as a toe cage or toe box) that corresponds with the toe end of the user's foot, and a heel (i.e., rear) end that corresponds with the heel of the foot. The upper805defines a cavity between the medial and lateral sides and the toe and heel ends such that, when secured to a portion of the sole structure810, the upper receives, covers and protects the foot within the cavity. The upper805further includes an instep positioned between the lateral side and the medial side, where the instep extends over the instep of the foot and can a tongue (where a fastener, such as a shoe lace, can be disposed at the instep to cinch or secure the lateral and medial sides as well as other portions of the upper together to tighten around a user's foot when placed within the cavity of the upper).

The composite material100(which includes a plurality of material layers and is formed in a manner as described herein) can be integrated at any one or more locations along the upper at the lateral and/or medial side, at the instep, at the toe end and/or at the heel end. The composite material100can be integrated into the upper805at any one or more suitable locations. In example embodiments, the composite material100,700can be used to form a substantial portion of the upper, with cells510that cover a substantial portion (e.g., some or all) of the lateral, medial, front and heel sides as well as the instep portion of the upper. It is understood that the lateral side705, medial side710, toe end715and heel end720of the composite material700, when used to form the upper805, respectively correspond with the lateral side L, medial side M, toe end at the forefoot section815C, and heel end at the815A of the upper and shoe.

In the example embodiment depicted inFIGS. 9A-9C, a shoe with an upper is depicted in which a significant portion of the upper is formed with a composite material100that provides cells510having auxetic shapes along the upper. Any suitable laminate film and/or printed material (e.g., printed design patterns) can also be provided along selected portions of the exterior surface of the composite material. For example, printed design patterns (or laminate film portions) can be provided at locations within cells510along the upper. The additional material provided along the exterior surface of the upper and within the cells can provide a pleasing aesthetic effect for the upper (e.g., by providing elaborate or other designs within cell locations). The additional material can provide a further functional effect for the upper for a particular application (e.g., to provide waterproofing, shielding protection for the foot of the wearer, abrasion resistance and/or further strengthening to portions of the upper at certain cell locations). As previously noted herein, a very thin laminate film can be provided to form a synthetic “skin” layer over the outer surface of the upper (e.g., to provide a protective outer layer or covering for the upper).

The composite material100can be implemented/integrated with the upper such that the expansion or stretch axis SA or direction of the composite material (i.e., the dimension of dominant stretch for the second layer120) is oriented transversely across the upper (transverse to the longitudinal axis LA, or from the lateral side L to the medial side M of the shoe). Accordingly, tension applied along the cell array in the transverse direction (along stretch axis SA) will cause the cells to splay/flatten as conditions warrant. Tension or load applied along the longitudinal axis LA, however, will have little to no effect on the expansion of the composite material. Further, the shapes of the cells510can be oriented such that at least some (e.g., most) of the stitch lines of the stitch network500are oriented in the direction of the longitudinal axis LA (i.e., in the toe-to-heel direction) of the upper. Further, cells510having auxetic shapes can be oriented such that reentrant angles of the auxetic shapes are aligned in the same direction as the longitudinal axis LA (i.e., a toe-to-heel dimension of the shoe) and thus transverse the stretch axis SA of the composite material.

Utilizing the composite material100to form some portion of the upper provides features to the upper including durability and an improved fit over the user's foot, because the stretch of the upper can be adapted to the individual user's foot. In particular, each cell510of the composite material100stretches and/or collapses only as far as is needed for the given area of the foot. This expansion characteristic imparted to the upper by the composite material applies not only when the user puts on the shoe, but also as he or she moves along a surface. The composite material100is further dynamic, adjusting to load conditions as the user moves, but where the cells510never collapse beyond their lockout dimensions (i.e., the dimensions of the patterned stitching surrounding each cell). In particular, when the cells510are in a dynamic state, the cells are capable of collapsing when the composite material is stretched and the cells are further capable of buckling or expanding in the “Z” direction from the second layer120when the stretch or tension on the composite material100is released. The cells are further in a static state when the cells collapse to a lockout position (e.g., as depicted inFIG. 7C) in which further expansion of the composite material is limited.

The above described embodiments of the composite material can also be used with or implemented in other types of articles of apparel. For example, the composite material100can be implemented for use in a brassiere, a shirt, pants, or other types of clothing.

Referring toFIGS. 10A and 10B, a brassiere, also referred to as a sports bra900, is depicted that includes a composite material905integrated within the textile material of the bra. The composite material905is similar to the composite material100as described herein and includes a first layer110and a second layer120. The stitch network used to form cells in the composite material905of the bra900defines cells having auxetic shapes similar to those depicted inFIG. 6C(hour glass auxetic shapes).

The bra900includes a body and a pair of shoulder straps915extending from a front portion910to a rear portion920. The front portion910is configured to generally span the front of the wearer's torso, while the rear portion920is configured to generally span the rear of the wearer's torso. The front and rear portions connect with each other via wing portions922that span either side of the wearer (under the arm). A neckline930extends along the front portion910between the shoulder straps915. A bottom or under band940extends along the bottom edge of the body between the front and rear portions and is configured to encircle the torso of the wearer. A cup area950continuously spans the front portion110and is aligned and configured to span the breasts of the wearer. The cup area950can further include one or more pockets in which pads may be fitted to align with the breasts of the wearer (in order to provide comfort to the wearer when the bra is worn).

The composite material905can be integrated in the bra at any one or more suitable locations. Other portions of the bra that may not include the composite material can be formed of any textile materials suitable for a bra and formed via any suitable method and including any suitable one or more types of fibers or strands (e.g., elastic strands, non-elastic strands, polyester strands, nylon strands, etc.) such as the types described herein for forming the different layers of the composite material. In an example embodiment (as depicted inFIGS. 9A and 9B), the composite material905is integrated at the cup area950to enhance stretching, fit and comfort of the bra for the wearer. The dynamic action and static lockout action of the cells formed in the composite material905at a location where the composite material is stretched is similar to that described for the composite material500and depicted inFIGS. 7A-7C.

In another embodiment depicted inFIG. 11, an article of apparel that implements the composite material905is in the form of an upper body garment or shirt1000(e.g., an athletic shirt). The shirt1000includes a torso section1010(to fit around the torso of the wearer) and two arm sleeve sections1020(to fit around the arms of the wearer). The composite material905can be implemented at any portion of the shirt. For example, the composite material905can be used to form one or more portions of either arm sleeve section1020and/or the torso section1010. The composite material905can further form a substantial portion of the shirt. Other portions of the shirt that may not include the composite material can be formed of any textile materials suitable for a shirt and formed via any suitable method and including any suitable one or more types of fibers or strands (e.g., elastic strands, non-elastic strands, polyester strands, nylon strands, etc.) such as the types described herein for forming the different layers of the composite material. The composite material905integrated in the shirt1000can provide enhanced stretching, fit and comfort for the wearer, where dynamic action and static lockout action of the cells formed in the composite material905at a location where the composite material is stretched is similar to that described for the composite material500and depicted inFIGS. 7A-7C.

In a further embodiment depicted inFIG. 12, an article of apparel that implements the composite material905is in the form of lower body garment1100(e.g., leggings, pants or shorts). The lower body garment1100includes a main torso section1110that is configured to extend around the waist, hip and/or upper thigh regions of the wearer, and further two leg sleeve sections1120that extend from the main torso section1110and are configured to extend around some portion of the legs of the wearer. An elastic band1130can further be provided at an upper edge of the garment1100around the main torso section1110. The composite material905can be implemented at any portion of the lower body garment. For example, the composite material905can be used to form one or more portions of either leg sleeve section1120and/or the main torso section1110. The composite material905can further form a substantial portion of the lower body garment. Other portions of the lower body garment that may not include the composite material can be formed of any textile materials suitable for a lower body garment and formed via any suitable method and including any suitable one or more types of fibers or strands (e.g., elastic strands, non-elastic strands, polyester strands, nylon strands, etc.) such as the types described herein for forming the different layers of the composite material. The composite material905integrated in the lower body garment1100can provide enhanced stretching, fit and comfort for the wearer, where dynamic action and static lockout action of the cells formed in the composite material905at a location where the composite material is stretched is similar to that described for the composite material500and depicted inFIGS. 7A-7C.

Other embodiments incorporating a composite material as described herein are also possible. For example, any textile material product can incorporate the composite material as described herein to enhance the stretchable properties of the product.

For example, while the example embodiments depicted in the figures show an article of footwear (shoe) configured for a right foot, it is noted that the same or similar features can also be provided for an article of footwear (shoe) configured for a left foot (where such features of the left footed shoe are reflection or “mirror image” symmetrical in relation to the right footed shoe).

The composite material can be implemented in any textile article to enhance stretchability of the composite material at one or more locations independent of other locations of the material. The composite material includes at least one resilient layer capable having an elongation value in a dominant stretch dimension of the resilient layer that is at least 50%, preferably at least 100% or greater. One or more layers are secured to the resilient layer such that any degree of stretch associated with such layer(s) along the same dimension of the composite material that corresponds or is parallel with the dominant stretch dimension of the resilient layer will have an elongation value that is less than the elongation value of the resilient layer in its dominant stretch dimension.

The stitch network used to form cells can be formed via embroidery or any other suitable stitching process. The cells forming by the stitch network along layers of the composite material can have any suitable shapes depending upon a particular application for the composite material. In particular, while auxetic shapes can be useful for certain applications, other enclosed shapes for the cells formed by the stitch network are also possible (e.g., enclosed circles or enclosed oval patterns, intersecting wavy line patterns, etc.).

The stitch network along a composite material can also include cells having different shapes and/or different sizes at different areas of the composite material. For example, a stitch network can be provided along a composite material used to form an article of apparel (e.g., an upper of a shoe) that includes a first pattern of cells having a first shape (e.g., arrowhead auxetic shapes) at a first area of the composite material and a second pattern of cells have a second shape (e.g., hourglass auxetic shapes) at a second area of the composite material.

It is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. It is to be understood that terms such as “top”, “bottom”, “front”, “rear”, “side”, “height”, “length”, “width”, “upper”, “lower”, “interior”, “exterior”, and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration.