Patent Publication Number: US-9427047-B2

Title: Methods of manufacturing articles of footwear with tensile strand elements

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a division of U.S. patent application Ser. No. 13/404,483, filed on Feb. 24, 2012 and entitled “Methods Of Manufacturing Articles Of Footwear With Tensile Strand Elements”, the disclosure of which application is entirely incorporated herein by reference. 
    
    
     BACKGROUND 
     Articles of footwear generally include two primary elements: an upper and a sole structure. The upper is often formed from a plurality of material elements (e.g., textiles, polymer sheet layers, polymer foam layers, leather, synthetic leather) that are stitched or adhesively bonded together to form a void within the footwear for comfortably and securely receiving a foot. More particularly, the upper forms a structure that extends over instep and toe areas of the foot, along medial and lateral sides of the foot, and around a heel area of the foot. The upper may also incorporate a lacing system to adjust fit of the footwear, as well as permitting entry and removal of the foot from the void within the upper. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability and comfort of the footwear, and the upper may incorporate a heel counter for stabilizing the heel area of the foot. 
     The sole structure is secured to a lower portion of the upper and positioned between the foot and the ground. In athletic footwear, for example, the sole structure often includes a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces (i.e., provides cushioning) during walking, running, and other ambulatory activities. The midsole may also include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot, for example. In some configurations, the midsole may be primarily formed from a fluid-filled chamber. The outsole forms a ground-contacting element of the footwear and is usually fashioned from a durable and wear-resistant rubber material that includes texturing to impart traction. The sole structure may also include a sockliner positioned within the void of the upper and proximal a lower surface of the foot to enhance footwear comfort. 
     SUMMARY 
     An article of footwear may have an upper and a sole structure secured together. The upper includes at least two material layers and a plurality of strand segments. The material layers are located adjacent to each other and in an overlapping configuration, and the material layers are located in (a) a lace region that includes a plurality of lace-receiving elements and (b) a lower region proximal to an area where the sole structure is secured to the upper. The strand segments extend from the lace region to the lower region. In some configurations, the strand segments are located and secured between the material layers in the lace region and the lower region. In some configurations, the strand segments form both an exterior surface of the upper and an opposite interior surface of the upper in an area between the lace region and the lower region. In some configurations, the material layers define an opening between the lace region and the lower region, and the strand segments extend across the opening. Various example methods for manufacturing a tensile strand element of the upper are also disclosed. 
     In another configuration, an upper for an article of footwear includes a plurality of material elements and strand segments. The material elements are joined together to define a lace region and a lower region. The material elements include a base material layer located in at least the lace region The base material layer has a first surface and an opposite second surface, and the base material layer defines an aperture of a lace-receiving element that extends from the first surface to the second surface in the lace region. The lower region is spaced from the lace region and located proximal to an area where the sole structure is secured to the upper. The strand segments extend from the lace region to the lower region and include a first strand segment and a second strand segment. The first strand segment is located adjacent to the first surface of the base material layer and extends at least partially around the aperture. The second strand segment is located adjacent to the second surface of the base material layer and extends at least partially around the aperture. 
     A method of manufacturing an article of footwear includes locating a strand adjacent to a surface of a base material layer, with the strand extending from a first area of the base material layer to a second area of the base material layer. The strand is secured to the base material layer. The strand and the base material layer are incorporated into a footwear upper, with the first area being located in a lace region of the upper and the second area being located in a lower region of the upper. The lower region is spaced from the lace region and located proximal to an area for securing a sole structure to the upper. 
     The advantages and features of novelty characterizing aspects of the invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying figures that describe and illustrate various configurations and concepts related to the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing Summary and the following Detailed Description will be better understood when read in conjunction with the accompanying figures. 
         FIG. 1  is lateral side elevational view of an article of footwear. 
         FIG. 2  is a medial side elevational view of the article of footwear. 
         FIGS. 3A-3C  are cross-sectional views of the article of footwear, as defined by section lines  3 A- 3 C in  FIG. 2 . 
         FIG. 4  is a plan view of a tensile strand element from the article of footwear. 
         FIGS. 5A and 5B  are perspective views of portions of the tensile strand element, as defined in  FIG. 4 . 
         FIGS. 6A and 6B  are exploded perspective views of the portions of the tensile strand element, as defined in  FIG. 4   
         FIGS. 7A-7C  are cross-sectional views of the tensile strand element, as defined by section lines  7 A- 7 C in  FIG. 4 . 
         FIG. 8  is a schematic perspective view of a portion of a strand from the tensile strand element. 
         FIGS. 9A-9E  are lateral side elevational views depicting further configurations of articles of footwear. 
         FIGS. 10A-10D  are plan views depicting further configurations of tensile strand elements. 
         FIG. 11  is a perspective view of a portion of the tensile strand element, as defined in  FIG. 10D . 
         FIG. 12  is an exploded perspective view of the portion of the tensile strand element, as defined in  FIG. 10D . 
         FIGS. 13A and 13B  are perspective views corresponding with  FIG. 5A  and depicting further configurations of the tensile strand element. 
         FIGS. 14A-14J  are schematic perspective views depicting a first example process for manufacturing a tensile strand element. 
         FIGS. 15A-15H  are schematic perspective views depicting a second example process for manufacturing a tensile strand element. 
         FIGS. 16A-16K  are schematic perspective views depicting a third example process for manufacturing a tensile strand element. 
         FIG. 17  is a schematic perspective view corresponding with  FIG. 16G  and depicting a variation of the third example process for manufacturing a tensile strand element. 
         FIGS. 18A-18G  are schematic perspective views depicting a fourth example process for manufacturing a tensile strand element. 
     
    
    
     DETAILED DESCRIPTION 
     The following discussion and accompanying figures disclose various articles of footwear having uppers that include tensile strand elements. The articles of footwear are disclosed, for purposes of example, as having configurations of running shoes, sprinting shoes, and basketball shoes. Concepts associated with the articles of footwear, including the uppers, may also be applied to a variety of other athletic footwear types, including baseball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, golf shoes, soccer shoes, walking shoes, hiking boots, ski and snowboard boots, and ice and roller skates, for example. The concepts may also be applied to footwear types that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. The concepts disclosed herein apply, therefore, to a wide variety of footwear types. 
     General Footwear Structure 
     An article of footwear  10  is depicted in  FIGS. 1 and 2  as including a sole structure  20  and an upper  30 . Sole structure  20  is secured to a lower area of upper  30  and extends between upper  30  and the ground. Upper  30  provides a comfortable and secure covering for a foot of a wearer. As such, the foot may be located within upper  30 , which effectively secures the foot within footwear  10 , and sole structure  20  extends under the foot to attenuate forces, enhance stability, or influence the motions of the foot, for example. Additional details of footwear  10  are depicted in the cross-sectional views of  FIGS. 3A-3C . 
     For purposes of reference in the following discussion, footwear  10  may be divided into three general regions: a forefoot region  11 , a midfoot region  12 , and a heel region  13 . Forefoot region  11  generally includes portions of footwear  10  corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region  12  generally includes portions of footwear  10  corresponding with an arch area of the foot. Heel region  13  generally corresponds with rear portions of the foot, including the calcaneus bone. Footwear  10  also includes a lateral side  14  and a medial side  15 , which extend through each of regions  11 - 13  and correspond with opposite sides of footwear  10 . More particularly, lateral side  14  corresponds with an outside area of the foot (i.e. the surface that faces away from the other foot), and medial side  15  corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). Regions  11 - 13  and sides  14 - 15  are not intended to demarcate precise areas of footwear  10 . Rather, regions  11 - 13  and sides  14 - 15  are intended to represent general areas of footwear  10  to aid in the following discussion. In addition to footwear  10 , regions  11 - 13  and sides  14 - 15  may also be applied to sole structure  20 , upper  30 , and individual elements thereof. 
     Sole structure  20  includes a midsole  21 , an outsole  22 , and a sockliner  23 . Midsole  21  is secured to a lower surface of upper  30  and may be formed from a compressible polymer foam element (e.g., a polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) when compressed between the foot and the ground during walking, running, or other ambulatory activities. In further configurations, midsole  21  may incorporate fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot, or midsole  21  may be primarily formed from a fluid-filled chamber. Outsole  22  is secured to a lower surface of midsole  21  and may be formed from a wear-resistant rubber material that is textured to impart traction. Sockliner  23  is located within upper  30 , as depicted in  FIGS. 3A and 3B , and is positioned to extend under a lower surface of the foot. Although this configuration for sole structure  20  provides an example of a sole structure that may be used in connection with upper  30 , a variety of other conventional or nonconventional configurations for sole structure  20  may also be utilized. Accordingly, the structure and features of sole structure  20  or any sole structure utilized with upper  30  may vary considerably. 
     Upper  30  may be formed from a variety of elements that are stitched, bonded, or otherwise joined together to form a structure for receiving and securing the foot relative to sole structure  20 . As such, upper  30  extends along the lateral side of the foot, along the medial side of the foot, over the foot, around a heel of the foot, and under the foot. Moreover, upper  30  defines a void  31 , which is a generally hollow area of footwear  10 , that has a general shape of the foot and is intended to receive the foot. Access to void  31  is provided by an ankle opening  32  located in at least heel region  13 . A lace  33  extends through various lace apertures  34  and permits the wearer to modify dimensions of upper  30  to accommodate the proportions of the foot. More particularly, lace  33  permits the wearer to tighten upper  30  around the foot, and lace  33  permits the wearer to loosen upper  30  to facilitate entry and removal of the foot from void  31  (i.e., through ankle opening  32 ). As an alternative to lace apertures  34 , upper  30  may include other lace-receiving elements, such as loops, eyelets, hooks, and D-rings. In addition, upper  30  includes a tongue  35  that extends between void  31  and lace  33  to enhance the comfort and adjustability of footwear  10 . In some configurations, upper  30  may also incorporate other elements, such as reinforcing members, aesthetic features, a heel counter that limits heel movement in heel region  13 , a wear-resistant toe guard located in forefoot region  11 , or indicia (e.g., a trademark) identifying the manufacturer. Accordingly, upper  30  is formed from a variety of elements that form a structure for receiving and securing the foot. 
     For purposes of reference in the following discussion, upper  30  also includes a lace region  36  and a lower region  37 , as shown for example in  FIG. 2 . Lace region  36  is proximal to and includes an area where lace apertures  34  or other lace-receiving elements are located. In general, lace region  36  may correspond with a throat area of footwear  10 , which includes one or more of lace  33 , lace apertures  34 , and tongue  35 . Lower region  37  is proximal to and includes an area where sole structure  20  is secured to upper  30 . Regions  36  and  37  are not intended to demarcate precise areas of footwear  30 . Rather, regions  36  and  37  are intended to represent general areas to aid in the following discussion. 
     Tensile Strand Element 
     Although a variety of material elements or other components may be incorporated into upper  30 , areas of one or both of lateral side  14  and medial side  15  incorporate a tensile strand element  40  that includes an exterior material layer  41 , an interior material layer  42 , and a strand  43 . An example of one tensile strand element  40  is depicted in  FIG. 4  and has a configuration suitable for extending through each of regions  11 - 13  on lateral side  14 . A similar or identical tensile strand element may also extend through medial side  15 . In further configurations, a single tensile strand element  40  may extend through each of sides  14  and  15 , or tensile strand element  40  may only extend through a relatively small area of lateral side  14 . Accordingly, the shape and size of tensile strand  40 , as well as the area of upper  30  in which tensile strand element  40  is located, may vary considerably. Additional details of tensile strand element  40  are depicted in  FIGS. 5A-7C . 
     Material layers  41  and  42  are located adjacent to each other and are generally coextensive with or otherwise overlap each other. Although material layers  41  and  42  are often stitched, bonded, adhered, or otherwise secured to each other, material layers  41  and  42  may also be unsecured. With reference to  FIGS. 3A and 3B , for example, exterior material layer  41  is located outward from interior material layer  42 . In this position, exterior material layer  41  forms a portion of an exterior surface of upper  30 , and interior material layer  42  forms a portion of an interior surface of upper  30 , thereby defining a portion of void  31 . In other configurations, additional material layers or elements may be secured to one or both of material layers  41  and  42 . For example, a durable and wear-resistant material layer may be secured to exterior material layer  41  to form the exterior surface of upper  30 . Trademarks, aesthetic elements, or other indicia may also be secured to exterior material layer  41 . As another example, which is discussed in greater detail below, a polymer foam layer may be secured to interior material layer  42  to enhance the comfort of footwear  10 , and a textile layer may be secured to the polymer foam layer to form a portion of the interior surface of upper  30 , enhance comfort, and wick moisture (e.g., from perspiration) away from the foot. 
     Strand  43  repeatedly extends between lace region  36  and lower region  37 . More particularly, segments of strand  43  (i.e., strand segments) extend from lace region  36  to lower region  37  and are located and secured between material layers  41  and  42  in each of regions  36  and  37 . Although portions of strand  43  are located between material layers  41  and  42 , other portions of strand  43  extend across an opening  44  that is formed through each of material layers  41  and  42  and positioned between regions  36  and  37 . The segments of strand  43  are unsecured, therefore, in the area between regions  36  and  37 , and the segments of strand  43  form both the exterior surface of upper  30  and the opposite interior surface of upper  30  in the area between regions  36  and  37 . In this regard, the foot or a sock worn over the foot may contact portions of strand  43  extending across opening  44 . 
     During activities that involve walking, running, or other ambulatory movements (e.g., cutting, braking), a foot within void  31  may tend to stretch upper  30 . That is, many of the material elements forming upper  30  (e.g., material layers  41  and  42 ) may stretch when placed in tension by movements of the foot. Although strand  43  or individual segments of strand  43  may also stretch, strand  43  generally stretches to a lesser degree than the other material elements forming upper  30 . The various segments of strand  43  may be located, therefore, to form structural components in upper  30  that (a) resist stretching in specific directions or locations, (b) limit excess movement of the foot relative to sole structure  20  and upper  30 , (c) ensure that the foot remains properly positioned relative to sole structure  20  and upper  30 , and (d) reinforce locations where forces are concentrated. 
     In addition to extending between regions  36  and  37 , the segments of strand  43  also extend at least partially around each of lace apertures  34 . As such, a segment of strand  43  extends (a) upward from lower region  37  to lace region  36 , (b) around one of lace apertures  33 , and (c) downward from lace region  36  to lower region  37  in a repeating pattern. In this manner, strand  43  effectively extends around each of lace apertures  34 . Moreover, segments of strand  43  form loops around portions of lace  33 , as generally depicted in  FIGS. 1 and 2 , as well as the cross-sections of  FIGS. 3A-3C . Moreover, the configuration of material layers  41  and  42  and strand  43  in the area of one of lace apertures  34  is depicted in  FIGS. 5A and 6A . When lace  33  is tightened, tension in lace  33  effectively places strand  43  in tension, which has the advantage of tightening upper  30  around the foot and further (a) limiting excess movement of the foot relative to sole structure  20  and upper  30  and (b) ensuring that the foot remains properly positioned relative to sole structure  20  and upper  30 . 
     Opening  44  is positioned between lace region  36  and lower region  37  and is an area of tensile strand element  40  where material layers  41  and  42  are absent. As such, opening  44  may be an aperture formed through each of material layers  41  and  42 , thereby extending from the exterior surface of upper  30  to void  31 . In addition, opening  44  is located in an inner area of tensile strand element  40  and is spaced inward from edges of material layers  41  and  42 . In other configurations, which are discussed below, opening  44  may extend to the edges of material layers  41  and  42 . Although an area of opening  44  may vary considerably, the area is often at least nine square centimeters. In some configurations of footwear  10  intended for wear by an adult, opening  44  may have a larger area of at least sixteen or twenty-five square centimeters. These examples of areas of opening  44  have advantages of (a) removing mass from footwear  10 , (b) facilitating breathability in footwear  10 , and (c) imparting a unique aesthetic to footwear  10 . Given these areas for opening  44 , the distance across opening  44  may be at least four centimeters. As such, segments of strand  43  located in opening  44  may be unsecured for the distance of at least four centimeters that extends across opening  44 . 
     Each of material layers  41  and  42  may be formed from any generally two-dimensional material. As utilized with respect to the present invention, the term “two-dimensional material” or variants thereof is intended to encompass generally flat materials exhibiting a length and a width that are substantially greater than a thickness. Accordingly, suitable materials for material layers  41  and  42  include various textiles, polymer sheets, or combinations of textiles and polymer sheets, for example. Material layers  41  and  42  may also be leather, synthetic leather, or polymer foam layers. Textiles are generally manufactured from fibers, filaments, or yarns that are, for example, either (a) produced directly from webs of fibers by bonding, fusing, or interlocking to construct non-woven fabrics and felts or (b) formed through a mechanical manipulation of yarn to produce a woven or knitted fabric. The textiles may incorporate fibers that are arranged to impart one-directional stretch or multi-directional stretch, and the textiles may include coatings that form a breathable and water-resistant barrier, for example. The polymer sheets may be extruded, rolled, or otherwise formed from a polymer material to exhibit a generally flat aspect. Two-dimensional materials may also encompass laminated or otherwise layered materials that include two or more layers of textiles, polymer sheets, or combinations of textiles and polymer sheets. In addition to textiles and polymer sheets, other two-dimensional materials may be utilized for material layers  41  and  42 . Although two-dimensional materials may have smooth or generally untextured surfaces, some two-dimensional materials will exhibit textures or other surface characteristics, such as dimpling, protrusions, ribs, or various patterns, for example. Despite the presence of surface characteristics, two-dimensional materials remain generally flat and exhibit a length and a width that are substantially greater than a thickness. In some configurations, mesh materials or perforated materials may be utilized for either or both of material layers  43  and  44  to impart greater breathability or air permeability. 
     As examples, interior material layer  42  may be formed from a textile material and exterior material layer  41  may be formed from a polymer sheet that is bonded to the textile material, or each of material layers  41  and  42  may be formed from polymer sheets that are bonded to each other. In circumstances where interior material layer  42  is formed from a textile material, exterior material layer  41  may incorporate thermoplastic polymer materials that bond with the textile material of interior material layer  42 . That is, by heating exterior material layer  42 , the thermoplastic polymer material of exterior material layer  42  may bond with the textile material of interior material layer  41 , as well as strand  43 . As an alternative, a thermoplastic polymer material may infiltrate or be bonded with the textile material of interior material layer  42  in order to bond with exterior material layer  41  and strand  43 . That is, interior material layer  42  may be a combination of a textile material and a thermoplastic polymer material. An advantage of this configuration is that the thermoplastic polymer material may rigidify or otherwise stabilize the textile material of interior material layer  42  during the manufacturing process of tensile strand element  40 , including portions of the manufacturing process involving laying and securing strand  43  upon interior material layer  42 . Another advantage of this configuration is that another material layer may be bonded to interior material layer  42  opposite exterior material layer  41  using the thermoplastic polymer material in some configurations. This general concept is disclosed in U.S. patent application Ser. No. 12/180,235, which was filed in the U.S. Patent and Trademark Office on 25 Jul. 2008 and entitled Composite Element With A Polymer Connecting Layer, such prior application being entirely incorporated herein by reference. 
     Strand  43  may be formed from any generally one-dimensional material. As utilized with respect to the present invention, the term “one-dimensional material” or variants thereof is intended to encompass generally elongate materials exhibiting a length that is substantially greater than a width and a thickness. Accordingly, suitable materials for strand  43  includes various filaments, fibers, yarns, threads, cables, cords, or ropes that are formed from rayon, nylon, polyester, polyacrylic, silk, cotton, carbon, glass, aramids (e.g., para-aramid fibers and meta-aramid fibers), ultra high molecular weight polyethylene, liquid crystal polymer, copper, aluminum, and steel. Whereas filaments have an indefinite length and may be utilized individually as strand  43 , fibers have a relatively short length and generally go through spinning or twisting processes to produce a strand of suitable length. An individual filament utilized in strand  43  may be formed form a single material (i.e., a monocomponent filament) or from multiple materials (i.e., a bicomponent filament). Similarly, different filaments may be formed from different materials. As an example, yarns utilized as strand  43  may include filaments that are each formed from a common material, may include filaments that are each formed from two or more different materials, or may include filaments that are each formed from two or more different materials. Similar concepts also apply to threads, cables, or ropes. The thickness of strand  43  may also vary significantly to range from less than 0.03 millimeters to more than 5 millimeters, for example. Although one-dimensional materials will often have a cross-section where width and thickness are substantially equal (e.g., a round or square cross-section), some one-dimensional materials may have a width that is greater than a thickness (e.g., a rectangular, oval, or otherwise elongate cross-section). Despite the greater width, a material may be considered one-dimensional if a length of the material is substantially greater than a width and a thickness of the material. 
     As an example, strand  43  may be formed from a bonded nylon 6.6 with a breaking or tensile strength of 3.1 kilograms and a weight of 45 tex, or strands  43  may be formed from a bonded nylon 6.6 with a breaking or tensile strength of 6.2 kilograms and a tex of 45. As a further example, strand  43  may have an outer sheath  51  that extends around an inner core  52 , as depicted in  FIG. 8 . Sheath  51  and core  52  extend along a length of strand  43 , thereby extending from lace region  36  to lower region  37 . Also, each of sheath  51  and core  52  may be formed from a plurality of intertwined (e.g., braided, woven) threads. In another configuration, sheath  51  may be formed from intertwined threads, and core  52  may be bundled threads with or without twist. Advantages of forming strand  43  to include sheath  51  and core  52  are that (a) sheath  51  imparts protection to core  52  and (b) each may have advantageous properties that are combined. 
     Strand  43  may be a continuous and unbroken filament, fiber, yarn, thread, cable, cord, or rope that extends through both lateral side  14  and medial side  15 . As an alternative, two separate sections of strand  43  may extend through lateral side  14  and medial side  15 . That is, one section may form strand  43  on lateral side  14  and another section may form strand  43  on medial side  15 . In any of these configurations, a section of strand  43  extends repeatedly between regions  36  and  37 . In some configurations, however, separate segments of strand  43  may extend between regions  36  and  37 . For example, one section of strand  43  may extend from lower region  37  to lace region  36 , around lace aperture  34 , and back to lower region  37 , and a separate section of strand  43  may traverse a similar path to extend around a different lace aperture  34 . Accordingly, strand  43  may be a continuous or unbroken element, or strand  43  may be a plurality of separate sections. In some configurations, the separate sections of strand  43  may be formed from different materials to vary the properties of strand  43  in different areas of upper  30 . 
     Based upon the above discussion, footwear  10  is generally formed from upper  20  and sole structure  30 , which are secured together. Upper  20  may be formed from a plurality of material elements, such as material layers  41  and  42 , and includes both lace region  36  and lower region  37 . Whereas lace region  36  includes a plurality of lace-receiving elements, such as lace apertures  34 , lower region  37  is proximal to an area where sole structure  20  is secured to upper  30 . A plurality of segments of strand  43  extend from lace region  36  to lower region  37 . The segments of strand  43  are secured to upper  30  in lace region  36  and lower region  37 , and the segments of strand  43  are unsecured for a distance of at least four centimeters in an area between lace region  36  and lower region  37 . In some configurations, segments of strand  43  form both the exterior surface of upper  30  and the opposite interior surface of upper  30  in the area between lace region  36  and lower region  37 . Additionally, in some configurations, the material layers forming upper  30  define opening  44  between lace region  36  and lower region  37 , with the segments of strand  43  extending across opening  44 . 
     Further Configurations 
     The various features discussed above provide example configurations for footwear  10  and tensile strand element  40 . In further configurations, however, numerous features of footwear  10  and tensile strand element  40  may vary to impart a variety of properties or aesthetics to footwear  10 . Although various examples of further configurations are discussed below, a variety of other configurations may also fall within the scope of the present discussion. Moreover, although the configurations are discussed and depicted separately, aspects of some configurations may be utilized in combination with aspects of other configurations. 
     A further configuration of footwear  10  is depicted in  FIG. 9A , wherein opening  44  extends from ankle opening  32  in heel region  13  to an area between lace region  36  and lower region  37  in midfoot region  12 . Forward areas of opening  44  may also extend into forefoot region  11 . Whereas opening  44  is discussed above as being located in an inner area of tensile strand element  40  and is spaced inward from edges of material layers  41  and  42 , this configuration of opening  44  extends to the edges of material layers  41  and  42 . Advantages of this configuration include (a) removing additional mass from footwear  10 , (b) facilitating greater breathability in footwear  10 , and (c) imparting a different aesthetic to footwear  10 . A similar configuration is depicted in  FIG. 9B , wherein another strand  43  extends from a upper area to a lower area of heel region  13  and effectively supports the portion of upper  20  that contacts the heel of the wearer. 
     Another configuration of footwear  10  is depicted in  FIG. 9C  as including a bootie element  38 . As discussed above, the various segments of strand  43  form both the exterior surface and the interior surface of upper  20  in the area between lace region  36  and lower region  37 , specifically in opening  44 . As such, strand  43  may contact the foot or a sock worn over the foot. Bootie element  38 , however, is locatable within void  31  and provides a covering for the foot and effectively extends between strand  43  and the foot. The various segments of strand  43  may, therefore, lay against bootie element  38 . Although bootie element  38  may be a knitted element with the configuration of a sock, bootie element  38  may incorporate various elements that (a) impart structure or stability to footwear  10 , (b) enhance comfort, (c) assist sole structure  20  in attenuating ground reaction forces, or (d) improve water resistance, for example. 
     Referring to  FIG. 9D , footwear  10  is depicted as having a configuration of a sprinting shoe, which is generally used during sprint-related track and field events. Although sprint shoes may exhibit various configurations, sole structure  20  includes a plurality of spikes  24  that impart traction. With respect to upper  30 , opening  44  extends from ankle opening  32  in heel region  13  to an area between lace region  36  and lower region  37  in midfoot region  12 . While segments of strand  43  located in forward areas of midfoot region  12  extend in a generally vertical direction, other segments of strand  43  angle rearwardly. As such, the various segments of strand  43  may extend in various directions. Moreover, segments of strand  43  extend in a generally horizontal direction in heel region  13  and join with an upper area of upper  30  in heel region  13 . When lace  33  is tensioned and tied, portions of upper  30  in heel region  13  may be tightened to further enhance the fit of footwear  10  and ensure that footwear  10  remains properly positioned on the foot during the sprint-related track and field events. 
     Another configuration of footwear  10  is depicted in  FIG. 9E  as having a configuration of a basketball shoe. In each of the configurations discussed above, only strand  43  extended around each of lace apertures  34 . In this configuration, however, segments of strand  43  and segments of a strand  45  extend around each of lace apertures  34  and across opening  44 . Whereas segments of strand  43  are oriented in a generally vertical direction between regions  36  and  37 , segments of strand  45  are oriented in a rearwardly-angled direction between regions  36  and  37 . This general configuration is disclosed in U.S. patent application Ser. No. 12/847,836, which was filed in the U.S. Patent and Trademark Office on 30 Jul. 2010 and entitled Footwear Incorporating Angled Tensile Strand Elements, such prior application being entirely incorporated herein by reference. Given this orientation, many segments of strand  43  are located in midfoot region  12 , but some segments of strand  45  are partially located in midfoot region  12  and extend into heel region  13 . 
     In the configuration of  FIG. 9E , segments of strand  43  have a generally vertical orientation between regions  36  and  37 . When performing a cutting motion (i.e., side-to-side movement of the wearer), strand  43  resists sideways movement of the foot to ensure that the foot remains properly positioned relative to footwear  10 . That is, strand  43  resists stretch in upper  30  that may otherwise allow the foot to roll off of sole structure  20 . Segments of strand  45  are oriented in a rearwardly-angled direction in the area between regions  36  and  37 . When performing a braking motion (i.e., slowing the forward momentum of the wearer), strand  45  resists stretch in upper  30  that may allow the foot to slide forward or separate from sole structure  20 . Strand  45  also resists stretch in upper  30  due to flexing of footwear  10  in the area between forefoot region  11  and midfoot region  12  to ensure that the heel area of the foot remains properly positioned in upper  30  and relative to sole structure  20 . Accordingly, strands  43  and  45  cooperatively (a) resist stretch in upper  30  due to cutting motions to ensure that the foot remains properly positioned relative to footwear  10  and (b) resist stretch in upper  30  due to braking motions, as well as jumping and running motions that flex or otherwise bend footwear  10 . 
     Continuing with the discussion of  FIG. 9E , segments of strand  43  are oriented in a generally vertical direction, whereas segments of strand  45  are oriented in a rearwardly-angled direction. Although segments of strand  43  may have a vertical orientation, the angle of the segments of strand  43  may also have a substantially vertical orientation between zero and twenty degrees from vertical. As utilized herein, the term “substantially vertical orientation” and similar variants thereof is defined as an orientation wherein segments of strand  43 . Although the orientation of the segments of strand  45  may vary, the angle of the segments of strand  45  may be from between twenty to more than seventy degrees from vertical. Additional details relating to the configuration of tensile strand element  40  in  FIG. 9E  will be discussed below. 
     Aspects relating to tensile strand element  40  may also vary from the general configuration discussed above. Referring to  FIG. 10A , for example, segments of strand  43  that extend around lace apertures  34  have a squared or otherwise angled aspect, rather than rounded. In the example of tensile strand element  40  in  FIG. 4 , material layers  41  and  42  are generally coextensive with each other. As such, the edges of exterior material layer  41  are aligned with the edges of interior material layer  42 . Referring to  FIG. 10B , however, exterior material layer  41  has a lesser area than interior material layer  42 . As such, the edges of exterior material layer  41  are spaced inward from edges of interior material layer  42 , with both of material layers  41  and  42  forming opening  44 . Moreover, exterior material layer  41  covers portions of strand  43  in both of regions  36  and  37 , but exposes portions of strand  43  that extend around lace apertures  34 . 
     Another configuration of tensile strand element  40  is depicted in  FIG. 10C . In addition to including material layers  41  and  42  and strand  43 , this configuration includes two separate material layers  41 ′ and  42 ′ that are spaced from material layers  41  and  42 . Moreover, separate portions of strand  43  and located between and secured to each of material layers  41  and  42  and material layers  41 ′ and  42 ′. When incorporated into footwear  10 , material layers  41  and  42  may be located in lace region  36 , with segments of strand  43  being located and secured between material layers  41  and  42  in lace region  36 . Additionally, material layers  41 ′ and  42 ′ may be located in lower region  37 , with segments of strand  43  being located and secured between material layers  41 ′ and  42 ′ in lower region  37 . In the prior configurations discussed above, each of material layers  41  and  42  extend from lace region  36  to lower region  37 . In this configuration, however, separate material elements or layers (e.g., material layers  41 ′ and  42 ′) may be located in lower region  37  to secure strand  43 . Accordingly, strand  43  may be located between or secured to numerous material elements located in various areas of upper  30 . 
       FIG. 10D  depicts a configuration of tensile strand element  40  that may be utilized in the configuration of footwear  10  depicted in  FIG. 9E . As such, tensile strand element  40  includes strands  43  and  45 . As incorporated into tensile strand element  40 , both of strands  43  and  45  may be located and secured between material layers  41  and  42 . Referring to  FIGS. 11 and 12 , however, an enlarged and more detailed area of tensile strand element  40  is depicted. Whereas strand  43  is located and secured between material layers  41  and  42 , strand  45  is located between interior material layer  42  and a backing material layer  46 . As such, strands  43  and  45  are located adjacent to opposite surfaces of interior material layer  42 , and each of strands  43  and  45  form loops that extend at least partially around an individual lace aperture  34 . A segment of strand  43 , therefore, (a) is located adjacent to a first surface of interior material layer  42 , (b) is positioned and secured between material layers  41  and  42 , and (c) forms a loop that extends at least partially around various aligned apertures in material layers  41 ,  42 , and  46  that combine to form one of lace apertures  34 . Similarly, a segment of strand  45  (a) is located adjacent to a second surface of interior material layer  42  that is opposite the first surface, (b) is positioned and secured between material layers  42  and  46 , and (c) forms a loop that extends at least partially around the various aligned apertures in material layers  41 ,  42 , and  46  that combine to form one of lace apertures  34 . 
     Referring to  FIG. 13A , a portion of tensile strand element  40  is depicted as including two additional material layers  53  and  54 . Material layer  53  is secured and located adjacent to interior material layer  42 , and material layer  54  is secured and located adjacent to material layer  53 . As an example, material layer  53  may be formed from a polymer foam material, and material layer  54  may be formed from a textile material. As noted above, a polymer foam layer (i.e., material layer  53 ) may be secured to interior material layer  42  to enhance the comfort of footwear  10 , and a textile layer (i.e., material layer  54 ) may be secured to the polymer foam layer to form a portion of the interior surface of upper  30 , enhance comfort, and wick moisture (e.g., from perspiration) away from the foot. 
     Although material layers  41  and  42  may be formed from a single material, each of material layers  41  and  42  may also be formed from multiple materials. Referring to  FIG. 13B , for example, exterior material layer  41  is depicted as being formed from an outer stratum  55  and an inner stratum  56  that are formed from different materials. As an example, outer stratum  55  may be formed from a thermoset polymer material and inner stratum  56  may be formed from a thermoplastic polymer material. As another example, outer stratum  55  may be formed from a thermoplastic polymer material and inner stratum  56  may be formed from a different thermoplastic polymer material with a lower glass transition or melting temperature. In either example, inner stratum  56  is located adjacent to the a surface of interior material layer  42  and the thermoplastic polymer material may be utilized to secure material layers  41  and  42  to each other. Moreover, an advantage of forming outer stratum  55  from the materials noted above is that outer stratum  55  may remain solid during the bonding of material layers  41  and  42  to each other, thereby ensuring that a texture or smooth (e.g., glossy) aspect of outer stratum  55  remains intact during bonding. It should also be noted that forming exterior material layer  41  to include strata  55  and  56  may also be utilized with other configurations of tensile strand element  40 , including the configuration of  FIG. 10D , for example. 
     Manufacturing Processes 
     Tensile strand element  40  may be manufactured through various processes. The following discussion details four example manufacturing processes that may be utilized to attain various features discussed in connection with the above configurations. Although the processes discussed below display a range of techniques for manufacturing tensile strand element  40 , variations upon these processes, combinations of these processes, or additional processes may also fall within the scope of the present discussion. 
     In the discussion below, four example manufacturing processes are presented. In general, three of the example manufacturing processes may be utilized to form tensile strand element  40  with the general configuration depicted in  FIGS. 4-7C . Moreover, substantially similar manufacturing processes may be utilized to form the configurations of tensile strand element  40  that are depicted in  FIGS. 9A-9D and 10A-10C . One of the example manufacturing processes may also be utilized to form the configuration of tensile strand element  40  depicted in  FIGS. 9E and 10D-12 . 
     Each of the example manufacturing processes utilize precursor elements (i.e., precursor elements  61  and  65 ) that become one of material layers  41  or  42  at later stages of the processes. One of the processes additionally utilizes a precursor element (i.e., a precursor element  73 ) that becomes backing material layer  46  at a later stage of the process. Although terminology may vary, either exterior material layer  41  or the precursor element forming exterior material element  41  may be referred to as a “cover material layer” given that exterior material layer  41  may be considered to cover interior material layer  42  and strand  43  during the manufacturing processes or when incorporated into footwear  10 . Similarly, either interior material layer  42  or the precursor element forming interior material element  42  may be referred to as a “base material layer” given that interior material layer  42  may be considered to form a base to which other elements (e.g., exterior material layer  41  and strand  43 ) are secured during the manufacturing processes or when incorporated into footwear  10 . Additionally, either backing material layer  46  or the precursor element forming backing material element  46  may be referred to as a “backing material layer” given that backing material layer  46  may be considered to form a support or lining element during the manufacturing processes or when incorporated into footwear  10 . 
     First Example Manufacturing Process 
     A first example manufacturing process will now be discussed. Referring to  FIG. 14A , a precursor element  61  that becomes interior material layer  42  is depicted. For purposes of reference during the following discussion, a dashed outline of interior material layer  42 , which is also an outline of tensile strand element  40 , is depicted upon precursor element  61 . Although other registration systems may be utilized, a pair of registration holes  62  are formed through precursor element  61  to ensure that interior material layer  42  remains properly positioned during subsequent operations. 
     Although the order of steps may vary in this manufacturing process, as well as other manufacturing processes,  FIG. 14B  depicts a portion of opening  44  (i.e., the portion of opening  44  defined by interior material layer  42 ) as being formed through interior material layer  42 . In addition to die cutting, opening  44  may be formed through laser cutting or manual cutting (i.e., manually forming opening  44  with scissors or a blade), for example. 
     Once opening  44  is formed, a first portion of strand  43  may be stitched to interior material layer  42  with a thread  63 , as depicted in  FIG. 14C . Although other methods may be utilized, a cording machine may be employed to simultaneously locate strand  43  on interior material element  42  and secure strand  43  to interior material element  42  by extending thread  63  through strand  43 . That is, the cording machine may include elements that (a) lay strand  43  according to a predetermined pattern upon interior material element  42  and (b) stitch strand  43  to interior material element  42  in predetermined locations. In other processes, separate machines or manual procedures may lay strand  43  and stitch strand  43  to interior material element  42 . 
     At this stage of the process, strand  43  is stitched to interior material element  42  with thread  63  at a location that generally corresponds with lower region  37 . Continuing with the manufacturing process, the cording machine extends strand  43  across opening  44  and stitches strand  43  to interior material element  42  on an opposite side of opening  44 , as depicted in  FIG. 14D . More particularly, strand  43  is stitched to interior material element  42  with thread  63  at a location that generally corresponds with lace region  36 , and strand  43  is laid in a manner that forms a loop. Although not shown as being formed at this stage of the process, the loop formed by strand  43  is positioned to correspond with the position of one of lace apertures  34 . In extending strand  43  across opening  44 , the cording machine may also extend thread  63  across opening  44 . 
     The general process discussed relative to  FIGS. 14C and 14D  is performed multiple times, as depicted in  FIG. 14E , to repeatedly (a) extend strand  43  across opening  44 , (b) stitch strand  43  to interior material layer  42  in locations that generally corresponds with each of regions  36  and  37 , and (c) form loops from strand  43  in lace region  36 . Additionally, the cording machine repeatedly extends thread  63  across opening  44 . 
     Although strand  43  is intended to extend over opening  44 , thread  63  may remain limited to the areas where strand  43  is secured to interior material element  42 . Aesthetic considerations may make it undesirable to have thread  63  extend across opening  44 . Moreover, thread  63  may snag or otherwise catch upon other objects and break. As such, a cutting device  64  may be utilized to cut thread  63 , as depicted in  FIG. 14F , thereby removing thread  63  from areas corresponding with opening  44 , as depicted in  FIG. 14G . 
     Although cutting device  64  may be scissors, a variety of other methods may be utilized to cut thread  63 , including a cutting device that is incorporated into the cording machine. In some manufacturing processes, thread  63  may also be cut during the process of repeatedly extending strand  43  across opening  44 . That is, strand  43  may be stitched to interior material layer  42  with thread  63  in one location, and thread  63  may be cut prior to stitching strand  43  to interior material layer  42  in a subsequent location. 
     Once thread  63  is removed from opening  44 , a precursor element  65  that becomes exterior material layer  41  may be positioned adjacent to precursor element  61 , as depicted in  FIG. 14H . In positioning precursor elements  61  and  65 , strand  43  is generally located between the portions of precursor elements  61  and  65  that form material layers  41  and  42  at a later stage of the process. Die cutting or other operations may also be utilized to define another portion of opening  44  (i.e., the portion of opening  44  defined by exterior material layer  41 ) through precursor element  65 . Additionally, precursor element  65  may include registration holes  66  to assist with aligning the portions of opening  44  formed by each of material layers  41  and  42 . 
     Precursor elements  61  and  65  are now bonded together, as depicted in  FIG. 14I . As an example, the assembled elements (i.e., strand  43 , thread  63 , and precursor elements  61  and  65 ) may be located within a heat press that simultaneously heats and compresses the elements. Thermoplastic polymer materials in one or both of precursor elements  61  and  65  may bond with the other of precursor elements  61  and  65  to effectively join the elements. The thermoplastic polymer material may also bond with strand  43  to further secure strand  43 . As other examples, adhesives or further stitching may be utilized to join the assembled elements or supplement the bond formed by the thermoplastic polymer materials. It should also be noted that other elements or material layers may be bonded or otherwise secured during this stage of the process. 
     A substantially completed tensile strand element  40  may be removed from excess portions of precursor elements  61  and  65 , as depicted in  FIG. 14J , with die cutting, laser cutting, or manual cutting, for example. If not formed during a previous operation, lace apertures  34  may be formed within the loops formed by strand  43  and through material layers  41  and  42 . The assembled elements forming tensile strand element  40  are then incorporated into footwear  10  such that (a) lace apertures  34  and the loops formed by strand  43  are located in lace region  36  and (b) areas across opening  44  are located in lower region  37 . Lace  33  is also threaded through the various lace apertures  34 . 
     Second Example Manufacturing Process 
     Although the first example manufacturing process discussed above provides a suitable process for forming for tensile strand element  40 , a second example manufacturing process will now be discussed. Referring to  FIG. 15A , the general configuration from  FIG. 14E  is depicted. As such, the various steps discussed relative to  FIGS. 14A-14E  may be performed to repeatedly (a) extend strand  43  across opening  44 , (b) stitch strand  43  to interior material layer  42  in locations that generally corresponds with each of regions  36  and  37 , and (c) form loops from strand  43  in lace region  36 . In contrast with  FIG. 14E , however, strand  43  is stitched to interior material layer  42  with a soluble thread  67 . As such, the cording machine repeatedly extends soluble thread  67  across opening  44  during initial portions of the process. 
     Continuing with the manufacturing process, the cording machine or another stitching machine stitches a portion of strand  43  to interior material layer  42  with thread  63 , as depicted in  FIG. 15B . Although various types of stitches may be utilized, thread  63  is shown as forming a zigzag stitch that repeatedly crosses over strand  43 . Moreover, as depicted in  FIG. 15C , the cording machine or another stitching machine continues stitching thread  63  to various portions of strand  43  located in areas corresponding with regions  36  and  37 . 
     At this stage of the process, strand  43  is effectively secured to interior material layer  42  by both thread  63  and soluble thread  67 . Additionally, soluble thread  67  extends across opening  44  in various locations, which may be undesirable for aesthetic considerations and ability to snag and break. Whereas thread  63  is insoluble in water, soluble thread  67  may be soluble in water. In order to remove soluble thread  67 , precursor element  61 , strand  43 , and both of threads  63  and  67  may be located within a water bath  68 , as depicted in  FIG. 15D . After soluble thread  67  dissolves, the combination of precursor element  61 , strand  43 , and thread  63  may be removed from water bath  68 , as depicted in  FIG. 15E . Although soluble thread  67  may be soluble in water, other types of soluble threads may be utilized, such as thread that is soluble in alcohol or other chemical solutions. 
     In the first example manufacturing process, cutting device  64  removed portions of thread  63  extending across opening  44 . When the cutting operations are performed by the cording machine, the cutting operations may consume time that could otherwise be utilized to lay strand  43  or perform other aspects of the process. That is, the time necessary (a) to lay strand  43  upon interior material layer  42 , (b) stitch strand  43  to interior material layer  42 , and (c) cut excess portions of thread  63  is greater than the time necessary to only (a) to lay strand  43  upon interior material layer  42  and (b) stitch strand  43  to interior material layer  42 . As such, when cutting operations are performed by the cording machine, fewer total tensile strand elements  40  may be produced by that cording machine in a given amount of time. Moreover, manual cutting operations may require additional personnel. Accordingly, the use of soluble thread  67  may permit the cording machine to produce a greater number of elements or otherwise enhance manufacturing efficiency. 
     Once soluble thread  67  is removed, the various steps discussed in relation to  FIGS. 14H-14J  may be performed. More particularly, precursor element  65 , which becomes exterior material layer  41 , may be positioned adjacent to precursor element  61 , as depicted in  FIG. 15F . Precursor elements  61  and  65  are then bonded together, as depicted in  FIG. 15G . A substantially completed tensile strand element  40  may then be removed from excess portions of precursor elements  61  and  65 , as depicted in  FIG. 15H , with die cutting, laser cutting, or manual cutting, for example. If not formed during a previous operation, lace apertures  34  may be formed within the loops formed by strand  43  and through material layers  41  and  42 . The assembled elements forming tensile strand element  40  are then incorporated into footwear  10  such that (a) lace apertures  34  and the loops formed by strand  43  are located in lace region  36  and (b) areas across opening  44  are located in lower region  37 . Lace  33  is also threaded through the various lace apertures  34 . 
     Third Example Manufacturing Process 
     In addition to the manufacturing processes discussed above, a third example manufacturing process may be utilized to produce tensile strand element  40 . Referring to  FIG. 16A , a precursor element  61  that becomes interior material layer  42  is depicted. For purposes of reference during the following discussion, a dashed outline of interior material layer  42 , which is also an outline of tensile strand element  40 , is depicted upon precursor element  61 . Portions of lace apertures  34  and opening  44  defined by interior material layer  42  are formed through precursor element  61 , as depicted in  FIG. 16B . Moreover, various apertures  69  are formed in an area corresponding with lower region  37 . In addition to die cutting, lace apertures  34 , opening  44 , and apertures  69  may be formed through laser cutting or manual cutting, for example. 
     At this stage of the process, precursor element  61  is placed upon a jig or other assembly apparatus that includes various lace pegs  71  and lower pegs  72 , as depicted in  FIG. 16C . More particularly, lace pegs  71  are positioned to protrude through lace apertures  34  and are located in an area corresponding with lace region  36 , and lower pegs  72  are positioned to protrude through apertures  69  and are located in an area corresponding with lower region  37 . In general, therefore, pegs  71  and  71  are located in different areas of interior material layer  42  and are spaced from each other across opening  44 . Although pegs  71  and  72  are depicted as having a cylindrical shape, pegs  71  and  72  may be other structures that perform in the manner discussed below. 
     Once pegs  71  and  72  are positioned to extend through lace apertures  34  and apertures  69 , a first portion of strand  43  may be stitched to interior material layer  42  with thread  63 , as depicted in  FIG. 16D . Although the specific position where strand  43  is first secured may vary, strand  43  is depicted as being stitched to interior material layer  42  around one of lower pegs  72 . In addition to other methods, a cording machine may be employed to simultaneously locate strand  43  on interior material element  42  and secure strand  43  to interior material element  42  by extending thread  63  through strand  43 . That is, the cording machine may include elements that (a) lay strand  43  according to a predetermined pattern upon interior material element  42  and (b) stitch strand  43  to interior material element  42  in predetermined locations. In other processes, separate machines may lay strand  43  and stitch strand  43  to interior material element  42 . 
     At this stage of the process, strand  43  is stitched to interior material element  42  with thread  63  at a location that generally corresponds with lower region  37 . Continuing with the manufacturing process, the cording machine extends strand  43  across opening  44  and to a location that generally corresponds with lace region  36 . Additionally, strand  43  passes around (or at least partially around) one of lace pegs  71 , as depicted in  FIG. 16E , thereby forming a loop from strand  43  in lace region  36  and around one of lace apertures  34 . Although strand  43  may be stitched to interior material layer  42 , lace peg  71  is generally sufficient to retain the position of strand  43 . Moreover, refraining from stitching strand  43  to interior material layer  42  may enhance the speed and efficiency of the manufacturing process. 
     The cording machine then extends strand  43  across opening  44  once again and around one of lower pegs  72 , as depicted in  FIG. 16F . The general process discussed relative to  FIGS. 16E and 16F  is now performed multiple times, as depicted in  FIG. 16G , to (a) repeatedly extend segments of strand  43  across opening  44  and between regions  36  and  37 , (b) alternately extend strand  43  around one of lace pegs  71  and lower pegs  72 , and (c) form loops from strand  43  in lace region  36  and around lace apertures  34 . In addition, a portion of strand  43  may be stitched to interior material layer  42 . Although the specific position where strand  43  is now secured may vary, strand  43  is depicted as being stitched to interior material layer  42  around one of lower pegs  72 . 
     With strand  43  still extending around pegs  71  and  72 , the cording machine or another stitching machine stitches portions of strand  43  to interior material layer  42  with thread  63  or another thread, as depicted in  FIG. 16H . Although various types of stitches may be utilized, thread  63  is shown as forming a zigzag stitch that repeatedly crosses over strand  43  in each of regions  36  and  37 . 
     Given that strand  43  is effectively secured to interior material layer  42  with thread  63 , pegs  71  and  72  are withdrawn from lace apertures  34  and apertures  69 . Additionally, precursor element  65 , which becomes exterior material layer  41 , may be positioned adjacent to precursor element  61 , as depicted in  FIG. 16I . In positioning precursor elements  61  and  65 , strand  43  is generally located between the portions of precursor elements  61  and  65  that form material layers  41  and  42  at a later stage of the process. Die cutting or other operations may also be utilized to form other portions of lace apertures  34  and opening  44  defined by exterior material layer  41  through precursor element  61 , 
     Precursor elements  61  and  65  are now bonded together, as depicted in  FIG. 16J . As an example, the assembled elements (i.e., strand  43 , thread  63 , and precursor elements  61  and  65 ) may be located within a heat press that simultaneously heats and compresses the elements. Thermoplastic polymer materials in one or both of precursor elements  61  and  65  may bond with the other of precursor elements  61  and  65  to effectively join the elements. The thermoplastic polymer material may also bond with strand  43  to further secure strand  43 . As other examples, adhesives or further stitching may be utilized to join the assembled elements or supplement the bond formed by the thermoplastic polymer materials. It should also be noted that other elements or material layers may be bonded or otherwise secured during this stage of the process. 
     A substantially completed tensile strand element  40  may be removed from excess portions of precursor elements  61  and  65 , as depicted in  FIG. 16K , with die cutting, laser cutting, or manual cutting, for example. The assembled elements forming tensile strand element  40  are then incorporated into footwear  10  such that (a) lace apertures  34  and the loops formed by strand  43  are located in lace region  36  and (b) areas across opening  44  are located in lower region  37 . Lace  33  is also threaded through the various lace apertures  34 . 
     As an additional matter,  FIG. 17  depicts an alternative manner in which the third example manufacturing process may be performed. Whereas lace pegs  71  extended through lace apertures  34  in the example discussed above, two lace pegs  71  extend through interior material layer  42  in areas that are adjacent to each of lace apertures  34 . This structure for lace pegs  71  may, for example, be utilized to form the general configuration of tensile strand element  40  depicted in  FIG. 10A . 
     Fourth Example Manufacturing Process 
     Each of the example manufacturing processes discussed above may be utilized to form the configurations of tensile strand element  40  in  FIGS. 9A-9D and 10A-10C . A fourth example manufacturing process that may be utilized to form the configuration of tensile strand element  40  depicted in  FIGS. 9E and 10D-12  will now be discussed. 
     With reference to  FIG. 18A , a precursor element  61  that becomes interior material layer  42  is depicted. For purposes of reference during the following discussion, a dashed outline of interior material layer  42 , which is also an outline of tensile strand element  40 , is depicted upon precursor element  61 . Portions of lace apertures  34  and opening  44  defined by interior material layer  42  area also formed through precursor element  61 . Although other registration systems may be utilized, a pair of registration holes  62  are formed through precursor element  61  to ensure that interior material layer  42  remains properly positioned during subsequent operations. 
     Strand  43  is now laid upon a first surface of interior material layer  42 , as depicted in  FIG. 18B , utilizing any of the techniques discussed above in the first, second, and third example manufacturing processes, for example. Moreover, strand  43  is secured to the first surface of interior material layer  42 , possibly with thread  63 . The combination of precursor element  61  and strand  43  is now turned over or otherwise reversed, as depicted in  FIG. 18C . Strand  45  is also laid upon a second or opposite surface of interior material layer  42 , as depicted in  FIG. 18D , utilizing any of the techniques discussed above, for example. Moreover, strand  45  is secured to the second surface of interior material layer  42 , possibly with thread  63 . Although other methods may be utilized, a cording machine may be employed to locate and secure strands  43  and  45  on the opposite surfaces of interior material element  42 . In other processes, separate machines or manual procedures may lay and secure strands  43  and  45 . 
     As this stage of the process, each of strands  43  and  45  (a) repeatedly extend across opening  44  and between locations that generally corresponds with each of regions  36  and  37 , (b) are stitched or otherwise secured to opposite surfaces of interior material layer  42 , and (c) form loops that extend around the portions of lace apertures  34  defined by interior material layer  42 . A precursor element  73  that becomes backing material layer  46  may be positioned adjacent to precursor element  61 , as depicted in  FIG. 18E , such that strand  45  is located between precursor elements  61  and  73 . Similarly, precursor element  65 , which becomes exterior material layer  41 , may be positioned adjacent to precursor element  61  such that strand  43  is located between precursor elements  61  and  65 . Die cutting or other operations may also be utilized to define further portions of opening  44  (i.e., the portions of opening  44  defined by material layers  41  and  46 ) through precursor elements  65  and  73 . Additionally, precursor elements  65  and  73  may include registration holes  66  to assist with aligning the portions of opening  44  formed by each of material layers  41  and  46 . 
     Precursor elements  61 ,  65 , and  73  are now bonded together, as depicted in  FIG. 18F . As an example, the assembled elements (i.e., strands  43  and  45 , precursor elements  61 ,  65 , and  73 ) may be located within a heat press that simultaneously heats and compresses the elements. Thermoplastic polymer materials in any of precursor elements  61 ,  65 , and  73  may bond with the other of precursor elements  61 ,  65 , and  73  to effectively join the elements. The thermoplastic polymer material may also bond with strands  43  and  45 . As other examples, adhesives or further stitching may be utilized to join the assembled elements or supplement the bond formed by the thermoplastic polymer materials. It should also be noted that other elements or material layers may be bonded or otherwise secured during this stage of the process. If not formed during a previous operation, lace apertures  34  may be formed within the loops formed by strands  43  and  45  through material layers  41 ,  42 , and  46 . 
     A substantially completed tensile strand element  40  may be removed from excess portions of precursor elements  61 ,  65 , and  73 , as depicted in  FIG. 18G , with die cutting, laser cutting, or manual cutting, for example. The assembled elements forming tensile strand element  40  are then incorporated into footwear  10  such that (a) lace apertures  34  and the loops formed by strands  43  and  45  are located in lace region  36  and (b) areas across opening  44  are located in lower region  37 . Lace  33  is also threaded through the various lace apertures  34 . 
     The invention is disclosed above and in the accompanying figures with reference to a variety of configurations. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to the invention, not to limit the scope of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the configurations described above without departing from the scope of the present invention, as defined by the appended claims.