Patent Publication Number: US-2021177095-A1

Title: Article of Footwear with Braided Upper

Description:
BACKGROUND 
     The present embodiments relate generally to articles of footwear, and in particular to articles of footwear with braided components. 
     Braided articles can be formed by overbraiding strands of material onto a form, such as shoe last. The resulting braided articles may be lightweight and durable. However, during the braiding process the form may be enclosed within the overbraided structure, making it difficult to remove the form. Additionally, if the resulting overbraided structure is relatively stiff, it may be difficult to apply conventional methods for securing the overbraided structure to another component, like a sole structure. 
     SUMMARY 
     In one aspect, an article of footwear includes a braided upper, where the braided upper includes a bottom opening and a bottom peripheral portion extending around the bottom opening. The article also includes a midsole component including an upper surface with a peripheral upper surface portion. The bottom peripheral portion is continuously bonded to the peripheral upper surface portion. 
     In another aspect, an article of footwear includes a braided upper, where the braided upper includes a bottom opening and a bottom peripheral portion extending around the bottom opening. The article also includes a midsole component, where a portion of the midsole component is sized to fit within the bottom opening. 
     In another aspect, an article of footwear includes a braided upper, where the braided upper includes a bottom opening and a bottom peripheral portion extending around the bottom opening. The article also includes an insole component including a base portion and a lower projecting portion, where the base portion is wider than the lower projecting portion, and a midsole component. The bottom peripheral portion of the upper is secured to a peripheral upper surface of the midsole component; and the lower projecting portion of the insole component is disposed within the bottom opening. 
     Other systems, methods, features, and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The embodiments can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. 
         FIG. 1  is a process for making an article of footwear with a braided upper, according to an embodiment; 
         FIG. 2  is a schematic view of a step of overbraiding a last to form a braided upper by passing the last through a braiding machine, according to an embodiment; 
         FIG. 3  is a schematic view of a cutting system for removing a bottom portion of a braided upper, where the cutting system comprises a hot-knife controlled by a multi-axis robot, according to an embodiment; 
         FIG. 4  is a schematic view of a step of cutting the braided upper using the hot-knife of  FIG. 3 ; 
         FIG. 5  is a schematic view of a braided upper with a bottom portion removed and with a last disposed within an interior cavity of the braided upper, according to an embodiment; 
         FIG. 6  is a schematic cross-sectional view of another embodiment of a cutting system for removing a bottom portion of a braided upper, in which a cutting plate is used to punch out the bottom portion, according to an embodiment; 
         FIG. 7  is a schematic cross-sectional view of another embodiment of a cutting system for removing a bottom portion of a braided upper, in which a cutting portion in the last is used to punch out the bottom portion, according to an embodiment; 
         FIG. 8  is a schematic view of a step of removing a last from a braided upper by passing the last through a bottom opening in the braided upper, according to an embodiment; 
         FIG. 9  is a schematic view of a step of associating a braided upper with a midsole, according to an embodiment; and 
         FIG. 10  is a schematic view of an article of footwear with a braided upper, according to an embodiment 
         FIG. 11  is a schematic view of a braided upper being cut while on a last, according to an embodiment; 
         FIG. 12  is a schematic view of the last of  FIG. 11  being removed from the braided upper; 
         FIG. 13  is a schematic view of one embodiment of an article of footwear with a braided upper, in which an insole component has a projecting portion; 
         FIG. 14  is a schematic cross-sectional view of the article of footwear of  FIG. 13 ; 
         FIG. 15  is a schematic view of one embodiment of an article of footwear with a braided upper, in which a midsole component has a projecting portion; 
         FIG. 16  is a schematic cross-sectional view of the article of footwear of  FIG. 15 ; 
         FIG. 17  is a schematic view of one embodiment of an article of footwear with a braided upper, in which a midsole component has a peripheral slot; 
         FIG. 18  is a schematic cross-sectional view of the article of footwear of  FIG. 17 ; 
         FIG. 19  is a schematic view of an embodiment of a step of inserting internal components into a braided upper through a bottom opening of the braided upper; 
         FIG. 20  is a schematic view of a step of assembling a sole component with the braided upper of  FIG. 19 , once the internal components have been placed inside the braided upper; and 
         FIG. 21  is a schematic view of an article with a braided upper in which a foot is in contact with an upper side of a midsole component, according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     The embodiments provide a method of making a braided upper and an article of footwear with a braided upper that is continuously bonded with a midsole. The method includes overbraiding strands of material onto a last and then cutting out a bottom portion of the overbraided structure to form the upper. Cutting out the bottom portion provides a sufficiently large opening through which the last can be removed, as typically the top openings of the article (for example, openings at the cuff and lacing region) may be too small to remove the last. Additionally, cutting out the bottom portion provides increased access to the interior of the upper. This increased access makes finishing the article easier. By leaving a bottom peripheral portion on the bottom side of the upper (and surrounding the bottom opening), the upper can be attached directly to a midsole without the need for a board, plate, or other attachment provision. Moreover, the attachment can be continuous, so that the attachment region between the upper and the midsole forms a complete loop with no gaps. This helps reduce the tendency of the upper to separate from the midsole at any locations where the upper and midsole might be unbonded. The embodiments can also include insole components or midsole components that are shaped to fit within the bottom opening of braided upper so that the footbed surface within the braided upper has a relatively smooth shape with no discontinuities. 
     In the following detailed description, reference is made to the accompanying figures that form a part hereof wherein like numerals designate like parts throughout, and in which is shown, by way of illustration, embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents. 
     Aspects of the disclosure are disclosed in the accompanying description. Alternate embodiments of the present disclosure and their equivalents may be devised without parting from the spirit or scope of the present disclosure. It should be noted that any discussion herein regarding “one embodiment,” “an embodiment,” “an exemplary embodiment,” and the like indicates that the embodiment described may include a particular feature, structure, or characteristic that may not necessarily be included in every embodiment. In addition, references to the foregoing do not necessarily comprise a reference to the same embodiment. Finally, irrespective of whether it is explicitly described, one of ordinary skill in the art would readily appreciate that each of the particular features, structure, or characteristics of the given embodiments may be utilized in connection or combination with those of any other embodiment discussed herein. 
     For the purposes of the present disclosure, the phrase “A and/or B” means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase “A, B, and/or C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B, and C). 
     The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments of the present disclosure, are synonymous. 
     The term “fixedly attached” refers to two components joined in a manner such that the components may not be readily separated (for example, without destroying one or both of the components). Exemplary modalities of fixed attachment may include joining with permanent adhesive, rivets, stitches, nails, staples, welding or other thermal bonding, or other joining techniques. In addition, two components may be “fixedly attached” by virtue of being integrally formed, for example, in a molding process. 
       FIG. 1  is an example of a process  100  for making an article of footwear with a braided upper, according to one embodiment. In a first step  102 , a last may be sent through a braiding machine to form a braided upper. Specifically, the last may be overbraided, so that after passing through the braiding machine, the last is enclosed within the braided upper. Next, in step  104 , a bottom opening may be cut, or otherwise removed, from a bottom side of the braided upper. At the same time as the bottom opening is cut into the braided upper, a peripheral edge of the bottom opening may be fused so that the strands of the braided upper do not fray or otherwise separate along the peripheral edge. Optionally, loose strands at the peripheral edge of the bottom opening could be fused after (and separately from) a step of cutting the strands. 
     In step  106 , the last may be removed from the braided upper by pulling the last through the bottom opening. After the last has been removed, the interior cavity of the braided upper may be accessible through the bottom opening. In some cases, stitches, adhesives, reinforcing components, and/or other materials could be applied to the interior of the cavity at this point. 
     Finally, in step  108 , a bottom peripheral portion of the braided upper could be bonded, or otherwise secured, to a midsole. Optionally, in other cases, the braided upper could be lasted and/or a plate could be secured to the braided upper. 
       FIG. 2  is a schematic view of a step of passing a last  200  through a braiding machine  210  so as to form a braided upper  230 , according to an embodiment. Braiding machine  210  includes a plurality of spools (not shown) that include strands of material for forming a braided structure. The term “strand”, as used herein, 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.). 
     To assist in clearly depicting the method used to form an article incorporating a braided component, braiding machine  210  is depicted without spools or a support structure in the following figures. Although depicted without a support structure or spools, it should be recognized that braiding machine  210  as well as other braiding machines depicted in this detailed description may include spools. 
     The spools pass by one another along a track such that a plurality of strands  212  intertwine and twist with one another. This twisting and intermeshing of plurality of strands  212  forms a braided structure. Although depicted as a radial braiding machine, it should be recognized that an axial braiding machine or other type of braiding machine may be utilized. Further, the braiding machine may also be configured to perform jacquard and non-jacquard motions. An example of a braiding machine is described in Richardson, U.S. Pat. No. 5,257,571, granted Nov. 2, 1993, entitled “Maypole Braider Having a Three Under and Three Over Braiding Path,” the entirety of which is hereby incorporated by reference. Additionally, another example of a braiding machine is described in Dow et al., U.S. Pat. No. 7,908,956, granted Mar. 22, 2011, entitled “Machine for Alternating Tubular and Flat Braid Sections,” the entirety of which is hereby incorporated by reference. 
     Braiding machine  210  may be utilized to overbraid an object. “Overbraid” as used herein shall refer to a method of braiding that forms the shape of a three-dimensional structure. An object or structure that is overbraided includes a braided structure that extends around an outer surface of the structure. An object need not be completely covered by a braided structure to be considered overbraided. Rather, an object that is overbraided includes a seamless braided structure that extends around a portion of the object. As an object is overbraided, strands are deposited along an outer surface of the object. 
       FIG. 3  is a schematic view of an automated cutting system  300 . In this example, automated cutting system  300  comprises a hot-knife  302  that is controlled by a multi-axis robot  310 . Hot-knife  302  is a tool with a heated blade  304 . The three-dimensional position and orientation of hot-knife  302  can be controlled automatically by multi-axis robot  310 . Multi-axis robot  310  could be programmed with a predetermined sequence of motions or positions, to facilitate cutting a predetermined pattern from a bottom (or lower) side of braided upper  230 . Alternatively, multi-axis robot  310  could incorporate one or more sensors (such as a camera) to sense braided upper  230  in order to cut out a predetermined pattern. Although not shown in  FIG. 3 , braided upper  230  (and the enclosed last  200 ) could be supported and held in place using any known apparatus. In an alternative embodiment, the position of the hot-knife could be fixed and the braided upper could be moved using, for example, a multi-axis robot. 
     Hot-knife  302  may be capable of cutting through one or more layers of the overbraided structure that comprise braided upper  230 , as best seen in  FIG. 4 . Hot-knife  302  may be associated with a bottom side  400  (or lower side) of braided upper  230 , so that a bottom portion of braided upper  230  can be removed. Here, bottom side  400  corresponds to the sole side of braided upper  230 . As hot-knife  302  comes into contact with braided upper  230 , the strands comprising the overbraided structure of braided upper  230  are cut. The cutting may be achieved by a combination of heat and pressure, as blade  304  may be both sharp and extremely hot. Moreover, the heat generated by hot-knife  302  may act to melt the strands  402  of braided upper  230  as they are cut, depending on the type of material comprising strands  402 . As strands  402  cool they may form a fused edge  404 , as seen in the enlarged view within  FIG. 4 . This fused edge ensures that the strands of braided upper  230  will not fray or come apart along the bottom side  400  of braided upper  230 . 
     The fusing of strands along the edge of the bottom opening may be facilitated by using thermoplastic materials and/or other hot-melt adhesives. For example, the braided structure could be covered in a thermoplastic layer (such as thermoplastic polyurethane) before or after the braided structure is formed. In another example, the braided strands may be coated with, or made entirely from, a thermoplastic material, such as TPU. As heat is applied by the hot-knife, the thermoplastic material may melt and help form a fused edge that locks the free ends (which have been cut) of the braided structure into place along the bottom opening. Alternatively, other suitable hot-melt materials could be used. 
     As seen in  FIG. 5 , after the cutting is completed, braided upper  230  includes a bottom opening  502  along bottom side  400 . Bottom opening  502  may extend through a forefoot portion  560 , a midfoot portion  562  and a heel portion  564  of braided upper  230 . However, bottom opening  502  does not extend all the way to a lower sidewall edge  552  of braided upper  230 . Instead, bottom side  400  still includes a bottom peripheral portion  510  that is disposed on bottom side  400 , and which bounds bottom opening  502 . Last  200  may be exposed through bottom opening  502 . Specifically, a sole surface  201  of last  200  may be exposed through bottom opening  502 . 
     The size of a bottom peripheral portion could vary. In some cases, the size could be selected according to the method used for assembling the braided upper with a midsole, lasting board, plate, or other structure. In the embodiment of  FIG. 5 , bottom peripheral portion  510  may have a width  550 . Width  550  is defined as a distance between a lower-sidewall edge  552  of braided upper  230  and bottom opening edge  554 . 
     The relative size of width  550  can be compared with, for example, a maximum overall width of braided upper  230 . In  FIG. 5 , maximum overall width  570  occurs in a forefoot portion  560  of braided upper  230 . Here, the overall width may be taken along a direction extending from a lateral side to a medial side of braided upper  230 . The ratio of width  550  to overall width  570  could have a value approximately in the range between 3% and 30%. In one embodiment, the ratio may have a value approximately in the range between 10% to 20%. The particular value of this ratio may be selected to ensure that 1) a bottom opening is large enough for the last to be removed, and 2) sufficient material is available along the bottom or lower side to attach the braided upper to a sole structure or other component. 
       FIGS. 6 and 7  depict schematic views of alternative ways of cutting out a bottom opening in a braided upper. In a first example, depicted in the schematic cross-sectional view of  FIG. 6 , a cutting plate  600  may be pressed against a lower side of a braided upper  630 . Cutting plate  600  may include cutting portion  602  that extends up from a base portion  604  of cutting plate  600 . Cutting portion  602  may be configured to punch through braided material as cutting plate  600  is pressed against a lower side  632  of braided upper  630 . As also seen in  FIG. 6 , last  620  may incorporate a slot  622  that can receive cutting portion  602 . Although depicted in cross-section, it may be appreciated that in some cases, cutting portion  602  may extend in a 2-D path around cutting plate  600  so that cutting portion  602  completely separates an interior bottom portion  634  of braided upper  630  from bottom peripheral portion  636  of braided upper  630 . 
     To facilitate cutting, heat and/or pressure could be applied. If cutting portion  602  is sufficiently sharp, or sufficient pressure is applied, no heat may be necessary. Alternatively, cutting plate  600  could comprise a material that can be heated so that cutting portion  602  can act to melt through strands of braided upper  630 . Moreover, heat from the cutting plate could also be used to fuse broken strands to form a fused edge along the periphery of the bottom opening. 
       FIG. 7  is a schematic view of another embodiment for cutting a bottom opening in a braided upper. In the example of  FIG. 7 , last  720  may be provided with a cutting portion  722 . Cutting portion  722  may be received within a slot  702  of a plate  700 . Although depicted in cross-section, it may be appreciated that in some cases, cutting portion  722  may extend in a 2-D path around the bottom side of last  720  so that cutting portion  722  completely separates an interior bottom portion  734  of braided upper  730  from bottom peripheral portion  736  of braided upper  730 . 
     Cutting portion  722  may be configured to punch through braided material as plate  700  is pressed against a lower side  732  of braided upper  730 . To facilitate cutting, heat and/or pressure could be applied. If cutting portion  722  is sufficiently sharp, or sufficient pressure is applied, no heat may be necessary. Alternatively, last  720  could comprise a material that can be heated so that cutting portion  722  can act to melt through strands of braided upper  730 . Moreover, heat from the last could also be used to fuse broken strands to form a fused edge along the periphery of the bottom opening. 
       FIG. 8  is a schematic view of a step of removing last  200  from braided upper  230 . Last  200  can be removed manually from braided upper  230 . Alternatively, a machine could be used to automatically remove last  200  from braided upper  230 . To facilitate grasping a last (using hands or a machine) the last could further incorporate small grasping features, or recesses to receive a removal tool. Such grasping features and/or recesses may be made sufficiently small so as not to interfere with the overbraiding process and/or deform the resulting braided upper. 
     Bottom opening  502  may have a smaller cross-sectional area than the cross-sectional area of a sole surface  201  of last  200 . Thus, it may be necessary to deform bottom peripheral portion  510  to facilitate the removal of last  200  through bottom opening  502 . Therefore, braided upper  230  may be made flexible enough to facilitate this deformation of bottom peripheral portion  510 . 
     As clearly seen in  FIG. 8 , once last  200  has been removed, bottom opening  502  provides access to the internal (or interior) cavity  800  of braider upper  230 . The “internal cavity” refers to the space enclosed within the upper and that is occupied by a wearer&#39;s foot when the article of footwear is worn. At this point, optional steps to finish the interior of braided upper  230  could be performed. For example, stitches could be applied to the interior surface  802  of interior cavity  800 . Other components, such as reinforcing components could also be added. For example, an interior heel counter could be inserted into interior cavity  800  and fixed into place at the heel. 
     A top opening can be cut out of a braided upper before or after a last is removed. A top opening may comprise a foot-receiving opening. The top opening could include both an opening at the cuff of the upper as well as an opening formed along a lacing region (that is, along an eyestay) of the upper. A top opening could be formed by cutting out material similar to the manner that material is cut out to form the bottom opening. For example, a hot-knife could be used to cut out material and simultaneously from a fused edge along the cuff and fastening area of the upper. However, in cases where the lacing area and cuff may be finished by applying additional layers, the top opening could simply be cut without the need to form a fused edge. 
     Because the overbraided structure is tightly formed around the last, the top opening may be insufficiently large for the last to be removed through the top opening. As an example,  FIG. 10  depicts a schematic (phantom) view of braided upper  230 . Top opening  238  is depicted along with bottom opening  502 . While top opening  238  may be widest along the cuff (in the heel region), top opening  238  may narrow significantly in the lacing region (in the midfoot region) and may be absent in much of the forefoot region adjacent the toes. That is, top opening  238  may have a substantially smaller cross-sectional area than bottom opening  502 . Thus, the presence of bottom opening makes it significantly easier to remove a last from the interior cavity of a braided upper than attempting to do so through a top opening. 
       FIGS. 9-10  depict steps of attaching braided upper  230  to a midsole component  900  to form an article of footwear  1000  (see  FIG. 10 ). As seen in  FIG. 9 , an adhesive  920  could be applied to bottom peripheral portion  510  of braided upper  230 . Then, braided upper  230  could be aligned with midsole component  900 . Depending on the type of adhesive used, a layer of adhesive  922  could also be applied to midsole component  900 . Next, the two pieces could be placed against one another. Heat and/or pressure could also be used to facilitate bonding. 
     Exemplary adhesives that could be used to bond an upper and midsole include, but are not limited to: contact adhesives, drying adhesives, polymer dispersion adhesives, pressure sensitive adhesives, and hot-melt adhesives. Exemplary contact adhesives include natural rubber and polychloroprene (Neoprene), as these adhesives have high shear resistance. Of course, any suitable adhesive known in the art could be selected. Moreover, the specific adhesive used may be selected according to the specific materials comprising the upper and midsole. 
     As seen in  FIG. 9 , bottom peripheral portion  510  also includes a fused edge  511 . This fused edge  511  ensures that the braided structure of braided upper  230  doesn&#39;t come undone when braided upper  230  is bonded with midsole component  900 . 
     This exemplary process produces an article of footwear  1000 , shown in  FIG. 10 . Article of footwear  1000 , or simply article  1000 , is comprised of a braided upper  230  and a midsole component  900 . Optionally, article  1000  may also include an outsole  932 . 
     For purposes of general reference, as illustrated in  FIG. 10 , article of footwear  1000  may be divided into three regions: forefoot region  1010 , midfoot region  1012 , and heel region  1014 . Forefoot region  1010  may be generally associated with the toes and joints connecting the metatarsals with the phalanges. Midfoot region  1012  may be generally associated with the arch of a foot, including the instep. Likewise, heel region  1014  or “hindfoot” may be generally associated with the heel of a foot, including the calcaneus bone. 
     It will be understood that the forefoot region, the midfoot region, and the heel region are only intended for purposes of description and are not intended to demarcate precise regions of an article of footwear. For example, in some cases, one or more of the regions may overlap. Likewise, the medial side and the lateral side are intended to represent generally two sides, rather than precisely demarcating an article of footwear into two halves. In addition, the forefoot region, the midfoot region, and the heel region, as well as the medial side and the lateral side, may also be applied to individual components of an article of footwear, including a sole structure, an upper, a lacing system, and/or any other component associated with the article. 
     In the exemplary embodiment depicted in  FIG. 10 , braided upper  230  comprises a full length upper that extends continuously through all of forefoot region  1010 , midfoot region  1012  and heel region  1014 . Specifically, braided upper  230  comprises a continuously braided structure extending through each of these regions. 
     In this exemplary embodiment, braided upper  230  is bonded directly to midsole component  900  without the need for an intermediate lasting board, plate, or other component to facilitate attaching the upper and sole structure. Moreover, the two components are connected by a substantially continuous bonding region  1050 . Furthermore, the substantially continuous bonding region forms a closed loop. This configuration ensures that there are no gaps along the boundaries of braided upper  230  and midsole component  900  where these two components are not fixedly attached. This helps reduce the tendency for the midsole to delaminate, while also reducing the tendency for particulate matter (or fluid) to enter the interior cavity through gaps between the upper and midsole. 
     Though not depicted in  FIG. 10 , an article could further include an insole. An insole may take the form of a sockliner adjacent the wearer&#39;s foot to provide a comfortable contact surface for the wearer&#39;s foot. It will be understood that an insole may be optional. 
     Although not shown in  FIG. 10 , article  1000  could include various fastening provisions. Examples include, but are not limited to, laces, cables, straps, buttons, zippers as well as any other provisions known in the art for fastening articles. For a lacing system, the fastening region may comprise a plurality of eyelets. In other embodiments, a fastening region may comprise one or more tabs, loops, hooks, b-rings, hollows, or any other suitable fasteners. 
     It may be appreciated that variations of the method described above and shown in  FIGS. 1-10  are possible. As an example, the method could incorporate steps to make it easier to remove a last from a braided upper, especially if the braided upper is relatively rigid and/or non-stretchable. To this end,  FIGS. 11 and 12  illustrate schematic views of another embodiment that incorporates a step of cutting the braided upper prior to removing the last. Referring first to  FIG. 11 , while a last  1100  is still disposed inside of braided upper  1130 , cuts or incisions could be made along a bottom peripheral portion  1140  of braided upper  1130 . In the example of  FIG. 11 , cuts  1142  are made in bottom peripheral portion  1140  using a hot-knife  1150 . The cuts  1142  may be spaced apart at regular or irregular intervals. The presence of cuts  1142  separates bottom peripheral portion  1140  into a plurality of peripheral tab portions  1144 . Moreover, these peripheral tab portions  1144  can flex outwardly (that is, away from an interior cavity of braided upper  1130 ), as shown in  FIG. 12 . With peripheral tab portions  1144  flexed outwardly, last  1100  may be more easily removed through a widened bottom opening  1132  of braided upper  1130 . 
     Although the exemplary embodiment depicts the use of a hot-knife to form tab-like portions in a bottom peripheral portion of a braieded upper, cuts could be made using other methods as well. For example, cuts could be made using a laser cutting machine. Alternatively, a last and/or cutting plate (see  FIGS. 6 and 7 ) could incorporate blades that make cuts or notches in the bottom peripheral portion. 
     In the example shown in  FIGS. 9 and 10 , a braided upper with a bottom opening is mounted to a sole component with a relatively flat upper surface. If the thickness of the braided upper is not sufficiently thin, there may be a discontinuity in the footbed due to the presence of the bottom peripheral portion along the outer edges of the footbed. To address this issue, some embodiments of a braided article could include structures that fit into the bottom opening and thereby create a relatively smooth footbed surface throughout the entire interior of the upper. As used herein, the term “footbed surface” refers to the entire surface within an upper that is in contact with a sole of the foot during use. The footbed surface may comprise part of a sole component (including insoles and/or midsoles) as well as part of an upper (including a bottom peripheral portion). 
       FIGS. 13 and 14  are schematic views of one embodiment of a braided article with a substantially smooth footbed surface. Specifically,  FIG. 13  is a schematic isometric exploded view of a braided article  1300 , while  FIG. 14  is a schematic cross-sectional view of braided article  1300 . 
     As seen in  FIGS. 13-14 , braided article  1300  may include a braided upper  1302 , an insole component  1304 , and a midsole component  1306 . Optionally, braided article  1300  could include an outsole on an outward facing surface of midsole component  1306 . For purposes of illustration, braided article  1300  is shown without a distinct outsole component. 
     Braided upper  1302  may include a bottom opening  1310 , the edge of which is indicated schematically in the cross-sectional view shown in  FIG. 14 . Braided upper  1302  may also include a bottom peripheral portion  1312  that bounds bottom opening  1310 . When assembled with midsole component  1306 , bottom peripheral portion  1312  creates a discontinuity in the surface at the boundary between midsole component  1306  and braided upper  1302 . This discontinuity is due to the nonzero thickness  1320  of bottom peripheral portion  1312 . 
     As also seen in  FIGS. 13 and 14 , insole component  1304  comprises a bottom projecting portion  1330 . Bottom projecting portion  1330  extends downwardly away from a base portion  1332  of insole component  1304 . Moreover, bottom projecting portion  1330  has a smaller cross-sectional area (and width) than base portion  1332 . Specifically, insole component  1304  has a cross-sectional shape that is configured to mate with bottom opening  1310  of braided upper  1302 . As seen in  FIG. 14 , a width  1340  of bottom projecting portion  1330  is substantianally similar to the width of bottom opening  1310  so that bottom projecting portion  1330  fits within bottom opening  1310 . Furthermore, the thickness of bottom projecting portion  1330  (measured relative to the downward surface  1334  of base portion  1332 ) is substantially similar to the thickness of bottom peripheral portion  1312 . Above bottom opening  1310 , base portion  1332  of insole component  1304  widens to match the full width  1346  of braided upper  1302 . That is, base portion  1332  extends outwardly so a peripheral base portion  1350  covers bottom peripheral portion  1312 . This configuration provides a relatively smooth footbed surface  1360  along the upper side of insole component  1304 . By contrast, if the insole component had a substantially constant thickness throughout braided upper  1302 , part of the insole component might deform down into bottom opening  1310  when a foot is placed inside braided upper  1302 , creating a discontinuity in the footbed surface. 
     As seen in  FIG. 14 , a lower surface  1370  of insole component  1304  is substantially flush with the lower surface  1372  of bottom peripheral portion  1312 . This ensures a relatively smooth surface for contacting and attaching to midsole component  1306 . 
     For purposes of illustration, no adhesives or other means of attachment are depicted in  FIG. 14 . It may be appreciated that methods of attaching different components of an article could vary. For example, an upper could be stitched to a midsole component along the bottom peripheral portion of the upper. Alternatively, an adhesive could be used to attach the bottom peripheral portion of the upper to a midsole component (for example, the layer of adhesive  922  in  FIG. 9 ). An insole could be further attached using an adhesive. Alternatively, an insole could be selectively stitched to the bottom peripheral portion of the upper. It&#39;s also possible that an insole could be secured inside an upper by a frictional fit between a bottom projecting portion and the bottom opening in the upper. 
       FIGS. 15 and 16  are schematic views of one embodiment of a braided article with a substantially smooth footbed surface. Specifically,  FIG. 15  is a schematic isometric exploded view of a braided article  1500 , while  FIG. 16  is a schematic cross-sectional view of braided article  1500 . 
     As seen in  FIGS. 15-16 , braided article  1500  may include a braided upper  1502 , an insole component  1504 , and a midsole component  1506 . Optionally, braided article  1500  could include an outsole on an outward facing surface of midsole component  1506 . For purposes of illustration, braided article  1500  is shown without a distinct outsole component. 
     Braided upper  1502  may include a bottom opening  1510 , the edge of which is indicated schematically in the cross-sectional view shown in  FIG. 16 . Braided upper  1502  may also include a bottom peripheral portion  1512  that bounds bottom opening  1510 . 
     As also seen in  FIGS. 15 and 16 , midsole component  1506  comprises an upper projecting portion  1530 . Upper projecting portion  1530  extends upwardly away from a base portion  1532  of midsole component  1506 . Moreover, upper projecting portion  1530  has a smaller cross-sectional area (and width) than base portion  1532 . Specifically, upper projecting portion  1530  has a cross-sectional shape that is configured to mate with bottom opening  1510  of braided upper  1502 . As seen in  FIG. 16 , a width  1540  of upper projecting portion  1530  is substantianally similar to the width of bottom opening  1510  so that upper projecting portion  1530  fits within bottom opening  1510 . This configuration provides a relatively smooth footbed surface  1560  along the foot-receiving surface of insole component  1504 . By contrast, if the midsole component had a substantially constant thickness throughout the width of article  1500 , part of the insole component  1504  might deform down into bottom opening  1510  when a foot is placed inside braided upper  1502 , creating a discontinuity in the footbed surface. Alternatively, in another embodiment, article  1500  may not include insole component  1504 . However, the footbed surface formed by midsole component  1506  and bottom peripheral portion  1512  may still be substantially smooth without any discontinuities. 
     Methods of permanently attaching these components can include any of the methods described above with respect to  FIGS. 13-14 . 
       FIGS. 17 and 18  are schematic views of one embodiment of a braided article with a substantially smooth footbed surface. Specifically,  FIG. 17  is a schematic isometric exploded view of a braided article  1700 , while  FIG. 18  is a schematic cross-sectional view of braided article  1700 . 
     As seen in  FIGS. 17-18 , braided article  1700  may include a braided upper  1702  and a midsole component  1706 . Optionally, braided article  1700  could include an outsole on an outward facing surface of midsole component  1706 . For purposes of illustration, braided article  1700  is shown without a distinct outsole component. Braided upper  1702  may include a bottom opening  1710 , the edge of which is indicated schematically in the cross-sectional view shown in  FIG. 18 . Braided upper  1702  may also include a bottom peripheral portion  1712  that bounds bottom opening  1710 . 
     As also seen in  FIGS. 17 and 18 , midsole component  1706  comprises a peripheral slot  1720  that extends around the entire peripheray of midsole component  1706 . Specifically, peripherl slot  1720  may be disposed in a sidewall  1721  of midsole component  1706 . Peripheral slot  1720  separates midsole component  1706  into a lower midsole portion  1724  and an upper midsole portion  1722 . As seen in  FIG. 18 , peripheral slot  1720  (that is, the space between lower midsole portion  1724  and upper midsole portion  1722 ) may be sized to receive bottom peripheral portion  1712 . If peripheral slot  1720  is sufficiently rigid, this may have the effect of locking midsole component  1706  to braided upper  1702 , without the need for additional adhesives, stitches, or other fasteners. Optionally, various kinds of adhesives, stitches, or other fasteners could be used to secure parts of midsole component  1706  to braided upper  1702 . 
     As seen in  FIG. 18 , upper midsole portion  1722  may have a width  1802  that matches the width of braided upper  1702  along the interior lower periphery. In particular, an outer peripheral portion  1726  of upper midsole portion  1722  extends over bottom peripheral portion  1712  of braided upper  1702 . This configuration provides a relatively smooth footbed surface  1860  along the upper side of midsole component  1704 . 
     When compared to alternative methods for making an article, the exemplary method facilitates easier insertion of various components into the interior of an upper. Specifically, alternative methods may rely on only the opening at the top of an upper (that is, the foot-receiving opening) for inserting parts. Because of the size and location of this foot-receiving opening, both the insertion and placement of interior components may be difficult. By contrast, the exemplary method allows components to be inserted through bottom opening, which is substantially larger than the opening at the top of the upper that typically receives a foot. This makes it easier to insert components that are substantially wider than the opening at the top of the upper. It also makes it easier to place parts within the interior, since the bottom opening extends along the entire length of the braided upper. 
     As seen in  FIG. 19 , a braided upper  1902  includes a forefoot region  1910 , a midfoot region  1912 , and a heel region  1914 . Moreover, braided upper  1902  includes a bottom opening  1920  that extends through each of forefoot region  1910 , midfoot region  1912 , and heel region  1914 . In the example shown in  FIG. 19 , the method of assembling a braided article can include a step of inserting interior components through bottom opening  1920 . For example, a toe reinforcing component  1930  can be inserted through bottom opening  1920  at forefoot region  1910 . This allows the toe reinforcing component  1930  to be easily placed within toe box portion  1940  of braided upper  1902 , as seen in  FIGS. 19-20 . Likewise, a heel reinforcing component  1932  (such as a heel cup or heel counter) can be easily placed within heel portion  1942  of braided upper  1902 , as also seen in  FIGS. 19-20 . In some cases, these reinforcing components could be further attached to the interior side of braided upper  1902  using adhesives, stitching, and/or other kinds of fasteners. If stitching or other adhesives are used to attach a reinforcing component along an interior of the upper, the present method may make this process easier and more accurate, as the tools for applying stitching or other fasteners can be readily placed through the bottom opening of the braided upper. 
     With these components in place, a midsole component  2002  can be assembled with braided upper  1902  to form article of footwear  2000 , as shown schematically in  FIG. 20 . For purposes of illustration, midsole component  2002  is shown generically in  FIG. 20 . However, midsole component may incorporate a raised upper portion (as in  FIGS. 15-16 ) or a peripheral slot (as in  FIGS. 17-18 ) to provide a smooth footbed surface. Alternatively, article  2000  could further include an insole component with a bottom projecting portion (as in  FIGS. 13-14 ). 
     It may be appreciated that the method described herein can also facilitate incorporating other kinds of internal footwear components beyond a toe reinforcing component and/or a heel reinforcing component. Some uppers may require the use of reinforcing panels at various portions along the upper. For example, some uppers may require the use of a component to reinforce the eyestay region of the upper from within the inside of the upper, as opposed to reinforcing the eyestay by attaching a reinforcing component to the external side of the upper. As another example, the present method may make it easier to add additional embroidered layers and/or knit layers to the interior of the braided upper by accessing the interior of the upper through the bottom opening. Furthermore, internal straps, bands, or other fasteners or tensioning elements could be more easily inserted and attached to interior portions of a braided upper using these same methods. 
     The exemplary methods produce an article of footwear in which user&#39;s foot may come into direct contact with a footbed surface of a sole component, even when there is no insole component used. As an example,  FIG. 21  shows a schematic view of an article of footwear  2100  with a braided upper  2102  that has been constructed using the exemplary processes described above. Article  2100  also includes a midsole component  2104 . 
     As shown in  FIG. 21 , a user&#39;s foot  2110  comes into direct contact with an upper surface  2120  of midsole component  2104 , which is disposed through a bottom opening  2130  of braided upper  2102 . This configuration may improve both cushioning and support compared to other configurations where a relatively rigid material acts to separate the footbed surface from the midsole component. Such a relatively rigid material could be a layer of an upper that closed along the bottom, and/or an adhesive layer. The presence of these layers in some cases may increase the rigidity of the structures between the footbed surface and the outermost surface of the midsole, thereby reducing cushioning and support. By eliminating the need for such structural layers, the present system can improve support and cushioning in an article of footwear. 
     As described above, a braided upper may be comprised of a plurality of strands. These strands may be formed of different materials. The properties that a particular strand will impart to an area of a braided structure depend on the materials that form the various filaments and fibers within the strands. For example, the filaments may be formed of cotton. Cotton may provide a soft hand, natural aesthetics as well as biodegradability. Other embodiments may include elastane or stretch polyester. In still further embodiments, nylon may be incorporated. Nylon is a durable, abrasion-resistant material with relatively high strength that may be incorporated into areas of an article of footwear that are more likely to be exposed to high stress or scraping than other areas. Polyester may be incorporated due to its hydrophobic nature. For example, a waterproof or water-resistant article may incorporate polyester. Additionally, various materials may be utilized for sweat removal or wicking. The materials chosen may also include properties that permit the material to melt or bond to various components. For example, the materials may include thermoplastic or thermoset materials as well as other heat-activated materials. Additionally, other materials may be utilized for various material properties. In addition to material, other aspects of the strand may be altered to affect the properties of the braided structure. For example, a strand may include monofilament or multifilament thread. The strand may also include separate filaments that are formed of different materials, such as bicomponent strands. 
     As used herein, the term “article” refers broadly to articles of footwear, articles of apparel (e.g., clothing), as well as accessories and/or equipment. Articles of footwear include, but are not limited to, hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross-training shoes, rugby shoes, basketball shoes, baseball shoes as well as other kinds of shoes. Various kinds of non-sports-related footwear, include, but are not limited to, slippers, sandals, high-heeled footwear, loafers as well as any other kinds of footwear. 
     Similar principles to those described above could be used with any other kinds of braided articles that may be formed by overbraiding onto a “last” or other form. Specifically, these principles could be applied to various kinds of apparel, accessories, and/or equipment. Examples of apparel include, but are not limited to, socks, pants, shorts, shirts, sweaters, undergarments, hats, gloves, as well as other kinds of garments. Accessories include scarves, bags, purses, backpacks, as well as other accessories. Equipment may include various kinds of sporting equipment including, but not limited to, bats, balls, various sporting gloves (e.g., baseball mitts, football gloves, ski gloves, etc.), golf clubs, as well as other kinds of sporting equipment. 
     While various embodiments have been described, the description is intended to be exemplary, rather than limiting, and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.