Patent Publication Number: US-11033076-B2

Title: Article of footwear having an upper with cord elements

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 14/469,039, filed Aug. 26, 2014, which is a divisional of U.S. patent application Ser. No. 13/184,715, filed Jul. 18, 2011, the entirety of each of which is hereby incorporated 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, foam layers, leather, synthetic leather) that are stitched or adhesively bonded together to form a void on the interior of 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. 
     The various material elements forming the upper impart different properties to different areas of the upper. For example, textile elements may provide breathability and may absorb moisture from the foot, foam layers may compress to impart comfort, and leather may impart durability and wear-resistance. As the number of material elements increases, the overall mass of the footwear may increase proportionally. The time and expense associated with transporting, stocking, cutting, and joining the material elements may also increase. Additionally, waste material from cutting and stitching processes may accumulate to a greater degree as the number of material elements incorporated into an upper increases. Moreover, products with a greater number of material elements may be more difficult to recycle than products formed from fewer material elements. By decreasing the number of material elements, therefore, the mass of the footwear and waste may be decreased, while increasing manufacturing efficiency and recyclability. 
     The sole structure is secured to a lower portion of the upper so as to be positioned between the foot and the ground. In athletic footwear, for example, the sole structure 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. 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 upper and proximal to a lower surface of the foot to enhance footwear comfort. 
     SUMMARY 
     An article of footwear is described below as having an upper and a sole structure secured to the upper. In one aspect, a method of manufacturing an article of footwear includes placing a cord on a bottom layer, temporarily securing the cord to the bottom layer, placing a second layer on the bottom layer, where the cord is disposed between the second layer and the bottom layer. The method also includes attaching the second layer to the bottom layer, where the second layer and bottom layer are configured to form a plurality of tunnels for receiving the cord. The method also includes detaching the cord from the bottom layer and creating an upper with the bottom layer, the second layer, and the cord. 
     In another aspect a method of manufacturing an article of footwear includes placing a cord on a bottom layer, stitching the cord to the bottom layer with a first thread, and placing a second layer on the bottom layer, where the cord is disposed between the second layer and the bottom layer. The method also includes attaching the second layer to the bottom layer, where the second layer and bottom layer are configured to form a plurality tunnels for receiving the cord. The method also includes removing the first thread and forming a loop from a portion of the cord, the loop being disposed outside of the plurality of tunnels and wherein the loop is configured to receive a lace. The method also includes forming an upper with the bottom layer, the second layer, and the cord. 
     In another aspect an article of footwear includes a sole structure and an upper. The upper includes a bottom layer and a second layer fixed to the bottom layer to create a tunnel system comprising a plurality of tunnels. The upper also includes at least one cord, where the cord is configured to be received by the tunnel system and where the cord is capable of moving longitudinally through the tunnel system. The upper also includes a lacing system in a lacing region, where cord elements of the cord are configured to form a plurality of loops to weave through the lacing system. Two or more of the plurality of loops are formed by a single cord and the cord elements are exposed from the tunnel system in at least one region of 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. 
    
    
     
       FIGURE DESCRIPTIONS 
       The foregoing Summary and the following Detailed Description will be better understood when read in conjunction with the accompanying figures. 
         FIG. 1  is a perspective view of an article of footwear; 
         FIG. 2  is a top plan view of the article of footwear; 
         FIG. 3  is a side elevational view of the article of footwear; 
         FIG. 4  is a schematic perspective view of a portion of an upper with cord elements, as defined in  FIG. 3 ; 
         FIG. 5  is an exploded schematic perspective view of the portion of the upper with cord elements; 
         FIG. 6  is a cross-sectional view of an embodiment of an article of footwear; 
         FIG. 7  is an exploded cross-sectional view of the embodiment of the article of footwear depicted in  FIG. 6 ; 
         FIG. 8  is a perspective view of an embroidery machine used for manufacturing in some footwear upper configurations; 
         FIG. 9  shows an example of a process for manufacturing an article of footwear; 
         FIGS. 10 and 11  depict a top plan view and cross-sectional view of an embodiment of a partially formed an article of footwear; 
         FIGS. 12 and 13  depict another top plan view and cross-sectional view of an embodiment of a partially formed article of footwear; 
         FIGS. 14 and 15  depict another top plan view and cross-sectional view of an embodiment of a partially formed article of footwear; 
         FIGS. 16 and 17  depict another top plan view and cross-sectional view of an embodiment of a partially formed article of footwear; 
         FIGS. 18 and 19  depict another top plan view and cross-sectional view of an embodiment of a partially formed article of footwear; 
         FIGS. 20 and 21  depict another top plan view and cross-sectional view of an embodiment of a partially formed article of footwear; 
         FIG. 22  is a schematic view of an additional step of cutting layers of an upper; 
         FIG. 23  is a schematic view of a process for removing a thread; 
         FIG. 24  is a schematic cross-sectional view of an alternative process for removing the first thread; 
         FIG. 25  is a cross-sectional view of an embodiment of a plurality of cord elements of cord a system; 
         FIG. 26  is a cross-sectional view of an embodiment of a plurality of cord elements of cord a system; 
         FIGS. 27-29  a cross-sectional views of an embodiment of a plurality of cord elements of cord a system; 
         FIG. 30  is an embodiment of an alternative configuration of a cord system; 
         FIG. 31  is a schematic view of an embodiment of an upper with a fully stitched perimeter; 
         FIG. 32  shows a schematic view of an embodiment of an upper with a partially stitched perimeter; 
         FIG. 33  shows a schematic view of an embodiment of an upper with a fully stitched perimeter without cord elements stitched into the perimeter; and 
         FIG. 34  is a side elevational view of an embodiment of an article of footwear with a partially stitched parameter. 
     
    
    
     DETAILED DESCRIPTION 
     The following discussion and accompanying figures disclose an article of footwear having an upper that includes a cord element. The article of footwear is disclosed as having a general configuration suitable for walking or running. Concepts associated with the footwear, including the upper, may also be applied to a variety of other athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking boots, 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 , herein referred to simply as footwear  10 , is depicted in  FIGS. 1-3  as including a sole structure  20  and an upper  30 . For reference purposes, footwear  10  may be divided into three general regions: a forefoot region  11 , a midfoot region  12 , and a heel region  13 . Footwear  10  also includes a lateral side  14  and a medial side  15 . 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 the arch area of the foot, and heel region  13  corresponds with rear portions of the foot, including the calcaneus bone. Lateral side  14  and medial side  15  extend through each of forefoot region  11 , midfoot region  12 , and heel region  13  (as seen in  FIG. 3 ) and correspond with opposite sides of footwear  10  that are separated by a lace region  16 , which extends through a length of footwear  10 . Forefoot region  11 , midfoot region  12 , heel region  13 , lateral side  14 , and medial side  15  are not intended to demarcate precise areas of footwear  10 . Rather, they are intended to represent general areas of footwear  10  to aid in the following discussion. In addition to footwear  10 , forefoot region  11 , midfoot region  12 , heel region  13 , lateral side  14 , and medial side  15  may also be applied to sole structure  20 , upper  30 , and individual elements thereof. 
     Sole structure  20  is secured to upper  30  and extends between the foot and the ground when footwear  10  is worn. The primary elements of sole structure  20  are 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  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. 
     The various portions of upper  30  may be formed from one or more of a plurality of material elements (e.g., textiles, polymer sheets, foam layers, leather, synthetic leather) that are stitched or bonded together to form a void within footwear  10  for receiving and securing a foot relative to sole structure  20 . The void is shaped to accommodate the foot and extends along the lateral side of the foot, along the medial side of the foot, over the foot, around the heel, and under the foot. Access to the void is provided by an ankle opening  31  located in at least heel region  13 . 
     A lace  32  extends through various lace apertures  33  and permits the wearer to modify dimensions of upper  30  to accommodate the proportions of the foot. More particularly, lace  32  permits the wearer to tighten upper  30  around the foot, and lace  32  permits the wearer to loosen upper  30  to facilitate entry and removal of the foot from the void (i.e., through ankle opening  31 ). As an alternative to lace apertures  33 , upper  30  may include other lace-receiving elements, such as loops, eyelets, and D-rings. In addition, upper  30  includes a tongue  34  that extends between ankle opening  31  and lace  32  to enhance the comfort of footwear  10 . In some configurations, upper  30  may incorporate a heel counter that limits heel movement in heel region  13  or a wear-resistant toe guard located in forefoot region  11 . 
     In some cases, upper  30  may include a plurality of lace apertures  33 , including evenly spaced apertures on lateral side  14  of lace region  16  extending from ankle opening  31  to forefoot region  11 . Similarly, upper  30  may include a symmetrical, evenly spaced group of apertures on medial side  14  of lace region  16 . Lace  32  may be interwoven though these apertures to provide structural support to upper  30 . In some cases, lace apertures may be formed by loops in exposed cord elements from a cord system. Such configurations are discussed in further detail below. 
     Corded Upper Configuration 
     Referring to  FIGS. 1-3 , article of footwear  10  includes provisions for providing structural support across the upper. Generally, article of footwear  10  may include support system  81  that comprises cord system  59  and tunnel system  65 . Cord system  59  can include one or more cords that extend throughout portions of upper  30 . A cord may be formed from any generally one-dimensional material. As utilized with respect to the present embodiments, the term “one-dimensional material” or variants thereof is intended to encompass generally elongated materials exhibiting a length that is substantially greater than a width and a thickness, such as yarns, cables, threads, ropes, chains, and strands. In one embodiment, cord system  59  includes cord  58 . In particular, in the embodiment shown in the Figures, cord system  59  comprises a single cord, rather than multiple cords. However, in other embodiments, more than one cord could be used with cord system  59 . In some cases, cord system  59  may be visible through tunnel system  65 . 
     The cord may be formed from a plurality of synthetic materials such as rayon, nylon, polyester, and polyacrylic, cotton, and silk. In addition, the cord may be formed from various engineering fibers, such as aramid fibers, para-aramid fibers, and carbon fibers. 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 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. In different embodiments, the material properties of cord  58  can vary. For example, in some cases, cord  58  can be substantially elastic. In other embodiments, however, cord  58  could be substantially rigid. In different cases, the degree of elasticity or rigidity of cord  58  could be selected according to desired properties for footwear  10 . 
     In some embodiments, support system  81  can include tunnel system  65  that is configured to receive portions of cord  58 . Tunnel system  65  generally comprises one or more tunnels disposed on an outer surface of upper  30  through which cord  58  extends. The term “tunnel” as used throughout this detailed description and in the claims refers to any passage, channel, cavity or other similar feature through which a cord can move and that covers at least a portion of the cord. In some embodiments, tunnel system  65  may comprise a single continuous tunnel. In other embodiments, tunnel system  65  may comprise multiple disjoint tunnels. Moreover, tunnel system  65  may comprise multiple tunnels that intersect or otherwise overlap. Tunnels may include passages formed between two layers of upper material defined by stitching or thermal welding, tube-like material attached to upper  30 , adhesive tape attached to a layer of upper material, or any other known mechanism. 
     In some embodiments, tunnel system  65  may be the same color or texture as the rest of upper  30 . In other embodiments, tunnel system  65  may be a different color or texture. Moreover, in some cases, tunnel system  65  could be substantially raised from the upper surface of upper  30 . In other cases, tunnel system  65  could be substantially flat with respect to an upper surface of upper  30 . 
     Support system  81  (including both cord system  59  and tunnel system  65 ) can be associated with various portions of upper  30 . In some cases, cord system  59  can be associated with forefoot region  11  of upper  30 . In other cases, cord system  59  can be associated with midfoot region  12  of upper  30 . In still other cases, cord system  59  can be associated with heel region  13  of upper  30 . In still other cases, cord system  59  can be associated with multiple different regions of upper  30 . In one embodiment, cord system  59  may extend through the substantial entirety of upper  30 , including forefoot region  11 , midfoot region  12 , and heel region  13 . 
     Cord system  59  may be incorporated into lace region  16  of upper  30 . In some cases, cord system  59  may comprise a plurality of exposed cord elements located in lace region  16 . A cord element is a subsection of cord system  59 . To be an exposed cord element, the cord element is configured to be exposed outside the tunnel system. Accordingly, lace  32  may be capable of being interwoven with the exposed cord elements of cord system  59 . For example, in the current embodiment, lace apertures  33  comprise exposed cord elements of cord system  59 . In such cases, when lace  32  is tightened, cord system  59  may provide additional structural support to upper  30 . 
     In other cases, cord system  59  may comprise exposed cord elements (not shown) located in the sole structure region. In such cases, those exposed cord elements may be disposed along sole structure  20  of article of footwear  10 . Such embodiments will be discussed in greater detail in later figures. It will be appreciated that exposed cord elements may exist in other regions of the article of footwear  10 , such as heel region  13  and forefoot region  11 . 
     In some cases, cord system  59  and tunnel system  65  may be in one or more variety of patterns. In some embodiments, tunnel system  65  may be configured with a plurality of linear tunnels extending across various portions of upper  30 . In other embodiments, tunnel system  65  may be configured with a plurality of curved (or nonlinear) tunnels extending across various portions of upper  30 . Moreover, tunnel system  65  may be configured with parallel tunnels or intersecting tunnels. In one embodiment, tunnel system  65  comprises a criss-crossing pattern of tunnels in forefoot region  11  and substantially parallel tunnels in midfoot region  12 . Also, in some cases, tunnel system  65  may include straight tunnels that generally extend from lace region  16  to sole structure  20 . 
     Cord  58  may extend through tunnel system  65  in various ways. In the current embodiment, cord  58  may wind through tunnel system  65  in a zigzag (or alternating) manner between lace region  16  and sole structure  20  at midfoot region  12 . Likewise, cord  58  may be configured in an intersecting pattern throughout the tunnels of tunnel system  65  disposed in forefoot region  11 . It will be appreciated that other patterns or placements of patterns are also possible. 
       FIGS. 4 and 5  illustrate embodiments of a segment  400  of upper  30  including multiple cord elements. In particular,  FIG. 4  illustrates an enlarged isometric view, while  FIG. 5  illustrates an exploded isometric view. 
     Referring to  FIGS. 4 and 5 , upper  30  may include provisions for maintaining a system of movable cords within a tunnel system. Generally, upper  30  may comprise at least a first layer  410  and a second layer  420 , herein referred to as the upper layers. Upper  30  may also comprise cord element  431 , cord element  433 , cord element  435 , and cord element  437 . It will be appreciated that while only four cord elements are shown, the illustration only depicts a subsection of upper  30 . Accordingly, there may be a greater number of cord elements. Cord element  431 , cord element  433 , cord element  435 , and cord element  437  may each be an element of the same cord or different cords within a system of cords. All cords within upper  30  will herein be referred to as cord system  59 . 
     First layer  410  and second layer  420  can be of any material or mixed materials, including but not limited to various textiles (woven, knitted, and non-woven) canvas, leather, or vinyl. In some embodiments, second layer  420  may be made of the same material as first layer  410 . In other embodiments, second layer  420  may be made of a different material or a mixture of materials. 
     Upper  30  may also comprise stitching  441  to secure second layer  420  to first layer  410 . Stitching  441  may comprise a thread that may be made of any material including, but not limited to, cotton, silk, and polyester. In some cases, the upper layers may be stitched together so as to form tunnel  451 , tunnel  453 , tunnel  455 , and tunnel  457 . Other tunnels of upper  30  may not be shown. All tunnels of upper  30  are herein referred to as the tunnel system. The cord system  59  may be disposed inside of the plurality of tunnels so they may move freely in multiple directions. It will be appreciated that while only a section of upper  30  is shown, these features may apply to any section of upper  30 . It should be noted that stitching  441  may be replaced by any other method or structure for securing layers  410  and  420 , including adhesive bonding, thermal bonding, tacking, stapling, and pinning, for example. 
     As seen in  FIG. 5 , without stitching  441  connecting the upper layers, the second layer  420  and first layer  410  may be physically separated. Similarly, cord system  59  may be physically separated from the upper layers.  FIGS. 6 and 7  show a cross-sectional view and exploded cross-sectional view of article of footwear  10 . Generally, article of footwear  10  may comprise sole structure  20 . Sole structure  20  may comprise outsole  22 , midsole  21 , and sockliner  23 . It will be appreciated that some illustrated elements of sole structure  20  may be optional. Alternatively, sole structure  20  may comprise additional layers (not shown). 
     Article of footwear  10  may also comprise upper  30 . Upper  30  may comprise second layer  420 , cord system  59 , and first layer  410 . Cord system  59  may be disposed between second layer  420  and first layer  410 . In some cases, cord system  59  may extend only as far as the bottom portion of upper  30 . However, in other embodiments, cord system  59  may extend to midsole  21  or outsole  22 . Such embodiments will be described in detail in later figures. It will be appreciated that some illustrated elements of upper  30  may be optional. Alternatively, other additional elements may be included. For example, upper  30  may comprise additional fabric layers (not shown). 
     Manufacturing Method 
     A method for making an article with a support system can include provisions for efficiently assembling an upper including a cord system and a tunnel system.  FIGS. 8 through 18  illustrate embodiments of a method of manufacturing an upper for an article of footwear including a support system. 
       FIG. 8  shows an embodiment of an embroidery machine  800 . In some cases, one or more steps of the manufacturing process may use embroidery machine. In other embodiments, many or all steps may be completed by hand. When embroidery machine  800  is used, placement patterns for the cord system may be easier, such as hairpin turns. 
     Embroidery machine  800  may include provisions for generating and controlling embroidery patterns. In some cases, embroidery machine  800  may be controlled manually. In other cases, embroidery machine  800  may be controlled by a computer system. The computer system may be located on embroidery machine  800 . However, in other embodiments, separate computer system  850  may control the actions of embroidery machine  800 . Computer system  850  may include connection  820  to embroidery machine  800 . While connection  820  is shown, it will be appreciated that computer system  850  may communicate with embroidery machine  800  through any known means, including using some form of wireless communication. 
     Computer  850  may be any type of personal computer, commercial computer, or use-specific computer. Generally, computer system  850  is controlled by a central processing unit. The central processing unit may be a general purpose processor, a digital signal processor or any other type of processor. Computer system  850  may also comprise other auxiliary elements, including but not limited to: a monitor, a mouse, a keyboard, a hard drive or solid state drive. 
     A proprietor may use embroidery machine  800  in conjunction with computer system  850  to design and/or create an upper including a support system such as the support system described above. For example, in some cases a proprietor could use computer system  850  to design or import an existing design for a predetermined pattern associated with a tunnel system and cord system. The design may be processed and submitted as instructions to control embroidery machine  800  to stitch together various layers of an upper as well as one or more cords in the manner discussed below. 
       FIG. 9  shows an embodiment of a process for manufacturing an article of footwear. Some or all steps in the process may be completed by a footwear manufacturer or proprietor. In other cases, some steps could be accomplished by a manufacturer and other steps could be accomplished by another party including another manufacturer, proprietor, retailer or any other entity. In some cases, one or more of the steps may be optional. In other cases, some steps may be completed in a different order. 
     In step  902 , a first layer may be placed on a working surface. In some embodiments, the first layer may have been pre-cut into the intended shape of the completed upper. As described in the embodiments below, the upper has not been pre-cut. In some cases, the first layer may be placed on any substantially flat surface. In other cases, the first layer may be placed in an embroidery machine, such as embroidery machine  800  (see  FIG. 8 ). 
     In step  904 , a cord system may be placed on the first layer. The cord system may comprise one or more cords and may be placed in any configuration. In some cases, the cord system may be placed to provide cord elements along a lacing region. In some cases, a computer program and embroidery machine may facilitate placing the cord system in a desired pattern. The computer program and embroidery machine may be capable of placing the cord system with consistent precision, allowing an accurate cord length to be provided in this step. The computer program and embroidery machine may also facilitate certain patterns that are difficult to perform by hand, such as hairpin turns or other complex patterns. 
     In step  906 , the cord system may be stitched or otherwise secured to the first layer using a first thread. Generally, the cord system is stitched so that it may not be moved in any direction relative to the first layer. The stitching may be completed by hand, by embroidery machine  800  or by any other process. In some cases, the first thread may be specially colored to facilitate later removal. In some cases, the type of stitching used in securing the cord system to the first layer can be selected so that the stitching is relatively easy to remove at a later time. For example, the stitching may be water-soluble or soluble with other chemicals so that the stitching is relatively easy to remove at a later time. It should be noted that stitching is only an example of a method of securing the cord system to the first layer, with other examples being adhesive bonding, thermal bonding, tacking, stapling, and pinning, for example. 
     In step  908 , the second layer may be placed on the first layer. In some cases, the second layer may be pre-cut into the shape of a completed upper; however, as illustrated, the second layer may not be pre-cut. If pre-cut, the second layer may be placed on the first layer so that the edges align. In other embodiments, the second layer shape and the first layer shape may differ. Accordingly, the cord system may be disposed between the second layer and the first layer. 
     In step  910 , the second layer may be stitched onto the first layer using a second thread. Generally, the stitching may be completed to form tunnels surrounding each cord element. In some cases, the tunnels may be configured so the tunnels fit snuggly around each cord element. In other cases, the tunnels may be configured to fit more loosely around each cord element. 
     In some embodiments, the first thread may be different than the second thread. In particular, the first thread may be designed to be a less permanent stitching than the second thread. In some cases, the first thread may be designed to be easily removed by cutting. In other cases, the first thread may be designed to be dissolved in water or another solution. Moreover, as discussed in detail below, in some cases, the second layer may be connected to the first layer by means other than stitching. In some cases, the second layer can be thermally welded to the first layer. 
     In step  912 , the first stitching with the first thread may be removed. More generally, the cord system is detached from the first layer. The thread used to stitch the cord system to the first layer may be removed. After this stitching is removed, the cord system may be allowed to move freely within the confines of the tunnels created by the second stitching with the second thread. The first thread may be removed by any known method, including but not limited to: cutting away the first thread or dissolving the first thread in water or another solution. 
     In step  914 , the combined first layer, cord system, and second layer may be used to form an upper. The upper may be formed using any known technique and subsequently added to a sole structure to form a completed article of footwear. It will be appreciated that the upper may be created using additional layers, cords or stitching not expressly mentioned. 
       FIGS. 10-11  show a schematic and cross-sectional view of a partially formed article of footwear. In particular, the illustration refers to step  902  of  FIG. 9  and shows a schematic view of bottom later  1010  as well as a cross-sectional view of portion  1090  of first layer  1010 . Accordingly, first layer  1010  may be placed down on a working surface of some kind. In some cases, first layer  1010  may be of substantially even thickness, as shown in the cross-sectional view of portion  1090 . In some cases, first layer  1010  may be placed on a flat surface. In other cases, first layer  1010  may be placed on a curved surface. In one embodiment, first layer  1010  may be placed on a surface of an embroidery machine, such as embroidery machine  800 . While first layer  1010 , as illustrated, has not been cut into the shape of an upper, in other embodiments, a step may occur prior to step  902 . In some cases, when uncut, the outline of the upper may be provided on first layer  1010  so that it may be visible to the manufacturer. 
       FIGS. 12-13  show another schematic and cross-sectional view of a partially formed article of footwear. In particular, the illustration refers to step  904  of  FIG. 9  and shows a schematic view of first layer  1010  and a cross-sectional view of portion  1090 . Accordingly, cord system  1159  may be placed upon first layer  1010 . Cord system  1159  may be comprised of one or more cords and may comprise a plurality of cord elements, including cord element  1131 , cord element  1133 , and cord element  1135 . In the current embodiment, cord element  1131 , cord element  1133 , and cord element  1135  comprise portions of cord system  1159 . 
     As shown in the cross-sectional view of portion  1090 , cord element  1131 , cord element  1133 , and cord element  1135  may have a substantially circular cross-section. It will be appreciated that cord element  1131 , cord element  1133 , and cord element  1135  may have any cross-sectional shape including, but not limited to: rounded, triangular, rectangular, flattened, polygonal, regular, irregular or any other kind of cross-sectional shape. 
     Cord system  1159  may be placed in any configuration. As illustrated, cord system  1159  may comprise several cord elements crossed in forefoot portion  11 . Similarly, both medial side  15  and lateral side  14  of the midfoot portion  12  may comprise cord elements in an approximately zigzagging pattern. In some cases, cord system  1159  may be configured so that some portions of the cord elements are arranged near a lace region  16 . In other cases, cord elements may be configured to be attached to portions of the sole structure (not shown). Such embodiments will be shown in greater detail in later figures. 
       FIGS. 14-15  show another schematic and cross-sectional view of a partially formed article of footwear. In particular, the illustrations refer to step  906  of  FIG. 9  and show a schematic view of first layer  1010  and cord system  1159  and a cross-sectional view of portion  1090 . Accordingly, cord system  1159  may be secured in place using first thread  1270 . In particular, first thread  1270  is used to stitch cord system  1159  to first layer  1010 . In some cases, first thread  1270  may be stitched along the entire length of cord system  1159 . In other cases, first thread  1270  may be stitched along some portions of cord system  1159 , but not others. In different embodiments, first thread  1270  could be made of varying materials. In some embodiments, first thread  1270  may be made of any material including, but not limited to: cotton, silk, and polyester. In other embodiments, any other materials known in the art could be used. As suggested above, stitching with first thread  1270  is only an example of a method of securing cord system  1159  to first layer  1010 , with other examples being adhesive bonding, thermal bonding, tacking, stapling, and pinning, for example. 
     Once stitched, cord system  1159  may be limited to little or no movement with respect to first layer  1010 . First thread  1270  may also be designed to be easily removed by any known method including, but not limited to: cutting or dissolving in water or another solution. In some cases, the type of stitching used to secure first thread  1270  to first layer  1010  may be selected to facilitate easy removal of first thread  1270  from cord system  1159  and first layer  1010 . 
       FIGS. 16-17  show another schematic and cross-sectional view of a partially formed article of footwear. In particular, the illustrations refer to step  908  of  FIG. 9  and show a schematic view of first layer  1010  and cord system  1159  and a cross-sectional view of portion  1090 . Accordingly, second layer  1320  may be placed on first layer  1010  and cord system  1159 . In some cases, second layer  1320  may be pre-cut into the form of an upper. As illustrated, second layer  1320  has not been pre-cut. Accordingly, a visible outline may be made on second layer  1320  to form the shape of the completed upper. If appropriate, the edges of second layer  1320  may be aligned with first layer  1010 . In some embodiments, first layer  1010  and cord system  1159  will not be visible through second layer  1320 . However, both first layer  1010  and cord system  1159  are visible for illustrative purposes. 
       FIGS. 18-19  show another schematic and cross-sectional view of a partially formed article of footwear. In particular, the illustrations refer to step  910  of  FIG. 9  and show a schematic view of first layer  1010 , cord system  1159 , and second layer  1320  and a cross-sectional view of portion  1090 . Accordingly, second layer  1320  may be secured to first layer  1010 . In some cases, the securing is completed by stitching with second thread  1460 . In other cases, the securing may be completed by thermal welding. If stitched, second thread  1460  may be configured to form a tunnel system for receiving various cord elements. As illustrated the tunnel system comprises tunnel  1451 , tunnel  1453 , and tunnel  1455 . In some cases, the tunnel system may be configured to fit snuggly upon cord system  1159 . In other cases, the tunnel system may be more loosely fit. In some embodiments, second layer  1320  may be designed to be substantially clear, allowing cord system  1159  to be visible through second layer  1320 . In other embodiments, second layer  1320  may be opaque. 
     In some embodiments, stitching from second thread  1460  may also form a perimeter along the edges of the upper for second layer  1320  and first layer  1010 . In such cases, second thread  1460  may be configured to stitch portions of cord system  1159  to the upper, for example along the parameter of the upper. Accordingly, second thread  1460  may restrict the movement of cord system  1159 . In other cases, second thread  1460  may not be configured to bind cord system  1159 . In still other cases, second thread  1460  may not be used at all in some perimeter portions, such as the lateral side  14  or the medial side  15 . Accordingly, cord elements of cord system  1159  may be capable of being exposed outside of an upper. 
       FIGS. 20-21  show another schematic and cross-sectional view of a partially formed article of footwear. In particular, the illustrations refer to step  912  of  FIG. 9  and show a schematic view of first layer  1010 , cord system  1159 , and second layer  1320  and a cross-sectional view of portion  1090 . Accordingly, the first stitching with the first thread  1270  may be removed. The removal may be completed by any known method, including soaking upper  30  in water or another solution or by cutting first thread  1270  with or without the use of a tool. 
     Once first thread  1270  is removed, cord system  1159  may be capable of moving more freely within the confines of the tunnel system. In some cases, cord system  1159  may still be stitched using second thread  1460  in some locations. Depending on the location of second thread  1460 , cord system  1159  may have varying ability to move within the tunnel system. As illustrated, second thread  1460  is configured very close to cord element  1131 , cord element  1133 , and cord element  1135 ; therefore, little movement is possible besides the one-dimensional, longitudinal movement through the tunnel system. In other cases, second thread  1460  may not fit against cord system  1159  as snuggly, providing cord system  1159  with a greater amount of lateral movement. 
       FIG. 22  shows an additional step for creating an upper. A method may include provisions for forming one or more layers into the shape of an upper. In some cases,  FIG. 22  may be incorporated in step  916  of  FIG. 9 . In other cases, the step shown in  FIG. 22  may be completed at other points, such has prior to step  902 . An instrument may be used to properly shape first layer  1010  and second layer  1320 . In some cases, hand instrument  1685 , such as a pair of scissors, may be used. It will be appreciated that in other embodiments, any cutting tool may be used to shape first layer  1010  and second layer  1320 . After the upper layers are cut, the combination of the upper layers and the cord system may remain in the shape of a flattened upper. 
     A method may also include provisions for removing thread from an upper.  FIGS. 23-24  show a schematic view of a process of removing first thread  1270  from upper  30 . In particular, the illustration refers to step  914  of  FIG. 9 . In  FIG. 23 , first thread  1270  may comprise a material that is capable of being dissolved in water or another solution. Accordingly, manufacturer  1700  may place upper  30  in a bowl of solution  1750 . In some cases, upper  30  may need to be left in solution  1750  for a certain amount of time to assure that first thread  1270  is fully removed. Solution  1750  may be comprised of water or any other solution capable of dissolving first thread  1270 . In some cases, first thread  1270  may be made of polar or charged ionic compounds to assist dissolving. 
     In an alternative embodiment,  FIG. 24  shows another step for removing first thread  1270 . In some cases, first thread  1270  may be removed by cutting first thread  1270  and pulling it out of upper  30 . In some cases, first thread  1270  may be configured so a user can remove first thread  1270  by hand. In other cases, tool  1800  may be necessary or helpful to remove first thread  1270 . As illustrated, tool  1800  may be a pair of scissors. It will be appreciated that any type of tool may be used including a typical household tool or a custom-made device. In some cases, first thread  1270  may be removed by a machine completing automated or computer-controlled movements. 
     Further Configurations 
       FIGS. 25-29  show a cross-sectional view of an embodiment of plurality of cord elements of a cord system.  FIG. 25  shows cord system  1959 , including cord element  1931 , cord element  1933 , cord element  1935 , and cord element  1937 . Each cord element may be confined by tunnel system  1965 , including tunnel  1951 , tunnel  1953 , tunnel  1955 , and tunnel  1957 . In some embodiments, cord system  1959  may be comprised of a flattened cord. The flattened cord may have a width W 1  and a height H 1 . In some cases, width W 1  may be substantially greater than height H 1 . In other cases, width W 1  may be slightly greater than height H 1 . In still other cases height H 1  may be slightly greater than width W 1 . In still other embodiments, height H 1  may be substantially greater than width W 1 . 
     A flattened cord may prevent excessive protrusion outward of upper  30 . This may result in stylistic advantages as well as advantages in packing and transporting upper  30 . Also, a flattened cord may provide additional friction against tunnel system  1965 , thereby providing additional support. 
     In other embodiments, such as  FIG. 26 , cord system  2059  may comprise cord element  2031 , cord element  2033 , cord element  2035 , and cord element  2037 . Each cord element may be confined by tunnel system  2065 , including tunnel  2051 , tunnel  2053 , tunnel  2055 , and tunnel  2057 . In some embodiments, cord system  2059  may comprise a rounded cord. The rounded cord may have a width W 2  and a height H 2 . In some cases, width W 2  may be substantially equivalent to height H 2 , hence providing a rounded cross-section. A rounded cord may have advantages of reduced friction within tunnel system  2065 , thereby providing a user with additional control over cord system  2059 . A rounded cord may also result in a simpler manufacturing process or stylistic advantages. 
     Upper  30  may include provisions for allowing a cord to move in a lateral direction within a tunnel system. Generally, a widened tunnel system may be used. Regarding  FIGS. 27-29 , cord system  2159  may further comprise cord element  2131 , cord element  2133 , and cord element  2135 . Each cord element may be confined by tunnel system  2165 , including tunnel  2151 , tunnel  2153 , and tunnel  2155 . The illustration shows three configurations, configuration  2110  in  FIG. 27 , configuration  2120  in  FIG. 28 , and configuration  2130  in  FIG. 29 . Configuration  2110  refers to step  910  of  FIG. 9 . Configuration  2120  and configuration  2130  refer to step  912  of  FIG. 9 , after first thread  1270  has been removed. In some cases, the second stitching may be configured such that cord element  2135  may have substantial multi-dimensional movement within the confines of tunnel  2155 . Such movement may include longitudinal movement and lateral movement. This greater degree of movement may provide a user with a greater flexibility when providing support to upper  30 . 
     It will be appreciated that the shape and material of the cord system may not be consistent for all cord elements. In some cases, the cord system may comprise both flattened cord elements and rounded cord elements. Similarly, the fit of the tunnel may not be consistent for the entire tunnel system. In some cases, a tunnel may fit some cord elements loosely and other cord elements snuggly. 
       FIG. 30  shows an alternative configuration of the cord system of upper  2230 . In some cases, cord system  2259  may not be located throughout upper  2230 . In some cases, cord system  2259  may be located exclusively in midfoot region  12 . In will be appreciated that in other embodiments cord system  2259  may instead be located exclusively in forefoot region  11 , heel region  13 , or any combination or permutation thereof. Similarly cord system  2259  may be limited to medial side  15  or lateral side  14 . 
       FIG. 31  shows a schematic view of an upper with a fully stitched perimeter. It will be appreciated for the following figures that some of the stitching is shown schematically, providing less detail than the actual embodiment. In particular, second stitching may be configured such that the perimeter of upper  2330  is fully stitched by second thread  2360 . Accordingly, cord system  2359  may be confined entirely to its movement within the tunnel system. Moreover, since several cord elements of cord system  2359  are sewn into the perimeter, the movement of cord system  2359  is even further restricted. 
     Alternatively,  FIG. 32  shows a schematic view of upper  2430  with a fully stitched perimeter. However, in this illustration, cord system  2459  is not sewn into the perimeter with second thread  2460 . Accordingly, the cord elements of cord system  2459  have an even greater range of motion through the tunnel system. 
       FIG. 33  shows a schematic view of upper  2530  with a partially stitched perimeter. 
     In some cases, second stitching with second thread  2560  may only be configured to surround a partial perimeter of upper  2530 . Accordingly, some cord elements of cord system  2559  may be capable of movement outside the boundary of the upper, as shown. 
       FIG. 34  shows a schematic view of an article of footwear with a partially stitched perimeter. In some cases, one or more cord elements of cord system  2659  may be exposed outside of upper  2630 . Cord system  2659  may comprise exposed cord element  2631 , exposed cord element  2633 , exposed cord element  2635 , and exposed cord element  2637 , and exposed cord element  2638 , herein the exposed cord elements. While five cord elements are exposed as illustrated, it will be appreciated that any number of cord elements may be exposed, such as one, three, or seven. Similarly, the exposed cord elements are illustrated in midfoot region  12  on lateral side  14  of article of footwear  2600 , but it will be appreciated that the exposed cord elements may be located on medial side  15 , forefoot region  11 , and heel region  13 . 
     Article of footwear  2600  may include provisions for controlling the positions of exposed cord elements. In some cases, the exposed cord elements may be disposed on sole structure  20 . In some cases, the exposed cord elements may be disposed on outsole  22 . In other cases, the exposed cord elements may be disposed on midsole  21 . As illustrated, the exposed cord elements are disposed using tack system  2670 . Tack system  2670  may comprise tack  2671  to dispose exposed cord element  2631 , tack  2673  to dispose exposed cord element  2633 , tack  2675  to dispose exposed cord element  2635 , tack  2677  to dispose exposed cord element  2637 , and tack  2678  to dispose exposed cord element  2638 . In some cases, the exposed cords may be capable of movement along each tack of tack system  2670 . As an example, exposed cord element  2631  may be able to slide around tack  2671  as if there is increased pressure on one side of exposed cord element  2631 . In still other embodiments, cord system  2659  may be disposed on apertures in sole structure  20 . In some cases, when cord elements of the cord system have an increased freedom of movement around each tack in tack system  2620 , article of footwear  10  may have increased control over the structural stability with lace  32 . 
     Of course, other attachment mechanisms and configurations are possible. For example, the exposed cords may attach to caps, lugs, or nubs. The exposed cords may also be disposed in apertures in various locations of the sole structure. In some cases, the exposed cords may be disposed in a bottom portion of the outsole. In other cases, the exposed cords may be looped through an aperture in the midsole and reattached to the upper. By attaching the exposed cords to midsole  21  or outsole  22 , upper  30  may have a more direct connection to sole structure  20 , facilitating a more secure fit. 
     Although a single cord or cord system is discussed above and shown in the figures as being located in each tunnel, multiple cords may also be positioned in a tunnel. For example, first layer  1010  and second layer  1320  may be joined to form a tunnel that receives multiple sections of cord system  1159  or multiple cords. As such, a tunnel or other area between layers may receive more than one cord in some configurations. 
     As a further variation upon the structure discussed above, one or both of first layer  1010  and second layer  1320  may have areas that expose the cords. For example, second layer  1320  may form an aperture that exposes areas of the cords on the side of an article of footwear. This may be used to enhance the aesthetics of the footwear or reduce weight of the footwear. 
     Conclusion 
     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.