Patent Description:
The upper is secured to the sole structure and forms a void on the interior of the footwear for receiving a foot in a comfortable and secure manner. The upper member may secure the foot with respect to the sole member. The upper may extend around the ankle, over the instep and toe areas of the foot. The upper may also extend along the medial and lateral sides of the foot as well as the heel of the foot. The upper may be configured to protect the foot and provide ventilation, thereby cooling the foot. Further, the upper may include additional material to provide extra support in certain areas.

The sole structure is secured to a lower area of the upper, thereby positioned between the upper and the ground. The sole structure may include a midsole and an outsole. The midsole often includes a polymer foam material that attenuates ground reaction forces to lessen stresses upon the foot and leg during walking, running, and other ambulatory activities. Additionally, the midsole may include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot. The outsole is secured to a lower surface of the midsole and provides a ground-engaging portion of the sole structure formed from a durable and wear-resistant material, such as rubber. The sole structure may also include a sockliner positioned within the void and proximal a lower surface of the foot to enhance footwear comfort.

A variety of material elements (e.g., textiles, polymer foam, polymer sheets, leather, synthetic leather) are conventionally utilized in manufacturing the upper. In athletic footwear, for example, the upper may have multiple layers that each includes a variety of joined material elements. As examples, the material elements may be selected to impart stretch resistance, wear resistance, flexibility, air permeability, compressibility, comfort, and moisture wicking to different areas of the upper. In order to impart the different properties to different areas of the upper, material elements are often cut to desired shapes and then joined together, usually with stitching or adhesive bonding. Moreover, the material elements are often joined in a layered configuration to impart multiple properties to the same areas.

As the number and type of material elements incorporated into the upper increases, the time and expense associated with transporting, stocking, cutting, and joining the material elements may also increase. Waste material from cutting and stitching processes also accumulates to a greater degree as the number and type of material elements incorporated into the upper increases. Moreover, uppers with a greater number of material elements may be more difficult to recycle than uppers formed from fewer types and number of material elements. Further, multiple pieces that are stitched together may cause a greater concentration of forces in certain areas. The stitch junctions may transfer stress at an uneven rate relative to other parts of the article of footwear, which may cause failure or discomfort. Additional material and stitch joints may lead to discomfort when worn. By decreasing the number of material elements utilized in the upper, waste may be decreased while increasing the manufacturing efficiency, the comfort, performance, and the recyclability of the upper.

<CIT> discloses a method for producing an upper part of a shoe, in particular of a sport shoe. To obtain a shoe upper part with enhanced wearing comfort the method comprises the steps: a) Supplying at least one shoe last, which corresponds to the inner shape of the upper part of the shoe which is to be produced; b) Applying a radial braiding machine having an annular creel, which is designed for weaving and/or braiding along three axes; c) Guiding the at least one shoe last through the center of the creel and simultaneously weaving and/or braiding along three axes using a fiber material, and therefore woven and/or braided material positions itself around the outer circumference of the shoe last; d) Once the at least one shoe last has been guided through the center of the creel: Terminating the weaving and/or braiding and removing the woven and/or braided material from the shoe last; e) Further processing the woven and/or braided material to complete the shoe.

<CIT> discloses an article of footwear including a braided upper comprised of a unitary braided structure. The unitary braided structure of the braided upper may be engineered with specific features tailored to particular activities. Different regions of the upper may have different braided configurations. For example, higher braid densities may be used in specific areas of the footwear to provide additional structural support or compression. Also, strands of a different material may be incorporated in different regions of the braided upper to provide specific properties to the footwear in those areas.

<CIT> discloses a three-dimensional fabric which is woven by disposing a large number of contiguous rotors in columns and rows in an area in which carriers move about, with a carrier holding a thread being held between a pair of adjoining rotors. One of the paired rotors turns to move the carrier held between them while using the other rotor as a guide to help the transfer of the carrier. The carrier is caused to move along a predetermined path by repeating the above cycle.

<CIT> discloses a method of connecting a plurality of mandrels to one another to constitute an integral mandrel, forming a fabric on the surface of the integral mandrel, and infiltrating the formed fabric with matrix. A plurality of products can simultaneously be manufactured, and this can reduce fiber loss and enhance productivity.

The invention provides a method according to claim <NUM>. Further preferred features of the invention are set out in the dependent claims.

The components in the figures are not necessarily to scale; emphasis instead is being placed upon illustrating the principles of the embodiments. Moreover, in the Figures, like reference numerals designate corresponding parts throughout the different views.

For clarity, the detailed descriptions herein describe certain exemplary embodiments, but the disclosure herein may be applied to any article of footwear comprising certain features described herein and recited in the claims. In particular, although the following Detailed Description discusses exemplary embodiments in the form of footwear such as running shoes, jogging shoes, tennis, squash or racquetball shoes, basketball shoes, sandals, and flippers, the disclosures herein may be applied to a wide range of footwear or possibly other kinds of articles.

The term "sole" as used herein shall refer to any combination that provides support for a wearer's foot and bears the surface that is in direct contact with the ground or playing surface, such as a single sole; a combination of an outsole and an inner sole; a combination of an outsole, a midsole, and an inner sole; and a combination of an outer covering, an outsole, a midsole, and an inner sole.

The term "overbraid" as used herein shall refer to a method of braiding that forms along the shape of a three-dimensional structure. An object that is overbraided includes a braid structure that extends around the outer surface of an object. An object that is overbraided does not necessarily include a braided structure encompassing the entire object; rather, an object that is overbraided includes a seamless braided structure that extends from the back to the front of the object.

The detailed description and the claims may make reference to various kinds of tensile elements, braided structures, braided configurations, braided patterns, and braiding machines.

As used herein, the term "tensile element" refers to any kinds of threads, yarns, strings, filaments, fibers, wires, cables as well as possibly other kinds of tensile elements described below or known in the art. As used herein, tensile elements may describe generally elongated materials with lengths much greater than corresponding diameters. In some embodiments, tensile elements may be approximately one-dimensional elements. In some other embodiments, tensile elements may be approximately two-dimensional (e.g., with thicknesses much less than their lengths and widths). Tensile elements may be joined to form braided structures. A "braided structure" may be any structure formed intertwining three or more tensile elements together. Braided structures could take the form of braided cords, ropes, or strands. Alternatively, braided structures may be configured as two-dimensional structures (e.g., flat braids) or three-dimensional structures (e.g., braided tubes) such as with lengths and widths (or diameters) significantly greater than their thicknesses.

A braided structure may be formed in a variety of different configurations. Examples of braided configurations include, but are not limited to, the braiding density of the braided structure, the braid tension(s), the geometry of the structure (e.g., formed as a tube, an article, etc.), the properties of individual tensile elements (e.g., materials, cross-sectional geometry, elasticity, tensile strength, etc.) as well as other features of the braided structure. One specific feature of a braided configuration may be the braid geometry, or braid pattern, formed throughout the entirety of the braided configuration or within one or more regions of the braided structure. As used herein, the term "braid pattern" refers to the local arrangement of tensile strands in a region of the braided structure. Braid patterns can vary widely and may differ in one or more of the following characteristics: the orientations of one or more groups of tensile elements (or strands), the geometry of spaces or openings formed between braided tensile elements, the crossing patterns between various strands as well as possibly other characteristics. Some braided patterns include lace-braided or jacquard patterns, such as Chantilly, Bucks Point, and Torchon. Other patterns include biaxial diamond braids, biaxial regular braids, as well as various kinds of triaxial braids.

Braided structures may be formed using braiding machines. As used herein, a "braiding machine" is any machine capable of automatically intertwining three or more tensile elements to form a braided structure. Braiding machines may generally include spools, or bobbins, that are moved or passed along various paths on the machine. As the spools are passed around, tensile strands extending from the spools toward a center of the machine may converge at a "braiding point" or braiding area. Braiding machines may be characterized according to various features, including spool control and spool orientation. In some braiding machines, spools may be independently controlled so that each spool can travel on a variable path throughout the braiding process, hereafter referred to as "independent spool control. " Other braiding machines, however, may lack independent spool control, so that each spool is constrained to travel along a fixed path around the machine. Additionally, in some braiding machines, the central axes of each spool point in a common direction so that the spool axes are all parallel, hereby referred to as an "axial configuration. " In other braiding machines, the central axis of each spool is oriented toward the braiding point (e.g., radially inward from the perimeter of the machine toward the braiding point), hereby referred to as a "radial configuration.

One type of braiding machine that may be utilized is a radial braiding machine or radial braider. A radial braiding machine may lack independent spool control and may, therefore, be configured with spools that pass in fixed paths around the perimeter of the machine. In some cases, a radial braiding machine may include spools arranged in a radial configuration. For purposes of clarity, the detailed description and the claims may use the term "radial braiding machine" to refer to any braiding machine that lacks independent spool control. The present embodiments could make use of any of the machines, devices, components, parts, mechanisms, and/or processes related to a radial braiding machine as disclosed in<CIT>, and titled "Machine for Alternating Tubular and Flat Braid Sections," and as disclosed in <CIT>, and titled "Maypole Braider Having a Three Under and Three Over Braiding path". These applications may be hereafter referred to as the "Radial Braiding Machine" applications.

Another type of braiding machine that may be utilized is a lace braiding machine, also known as a Jacquard or Torchon braiding machine. In a lace braiding machine the spools may have independent spool control. Some lace braiding machines may also have axially arranged spools. The use of independent spool control may allow for the creation of braided structures, such as lace braids, that have an open and complex topology, and may include various kinds of stitches used in forming intricate braiding patterns. For purposes of clarity, the detailed description and the claims may use the term "lace braiding machine" to refer to any braiding machine that has independent spool control. The present embodiments could make use of any of the machines, devices, components, parts, mechanisms, and/or processes related to a lace braiding machine as disclosed in <CIT>, and titled "Torchon Lace Machine," and as disclosed in <CIT>, issued July <NUM>, <NUM>, and titled "Lace-Machine". These applications may be hereafter referred to as the "Lace Braiding Machine" applications.

Spools may move in different ways according to the operation of a braiding machine. In operation, spools that are moved along a constant path of a braiding machine may be said to undergo "non-jacquard motions," while spools that move along variable paths of a braiding machine are said to undergo "jacquard motions. " Thus, as used herein, a lace braiding machine provides means for moving spools in jacquard motions, while a radial braiding machine can only move spools in non-jacquard motions. Additionally a jacquard portion or structure refers to a portion formed through the individual control of each thread. Additionally, a non-jacquard portion may refer to a portion formed without individual control of threads. Additionally, a non-jacquard portion may refer to a portion formed on a machine that utilizes the motion of a non-jacquard machine.

The embodiments may also utilize any of the machines, devices, components, parts, mechanisms, and/or processes related to a braiding machine as disclosed in <CIT>, and titled "Braiding Machine and Method of Forming an Article Incorporating Braiding Machine," published as <CIT>, hereafter referred to as the "Fixed Last Braiding" application.

Referring to <FIG>, a braiding machine is depicted. Braiding machine <NUM> includes a plurality of spools <NUM>. Plurality of spools <NUM> include threads <NUM> (see <FIG>). Threads <NUM> may be wrapped around plurality of spools <NUM> such that as threads <NUM> are tensioned or pulled, threads <NUM> may unwind or unwrap from plurality of spools <NUM>. Threads <NUM> may be oriented to extend through ring <NUM> and form a braided structure.

Threads <NUM> may be formed of different materials. The properties that a particular type of thread will impart to an area of a braided component partially depend upon the materials that form the various filaments and fibers within the yarn. Cotton, for example, provides a soft hand, natural aesthetics, and biodegradability. Elastane and stretch polyester each provide substantial stretch and recovery, with stretch polyester also providing recyclability. Rayon provides high luster and moisture absorption. Wool also provides high moisture absorption, in addition to insulating properties and biodegradability. Nylon is a durable and abrasion-resistant material with relatively high strength. Polyester is a hydrophobic material that also provides relatively high durability. In addition to materials, other aspects of the thread selected for formation of a braided component may affect the properties of the braided component. For example, a thread may be a monofilament thread or a multifilament thread. The thread may also include separate filaments that are each formed of different materials. In addition, the thread may include filaments that are each formed of two or more different materials, such as a bicomponent thread with filaments having a sheath-core configuration or two halves formed of different materials.

Plurality of spools <NUM> may be located in a position guiding system. In some embodiments, plurality of spools <NUM> may be located within a track. As shown, track <NUM> may secure plurality of spools <NUM> such that as threads <NUM> are tensioned or pulled, plurality of spools <NUM> may remain within track <NUM> without falling over or becoming dislodged.

Track <NUM> may be secured to a support structure. In some examples, the support structure may elevate the spools off of a ground surface. Additionally, a support structure may secure a brace or enclosure, securing portion, or other additional parts of a braiding machine. In the example shown in <FIG>, braiding machine <NUM> includes support structure <NUM>.

<FIG> illustrates an isometric view of a braiding machine <NUM>. <FIG> illustrates a side view of braiding machine <NUM>. In some examples, braiding machine <NUM> may include a support structure <NUM> and a plurality of spools <NUM>. Support structure <NUM> may be further comprised of a base portion <NUM>, a top portion <NUM> and a central fixture <NUM>.

In some examples, base portion <NUM> may comprise one or more walls <NUM> of material. In the example of <FIG>, base portion <NUM> is comprised of four walls <NUM> that form an approximately rectangular base for braiding machine <NUM>. However, in other examples, base portion <NUM> could comprise any other number of walls arranged in any other geometry. In this example, base portion <NUM> acts to support top portion <NUM> and may, therefore, be formed in a manner so as to support the weight of top portion <NUM>, as well as central fixture <NUM> and plurality of spools <NUM>, which are attached to top portion <NUM>.

Top portion <NUM> may comprise a top surface <NUM>, which may further include a central surface portion <NUM> and a peripheral surface portion <NUM>. In some embodiments, top portion <NUM> may also include a sidewall surface <NUM> that is proximate peripheral surface portion <NUM>. In this example, top portion <NUM> has an approximately circular geometry; though in other examples, top portion <NUM> could have any other shape. Moreover, in this example, top portion <NUM> is seen to have an approximate diameter that is larger than a width of base portion <NUM>, so that top portion <NUM> extends beyond base portion <NUM> in one or more horizontal directions.

Central fixture <NUM> may include an enclosure <NUM>. Enclosure <NUM> may house or contain knives <NUM>. In other examples, enclosure <NUM> may provide a passageway toward ring <NUM>. In still further examples, enclosure <NUM> may provide a covering for internal parts of braiding machine <NUM>.

Plurality of spools <NUM> may be evenly spaced around a perimeter portion of braiding machine <NUM>. In other examples, plurality of spools <NUM> may be spaced differently than as depicted in <FIG>. In some examples, about half the number of spools may be included in plurality of spools <NUM>. In such examples, the spools of plurality of spools <NUM> may be spaced in various manners. In some examples, plurality of spools <NUM> may be located along <NUM> degrees of the perimeter of lace braiding machine. In other examples, the spools of plurality of spools <NUM> may be spaced in other configurations. That is, in some examples, each spool may not be located directly adjacent to another spool.

In some examples, plurality of spools <NUM> are located within gaps <NUM> (see <FIG>) that are located between each of the plurality of rotor metals <NUM> (see <FIG>). Plurality of rotor metals <NUM> may rotate clockwise or counterclockwise, contacting plurality of spools <NUM>. The contact of plurality of rotor metals <NUM> with plurality of spools <NUM> may force the plurality of spools <NUM> to move along track <NUM>. The movement of the plurality of spools <NUM> may intertwine the threads <NUM> from each of the plurality of spools <NUM> with one another. The movement of plurality of spools <NUM> additionally transfers each of the spools from one gap to another gap of gaps <NUM>.

The movement of plurality of spools <NUM> may be programmable. In some examples, the movement of plurality of spools <NUM> may be programmed into a computer system. In other examples, the movement of plurality of spools <NUM> may be programmed using a punch card or other device. The movement of plurality of spools <NUM> may be preprogrammed to form particular shapes, designs, and thread density of a braided component.

Individual spools may travel completely around the perimeter of braiding machine <NUM>. In some examples, each spool of plurality of spools <NUM> may rotate completely around the perimeter of braiding machine <NUM>. In still further examples, some spools of plurality of spools <NUM> may rotate completely around the perimeter of braiding machine <NUM> while other spools of plurality of spools <NUM> may rotate partially around braiding machine <NUM>. By varying the rotation and location of individual spools of plurality of spools <NUM>, various braid configurations may be formed.

Each spool of plurality of spools <NUM> may not occupy each of gaps <NUM>. In some examples, every other gap of gaps <NUM> may include a spool. In still other examples, a different configuration of spools may be placed within each of the gaps <NUM>. As plurality of rotor metals <NUM> rotate, the location of each of the plurality of spools <NUM> may change. In this manner, the configuration of the spools and the location of the spools in the various gaps may change throughout the braiding process.

A lace braiding machine may be arranged in various orientations. For example, braiding machine <NUM> is oriented in a horizontal manner. In a horizontal configuration, plurality of spools <NUM> are placed in a track that is located in an approximately horizontal plane. The horizontal plane may be formed by an X axis and a Y axis. The X axis and Y axis may be perpendicular to one another. Additionally, a Z axis may be related to height or a vertical direction. The Z axis may be perpendicular to both the Y axis and the X axis. As plurality of spools <NUM> rotate around braiding machine <NUM>, plurality of spools <NUM> pass along track <NUM> that is located in the horizontal plane. In this configuration, each of plurality of spools <NUM> locally extends in a vertical direction or along the Z axis. That is, each of the spools extends vertically and also perpendicularly to track <NUM>. In other examples, a vertical lace braiding machine may be utilized. In a vertical configuration, the track is oriented in a vertical plane.

A lace braiding machine may include a thread organization member. The thread organization member may assist in organizing the strands or threads such that entanglement of the strands or threads may be reduced. Additionally, the thread organization member may provide a path or direction through which a braided structure is directed. As depicted, braiding machine <NUM> may include a fell or ring <NUM> to facilitate the organization of a braided structure. The strands or threads of each spool extend toward ring <NUM> and through ring <NUM>. As threads <NUM> extend through ring <NUM>, ring <NUM> may guide threads <NUM> such that threads <NUM> extend in the same general direction.

Additionally, in some examples, ring <NUM> may assist in forming the shape of a braided component. In some examples, a smaller ring may assist in forming a braided component that encompasses a smaller volume. In other examples, a larger ring may be utilized to form a braided component that encompasses a larger volume.

Ring <NUM> may be located at the braiding point. The braiding point is defined as the point or area where threads <NUM> consolidate to form a braid structure. As plurality of spools <NUM> pass around braiding machine <NUM>, thread from each spool of plurality of spools <NUM> may extend toward and through ring <NUM>. Adjacent or near ring <NUM>, the distance between thread from different spools diminishes. As the distance between threads <NUM> is reduced, threads <NUM> from different spools intermesh or braid with one another in a tighter fashion. The braiding point refers to an area where the desired tightness of threads <NUM> has been achieved on the braiding machine.

A tensioner may assist in providing the strands with an appropriate amount of force to form a tightly braided structure. In other examples, knives <NUM> may extend from enclosure <NUM> to "beat up" the strands and threads so that additional braiding may occur. Additionally, knives <NUM> may tighten the strands of the braided structure. Knives <NUM> may extend radially upward toward and against threads <NUM> of the braided structure as threads <NUM> are braided together. Knives <NUM> may press and pat the threads upward toward ring <NUM> such that the threads are compacted or pressed together. In some examples, knives <NUM> may prevent the strands of the braided structure from unraveling by assisting in forming a tightly braided structure. Additionally, in some examples, knives <NUM> may provide a tight and uniform braided structure by pressing threads <NUM> toward ring <NUM> and toward one another. In other Figures in this Detailed Description, knives <NUM> may not be depicted for ease of viewing.

Ring <NUM> may be secured to braiding machine <NUM>. In some examples, ring <NUM> may be secured by brace <NUM>. In other examples, ring <NUM> may be secured by other mechanisms.

Braiding machine <NUM> may include a path, passageway, channel, or tube that extends from enclosure <NUM> to a base portion of braiding machine <NUM>. In some examples, a first opening <NUM> to passageway <NUM> may be located at an upper portion of enclosure <NUM>. In some examples, the shape of first opening <NUM> may be similar to the shape of ring <NUM>. In other examples, the shape of first opening <NUM> may be a different shape than the shape of ring <NUM>.

First opening <NUM> may be aligned with ring <NUM>. For example, in some embodiments, the central point of ring <NUM> may be aligned with first opening <NUM> along vertical axis <NUM>. In other examples, first opening <NUM> may be offset from ring <NUM>.

First opening <NUM> may be located above track <NUM>. In other examples, first opening <NUM> may be located vertically above plurality of spools <NUM>. That is, in some examples, the plane in which first opening <NUM> is located may be vertically above the plane in which plurality of spools <NUM> are located. In other examples, first opening <NUM> may be located in the same plane as plurality of spools <NUM> or track <NUM>. In still further examples, first opening <NUM> may be located below track <NUM>.

In still further examples, a braiding machine may be arranged in a different configuration. In some examples, a braiding machine may be configured without a first opening through an enclosure. For example, in configurations in which the braiding machine is oriented in a radial configuration, the braiding machine may not include an enclosure or other structures.

The shape of the openings within braiding machine <NUM> may be varied. In some examples, the shape of the first opening may be the same as the shape of the second opening. In other examples, the shape of the first opening may be different than the second opening. By varying the shape of the openings, differently shaped objects may be passed through the openings. Additionally, different shapes may be used to fit within the layout or configuration of braiding machine <NUM>. For example, enclosure <NUM> and first opening <NUM> may have a similar circular shape. This similar shape may allow for knives <NUM> to be evenly distributed around enclosure <NUM> and may allow for each of the knives of knives <NUM> to extend toward first opening <NUM> in the same or similar manner as each other. As depicted in <FIG>, first opening <NUM> has an approximately circular shape, while second opening <NUM> has an approximately rectangular shape.

First opening <NUM> and second opening <NUM> may be in fluid communication with each other. That is, in some examples, a channel or passageway may extend between first opening <NUM> and second opening <NUM>. In some examples, the cross-section of the passageway may be circular. In other examples, the cross-section of the passageway may be rectangular. In still further examples, the cross-section of the passageway may be a different shape. In other examples, the cross-section of the passageway may be regularly shaped or irregularly shaped.

The shape of the objects passing from second opening <NUM> to first opening <NUM> is in the shape of a foot or a last. As shown in <FIG>, multiple foot-shaped objects or forming lasts are depicted. For example, in <FIG>, first forming last <NUM>, second forming last <NUM>, third forming last <NUM>, and fourth forming last <NUM> are depicted. Each of the forming lasts is in the shape of a foot or footwear last.

An object is passed from second opening <NUM> to first opening <NUM>. In some embodiments, the LThe object passes through passageway <NUM> that extends from first opening <NUM> to second opening <NUM>. Passageway <NUM>, as depicted in <FIG>, is not shown in <FIG> and <FIG> for ease of viewing. As shown in <FIG>, fourth forming last <NUM> may be located outside of passageway <NUM> between second opening <NUM> and first opening <NUM>. Additionally, third forming last <NUM> may extend partially through second opening <NUM>. Further, first forming last <NUM> and second forming last <NUM> may be located within passageway <NUM> between second opening <NUM> and first opening <NUM>. That is, first forming last <NUM> and second forming last <NUM> may not be visible from a side view of braiding machine <NUM>. An isometric view of the depiction shown in <FIG> is shown in <FIG>.

Second opening <NUM> may be located a distance away from first opening <NUM>. In some examples, second opening <NUM> may be located in the base portion of braiding machine <NUM>. In other embodiments, second opening <NUM> may be located in different areas.

By varying the location of first opening <NUM>, the distance that a last may travel during the braiding process may be varied. In embodiments that include a first opening that is further away from the braiding point, a last or other object that is passed through passageway <NUM> may be exposed for a longer distance without being braided upon. In some embodiments, additional processes may be performed upon a last prior to being overbraided by threads. In other embodiments, a first opening may be located closer to the braiding point. In such embodiments, a last may not be exposed for a large distance prior to being overbraided. In such a configuration, misalignment of lasts through the braiding point may be reduced. Additionally, by locating the first opening close to the braiding point, additional guides for aligning the lasts may not be necessary.

Multiple objects are passed from second opening <NUM> to first opening <NUM>. The multiple objects are connected to one another. Each object is connected to an adjacent object by a connection mechanism. In some embodiments, the connection mechanism may be a rope, strand, chain, rod, or other connection mechanism.

Referring to <FIG>, each of the forming lasts are connected to each other by connection mechanism <NUM>. In some embodiments, each of the connection mechanisms may be the same length. In other embodiments, the length of the connection mechanisms may be varied. By changing the length of the connection mechanisms, the amount of waste formed during manufacturing of an article of footwear may be changed.

In some embodiments, connection mechanism <NUM> may extend from a forefoot region of a first object to a heel region of a second object. As shown in <FIG>, connection mechanism <NUM> extends from a forefoot region of fourth forming last <NUM> to a heel region of third forming last <NUM>. In other embodiments, different orientations of forming lasts may be utilized. For example, in some embodiments, connection mechanism <NUM> may extend between adjacent heel regions of adj acent forming lasts.

The connection mechanism is a non-rigid structure. In this Detailed Description, a non-rigid structure includes structures that are able to bend or distort without permanently deforming or substantially diminishing the strength of the structure. In some embodiments, as the forming lasts pass from second opening <NUM> to first opening <NUM>, the passageway that connects first opening <NUM> and second opening <NUM> may twist or turn. In such embodiments, a connection mechanism that is able to bend or turn may be used so that the objects may continuously pass from second opening <NUM> to first opening <NUM>.

In some embodiments, a non-rigid structure may be formed by varying the geometry of the connection mechanism or the material from which the connection mechanism is formed. For example, a non-rigid structure may be formed by using links within a chain. In other embodiments, a non-rigid structure may be formed by using a pliable rubber material or other non-rigid material.

In some embodiments, the shape and size of the forming lasts may be varied. In some embodiments, the forming lasts may be the same size or shape. In other embodiments, differently sized forming lasts may be used. In still further embodiments, an object the shape of a last may be connected to an object that is a different shape; for example, a forming last may be connected to an object that is the shape of an arm or a leg. By varying the shape and size of the object, a differently shaped braided component may be formed.

The forming lasts pass through braiding machine <NUM>. As depicted in <FIG>, the forming lasts begin to move through braiding machine <NUM>. Referring specifically to first forming last <NUM>, a portion of first forming last <NUM> extends out of first opening <NUM>. Additionally, a portion of first forming last <NUM> extends through the braiding point located at ring <NUM>. As shown in <FIG>, first forming last <NUM> passes from one side of ring <NUM> to the other side of ring <NUM>. In this embodiment, as first forming last <NUM> passes from one side of ring <NUM> to the other side of ring <NUM>, first forming last <NUM> passes through the braiding point of braiding machine <NUM>. As plurality of spools <NUM> rotate around braiding machine <NUM>, threads <NUM> overbraid first forming last <NUM> as first forming last <NUM> passes through the braiding point. Threads <NUM> may interact with one another to form braided component <NUM> that extends around first forming last <NUM>. An alternate isometric view of the depiction of <FIG> is shown in <FIG>.

As the spools of braiding machine <NUM> travel around track <NUM>, the forming lasts may advance through braiding machine <NUM>. In some embodiments, a tensioner, such as a carrier, may tension or pull threads <NUM> as threads <NUM> extend through ring <NUM>. The tension upon threads <NUM> may pull the forming lasts through braiding machine <NUM> as the forming lasts are overbraided. In other embodiments, a connection mechanism or similar mechanism may be secured to first forming last <NUM>. The connection mechanism may extend through ring <NUM> and toward a carrier or other tension device. In some embodiments, the connection mechanism may be tensioned such that the forming lasts are pulled through braiding machine <NUM> and the braiding point.

Referring to <FIG>, forming lasts are shown passing through braiding machine <NUM>. As depicted, the forming lasts may pass from one side of ring <NUM> through ring <NUM> to the other side of ring <NUM> one after another in a continuous manner. As each of the forming lasts pass through the braiding point of braiding machine <NUM>, threads <NUM> may overbraid around the forming lasts. Additionally, connection mechanism <NUM> between each of the forming lasts may be overbraided as well. As threads <NUM> extend around the forming lasts, a braided component that conforms to the shape of the forming lasts may be formed.

In some embodiments, forming lasts may be pulled along a roller or conveyor belt. As shown in <FIG>, conveyor <NUM> may be utilized to organize the forming lasts. As each forming last is overbraided, the forming last may be pulled toward conveyor <NUM> and advanced for additional processing. As shown in <FIG>, first forming last <NUM> and second forming last <NUM> are both advanced along conveyor <NUM>. In some embodiments, conveyor <NUM> may assist in altering the direction of tension that is directed along threads <NUM> and braided component <NUM>. As shown, conveyor <NUM> may assist in aligning tension along a vertical direction between conveyor <NUM> and ring <NUM>. As threads <NUM> and forming lasts extend across conveyor <NUM>, the tension may extend in a horizontal direction. In this configuration, a horizontal tensile force may, therefore, be transitioned into a vertical tensile force by the use of conveyor <NUM>. By varying the location of conveyor <NUM>, the direction of a tensile force may be altered. For example, by locating a roller off center from a ring, the direction of the tensile force may not be vertical. In such embodiments, a forming last may pass through the ring at an angle. This may cause different designs to be formed along the forming last as the forming last would pass through the braiding point at an angle.

As shown in <FIG>, in some embodiments, an opening may be formed along the side of the forming lasts. For example, an opening <NUM> may be formed around an ankle portion of first forming last <NUM>. In some embodiments, opening <NUM> may be formed during the braiding process.

Referring to <FIG>, a braided portion is formed along and around a forming last. As shown, braided portion <NUM> extends along first forming last <NUM>. Braided portion <NUM> may be a portion of braided component <NUM>. In some embodiments, braided portion <NUM> may be cut or separated from the braided component after manufacturing. Braided portion <NUM> may include an opening that is associated with the location of ankle portion <NUM>. In some embodiments, an ankle opening may be formed within braided portion <NUM> that generally surrounds or encompasses the shape of ankle portion <NUM>. In other embodiments, an ankle opening may be formed that is larger than ankle portion <NUM>. In still further embodiments, a braided portion may be formed that does not include an ankle opening. Rather, a braided portion may extend around the ankle portion such that no opening is formed.

In some embodiments, the forming last may not be overbraided completely around the forming last. In some embodiments, a portion of the forming last may not be overbraided. In some embodiments, an opening may be formed within a braided component that is along or parallel to the braiding direction. Additionally, the forming last may not be covered or overbraided in a plane or surface that is located along ankle portion surface <NUM>. In other embodiments, the forming last may be completely overbraided. Additionally, the ankle portion of a braided portion may be cut out or removed in embodiments that overbraid the ankle portion. As shown in <FIG> and <FIG>, the opening of braided portion <NUM> around ankle portion <NUM> is parallel to braiding direction <NUM>. That is, the opening may be formed in a vertical plane along braided portion <NUM>. In this Detailed Description, a vertical plane incorporates the vertical axis. Braiding direction, as used in this Detailed Description, is used to describe the direction in which the braided portion extends away from the braiding machine. In <FIG>, for example, braiding direction <NUM> extends vertically away from braiding machine <NUM>.

Generally, braiding machines may form openings that are perpendicular to the braiding direction on either end of a braided structure. That is, the openings generally extend in an area occupied by ring <NUM>. In this embodiment, the openings are located in the horizontal plane, or the plane in which ring <NUM> is located. Additionally, radial braiding machines or non-jacquard machines may not form additional openings that are parallel to the braiding direction. Lace braiding machines, however, may be programmed to form openings parallel to the braiding direction. For example, a lace braiding machine may form an opening in a vertical plane or a plane that is perpendicular to the plane in which ring <NUM> is located, within a braided portion.

As shown, braided portion <NUM> may be formed vertically and parallel with braiding direction <NUM>. As braiding machine <NUM> forms a braided portion, the braided portion extends vertically. The initial braided portion may form an opening in the horizontal plane, such as the opening at the end of a tube. Upon completion of a braided structure, another opening may be formed in the horizontal plane. These openings are formed perpendicular to the braiding direction and are part of the manufacturing process. Additionally, the openings are parallel to the horizontal plane in which ring <NUM> is located. In some embodiments, these openings may correspond in shape and location to connection mechanisms that extend between the forming lasts.

In some embodiments, braided portion <NUM> may include an opening parallel with the braiding direction or within a vertical plane. In some embodiments, the opening may correspond to an ankle opening. In other embodiments, an opening may be located along other areas of an article. An opening is used to define a space within the braided structure that is formed as a deliberate altering of the braided structure. For example, the spaces between strands of a radially braided structure may not be considered openings for purposes of this Detailed Description. As shown in <FIG>, opening <NUM> may be formed parallel to the braiding direction.

Opening <NUM> may be formed of various shapes and sizes. In some embodiments, opening <NUM> may be largely circular. In other embodiments, opening <NUM> may be irregularly shaped. Additionally, in some embodiments, opening <NUM> may correspond to the shape of ankle portion <NUM>. That is, in some embodiments, braided portion <NUM> may extend to the end of ankle portion <NUM>. In this embodiment, however, braided portion <NUM> may not cover ankle portion surface <NUM>.

Referring to <FIG>, a cross-sectional view of braided portion <NUM> and first forming last <NUM> is depicted. As shown, braided portion <NUM> surrounds the outer periphery of first forming last <NUM>. Braided portion <NUM>, however, does not completely envelop first forming last <NUM>. Rather, braided portion <NUM> conforms around the outer periphery of first forming last <NUM>. Additionally, ankle opening <NUM> is formed along a vertical plane, for example, vertical plane <NUM>, in the braiding direction of braided portion <NUM>. Opening <NUM>, therefore, does not cover ankle portion surface <NUM>, which is parallel to the braiding direction and located along vertical plane <NUM>.

In some embodiments, the interior surface of a braided portion may correspond to the surface of the forming mandrel. As depicted, interior surface <NUM> largely corresponds to forming last surface <NUM>. As threads <NUM> extend through ring <NUM>, threads <NUM> interact with first forming last <NUM>. First forming last <NUM> interrupts the path of threads <NUM> such that threads <NUM> are overbraided around first forming last <NUM>. In this embodiment, as first forming last <NUM> passes through the braiding point, a braided component may tightly conform to the shape of first forming last <NUM>.

Referring to <FIG>, first forming last <NUM> and braided portion <NUM> are shown in isolation from other braided portions and forming lasts. Braided portion <NUM> is depicted being formed into a component of an article of footwear with the assistance of first forming last <NUM>.

In some embodiments, parameters of the braiding process may be varied to form braided portions with various dimensions or different braid densities. In some embodiments, a forming last may be advanced through the braiding point at different velocities. For example, in some embodiments, first forming last <NUM> may advance at a high rate of speed through the braiding point. In other embodiments, first forming last <NUM> may advance by a slow rate of speed. That is, braided portion <NUM> may be formed at different rates of speeds. By changing the vertical advancement of first forming last <NUM> through the braiding point, the density of the braided structure may vary. A lower density structure may allow for a larger braided portion or less coverage around the forming last. A lower density structure may be formed when a forming last is passed through the braiding point at a higher rate of speed. A higher density structure may be formed when a forming last is passed through the braiding point at a lower rate of speed. Additionally, the plurality of spools may rotate at various speeds. By varying the speed of rotation of the plurality of spools, the density of the braided structure may vary. For example, when advancing a forming last through the braiding point at a constant speed, the speed at which the plurality of spools rotate may adjust the density of the braided structure. By increasing the speed of rotation of the plurality of spools, a higher density braided structure may be formed. By decreasing the speed of rotation of the plurality of spools, a lower density braided structure may be formed. By varying the speed of advancement of first forming last <NUM> and the speed that plurality of spools <NUM> rotate, differently sized braided portions may be formed as well as braided portions of different densities.

In some embodiments, braided portion <NUM> may include opening <NUM>. Although shown extending around ankle portion <NUM> (see <FIG>), in some embodiments, opening <NUM> may extend toward an instep area. Further, opening <NUM> may extend from heel region <NUM> to midfoot region <NUM>. In still other embodiments, opening <NUM> may extend into forefoot region <NUM>.

In some embodiments, the instep area may include lace apertures (see <FIG>). In some embodiments, lace apertures may be formed during the braiding process. That is, in some embodiments, the lace apertures may be formed integrally with braided portion <NUM>. Therefore, there may not be a need to stitch or form lace apertures after braided portion <NUM> is formed. By integrally forming lace apertures during manufacturing, the manufacturing process may be simplified while reducing the amount of time necessary to form an article of footwear.

In some embodiments, a free portion may extend from forefoot region <NUM> of braided portion <NUM>. In some embodiments, a free portion <NUM> of braided portion <NUM> may be cut or otherwise removed from braided portion <NUM>. Additionally, in other embodiments, free portion <NUM> may be wrapped below braided portion <NUM>. Additionally, in some embodiments, a free portion <NUM> may extend from heel region <NUM>. Free portion <NUM> may additionally be cut or otherwise removed from braided portion <NUM>. Further, free portion <NUM> may be wrapped below braided portion <NUM>. Free portion <NUM> may be formed during the braiding process as a braided structure is formed over a connection mechanism. Likewise, free portion <NUM> may be formed in the same or similar manner.

Referring to <FIG>, article of footwear or simply article <NUM> is depicted. As shown, braided portion <NUM> is incorporated into article <NUM> and forms a portion of upper <NUM>. Additionally, in some examples, sole structure <NUM> is included and secured to upper <NUM>. In this manner, article <NUM> is formed. By using a braiding machine, the number of elements used to form an article of footwear may be reduced as compared to conventional methods. Additionally, by utilizing a braiding machine, the amount of waste formed during the manufacturing of an article of footwear may be reduced as compared to other conventional techniques.

Opening <NUM> may be various sizes. Although depicted as being located largely in an ankle portion in heel region <NUM>, opening <NUM> may extend toward forefoot region <NUM>. Additionally, opening <NUM> may extend from an ankle portion toward sole structure <NUM>. That is, opening <NUM> may be varied in the vertical direction. For example, opening <NUM> may extend from an upper area adjacent the ankle portion of article <NUM> toward sole structure <NUM>.

While the examples of the figures depict articles having low collars (e.g., low-top configurations), other examples could have other configurations. In particular, the methods and systems described herein may be utilized to make a variety of different article configurations, including articles with higher cuff or ankle portions. In another example, the systems and methods discussed herein can be used to form a braided upper with a cuff that extends up a wearer's leg (i.e., above the ankle). In another example, the systems and methods discussed herein can be used to form a braided upper with a cuff that extends to the knee. In still another example, the systems and methods discussed herein can be used to form a braided upper with a cuff that extends above the knee. Thus, such provisions may allow for the manufacturing of boots comprised of braided structures. In some cases, articles with long cuffs could be formed by using lasts with long cuff portions (or leg portions) with a braiding machine (e.g., by using a boot last). In such cases, the last could be rotated as it is moved relative to a braiding point so that a generally round and narrow cross-section of the last is always presented at the braiding point.

Referring to <FIG>, various forming lasts are depicted. Additionally, an article that incorporates a braided portion is shown below each forming last that depicts an example of the type of article that may be formed by using a particularly shaped and sized forming last.

In some embodiments, forming lasts may be used to form different types of articles of footwear. In some embodiments, the same forming last may be used to form a different type of footwear. For example, forming last <NUM> and forming last <NUM> may be formed in approximately the same shape. Article <NUM> may be formed by using forming last <NUM> in conjunction with braiding machine <NUM>. As shown, article <NUM> is shaped similarly to a sandal or slipper. Article <NUM> may be formed by using forming last <NUM>. As shown, article <NUM> has a different shape than article <NUM>. In this depiction, article <NUM> is similarly shaped to a low-top article of footwear. Therefore, a similarly shaped forming last may be used to form articles that have different shapes or designs. By varying the frequency of the interaction between threads <NUM> and the location of plurality of spools <NUM> as each forming mandrel is passed through braiding machine <NUM>, different designs may be formed by using the same or similarly shaped forming lasts.

In some embodiments, differently sized and shaped forming lasts may be passed through braiding machine <NUM>. In some embodiments, the differently sized and shaped forming lasts may be used to form articles of different sizes and shapes. For example, forming last <NUM>, forming last <NUM> and forming last <NUM> may be shaped and sized differently. Forming last <NUM> may be used to form a portion of the upper of article <NUM>. Article <NUM> may be shaped as a mid-top article of footwear. Forming last <NUM> may be used to form a portion of the upper of article <NUM>. Article <NUM> may be shaped as a high-top article of footwear. Forming last <NUM> may be used to form a portion of the upper of article <NUM>. Article <NUM> may be shaped as a boot. Therefore, by changing the shape and size of a forming last, various articles of footwear with various shapes and sizes may be formed.

In some embodiments, a single sized and shaped article may be used to form multiple types of articles. For example, forming last <NUM> may be utilized to form a boot-type article. In some embodiments, the large ankle and leg portion of forming last <NUM> may not be overbraided. In such embodiments, a portion of an article that is similar to a high-top article of footwear may be formed. In still further embodiments, even less of the ankle portion of forming last <NUM> may be overbraided. In such embodiments, a portion of article that is similar to a mid-top article may be formed. By varying the amount of forming last <NUM> that is overbraided, portions of various types of articles may be formed.

Generally, the types of braiding machines include lace braiding machines, axial braiding machines, and radial braiding machines. For the purpose of this Detailed Description, radial braiding machines and axial braiding machines include intermeshed horn gears. These horn gears include "horns" that are openings or slots within the horn gears. Each of the horns may be configured to accept a carrier or carriage. In this configuration, therefore, axial braiding machines and radial braiding machines are configured to form non-jacquard braided structures.

A carriage is a vessel that may be passed between various horn gears. The carriages may be placed within various horns in the horn gears of the radial braiding machine. As a first horn gear rotates, the other horn gears rotate as well because each of the horn gears is intermeshed with one another. As a horn gear rotates, the horns within each horn gear pass by one another at precise points. For example, a horn from a first horn gear passes by a horn from an adjacent second horn gear. In some embodiments, a horn of a horn gear may include a carriage. As the horn gear rotates, the adjacent horn gear may include an open horn. The carriage may pass to the open horn. The carriage may pass around the braiding machine from horn gear to horn gear, eventually traversing around the braiding machine. An example of a radial braiding machine and components of a radial braiding machine are discussed in <CIT>, entitled "Maypole Braider Having a Three Under and Three Over Braiding Path".

Additionally, each carriage may hold a spool or bobbin. The spools include a thread, strand, yarn, or a similar material that may be braided together. The thread from the spools extends toward a braiding point. In some embodiments, the braiding point may be located in the center of the braiding machine. In some embodiments, the thread from the spools may be under tension such that the thread from the spools are generally aligned and may remain untangled.

As each carriage and spool combination is passed along the horn gears, the thread from each of the spools may intertwine. Referring to <FIG>, a top schematic view of radial braiding machine <NUM> is depicted. Radial braiding machine <NUM> includes a plurality of horn gears <NUM>. Each of the plurality of horn gears <NUM> includes an arrow indicating the direction in which the horn gear turns. For example, horn gear <NUM> rotates in a clockwise manner. In contrast, horn gear <NUM> rotates in a counterclockwise manner. As depicted, each of the horn gears rotates in the opposite direction of the adjacent horn gear. This is because the horn gears are intermeshed with one another. Therefore, radial braiding machine <NUM> is considered to be a fully non-jacquard machine.

Due to the intermeshing of the horn gears, each carriage and spool may take particular paths. For example, carriage <NUM>, including a spool, rotates counterclockwise on horn gear <NUM>. As horn gear <NUM> rotates counterclockwise, horn gear <NUM> may rotate clockwise. While each of the horn gears rotates, horn <NUM> may align with carriage <NUM>. Because horn <NUM> is open, that is, horn <NUM> is not occupied by another carriage, horn <NUM> may accept carriage <NUM>. Carriage <NUM> may continue on horn gear <NUM> and rotate in a clockwise manner until carriage <NUM> aligns with another open horn.

Additionally, other carriages may rotate in a different direction. For example, carriage <NUM>, including a spool, may rotate clockwise on horn gear <NUM>. Carriage <NUM> may eventually align with a horn <NUM> of horn gear <NUM> that is not occupied by a carriage. As carriage <NUM> aligns with horn <NUM>, carriage <NUM> may pass onto horn gear <NUM>. Once carriage <NUM> is on horn gear <NUM>, carriage <NUM> may rotate counterclockwise on horn gear <NUM>. Carriage <NUM> may continue on horn gear <NUM> until carriage <NUM> aligns with another open horn on an adjacent horn gear.

As the carriages extend around radial braiding machine <NUM>, the thread from the spools located within the carriages may intertwine with one another. As the thread intertwines, a non-jacquard braided structure may be formed.

Referring to <FIG>, the general path of a carriage on radial braiding machine <NUM> is depicted. Path <NUM> indicates the path that carriage <NUM> may take. Path <NUM> indicates the path that carriage <NUM> may take. Although path <NUM> generally follows a counterclockwise rotation, it should be recognized that carriage <NUM> rotates locally in a clockwise and counterclockwise manner as carriage <NUM> passes from horn gear to horn gear. Additionally, path <NUM> generally follows a clockwise rotation; however, carriage <NUM> rotates locally in a clockwise and counterclockwise manner as carriage <NUM> passes between the horn gears. As shown, path <NUM> and path <NUM> are continuous around radial braiding machine <NUM>. That is, path <NUM> and path <NUM> do not change overall direction around radial braiding machine <NUM>.

In the configuration as shown, radial braiding machine <NUM> may not be configured to form intricate and customized designs of braided structures. Due to the construction of radial braiding machine <NUM>, each carriage passes between plurality of horn gears <NUM> in largely the same path. For example, carriage <NUM> rotates clockwise around radial braiding machine <NUM> along path <NUM>. Carriage <NUM> is generally fixed in this path. For example, carriage <NUM> generally cannot transfer onto path <NUM>.

Additionally, the interaction and intertwining of strands on each of the carriages is generally fixed from the beginning of the braiding cycle. That is, the placement of carriages in the beginning of the braiding cycle may determine the formation of the braided structure formed by radial braiding machine <NUM>. For example, as soon as the carriages are placed in specific horns within the horn gears, the pattern and interaction of the carriages is not altered unless radial braiding machine <NUM> is stopped and the carriages are rearranged. This means that the braided portion formed from a radial braiding machine <NUM> may form a repeating pattern throughout the braided portion that may be referred to as a non-jacquard braided portion. Additionally, this configuration does not allow for specific designs or shapes to be formed within a braided portion.

With reference to radial braiding machine <NUM>, in some embodiments, the carriages placed within the horns or slots of plurality of horn gears <NUM> may be placed in predetermined locations. That is, the carriages may be placed so that as the horn gears of radial braiding machine <NUM> rotate, the carriages will not interfere with one another. In some embodiments, radial braiding machine <NUM> may be damaged if carriages are not preplaced in a particular arrangement. As the carriages extend from one horn gear to another, an open horn must be available at the junction of adjacent horn gears for the carriages to pass from one horn gear to another. If the horn of a horn gear is not open, the attempted transfer of carriages may cause damage to the radial braiding machine. For example, as shown in <FIG>, horn <NUM> is not occupied by a carriage. If horn <NUM> were to be occupied by a carriage in the current configuration, carriage <NUM> would interfere with that carriage. In such a configuration, radial braiding machine <NUM> may be damaged due to the interference. The carriages may be particularly placed within horns such that interference between carriages may be avoided.

Referring to <FIG>, a configuration of a braided structure, not embodying the invention, formed from radial braiding machine <NUM> is depicted. As shown braided portion <NUM> is formed in a largely tubular shape. The same non-jacquard braid structure is depicted throughout the length of braided portion <NUM>. Additionally, there are no holes, openings, or designs within the side of braided portion <NUM> that are parallel to the braiding direction. Rather, braided portion <NUM> depicts an opening at either end of braided portion <NUM>. That is, the openings of braided portion <NUM> are only depicted in an area that is perpendicular to the braiding direction of radial braiding machine <NUM>.

Referring to <FIG>, a cutaway portion of braiding machine <NUM> is depicted. As shown, a portion of track <NUM> has been removed for ease of description. Additionally, plurality of spools <NUM> are shown located in gaps <NUM> between plurality of rotor metals <NUM>. Gaps <NUM> may be the area or space between adjacent plurality of rotor metals <NUM>. As discussed previously, plurality of rotor metals <NUM> may rotate and press or slide the spools to an adjacent gap.

In some examples, plurality of rotor metals <NUM> may be turned by motors. In some examples, plurality of rotor metals <NUM> may each be controlled by a motor. In other examples, plurality of rotor metals <NUM> may be controlled by various gears and clutches. In still further examples, plurality of rotor metals <NUM> may be controlled by another method.

Referring to <FIG>, a schematic of a top view of braiding machine <NUM> is depicted. Braiding machine <NUM> includes plurality of rotor metals <NUM> and a plurality of carriages <NUM>. Each of the plurality of carriages <NUM> may include spools that include thread. As depicted, a plurality of spools <NUM> is arranged within the plurality of carriages <NUM>. Additionally, threads <NUM> extend from each of the plurality of spools <NUM>.

The size of braiding machine <NUM> may be varied. In some examples, braiding machine <NUM> may be able to accept <NUM> carriages. In other examples, braiding machine <NUM> may be able to accept <NUM> carriages. In still further examples, braiding machine <NUM> may be able to accept <NUM> carriages or more. In further examples, braiding machine <NUM> may be able to accept between about <NUM> carriages and about <NUM> carriages. In still further examples, the number of carriages may be less than <NUM> carriages or over <NUM> carriages. By varying the number of carriages and spools within a braiding machine, the density of the braided structure as well as the size of the braided component may be altered. For example, a braided structure formed with <NUM> spools may be denser or include more coverage than a braided structure formed with fewer spools. Additionally, by increasing the number of spools, a larger-sized objected may be overbraided.

Plurality of rotor metals <NUM> may have various shapes. Each rotor metal may be evenly spaced from one another and is formed in the same shape. Referring particularly to rotor metal <NUM>, in some examples, an upper and a lower end may include convex portions. As shown, rotor metal <NUM> includes first convex edge <NUM> and second convex edge <NUM>. As shown, first convex edge <NUM> and second convex edge <NUM> extend away from a central portion of rotor metal <NUM>. Additionally, first convex edge <NUM> is located on an opposite side of rotor metal <NUM> from second convex edge <NUM>. In this position, first convex edge <NUM> and second convex edge <NUM> are oriented radially from ring <NUM>. That is, first convex edge <NUM> faces an outer perimeter of braiding machine <NUM> and second convex edge <NUM> faces toward ring <NUM>. In this configuration, rotor metal <NUM> is in a steady state or starting position. The orientation of first convex edge <NUM> and second convex edge <NUM> may change during use of braiding machine <NUM>.

The sides of the rotor metals may include concave portions. As depicted, rotor metal <NUM> includes first concave edge <NUM> and second concave edge <NUM>. First concave edge <NUM> and second concave edge <NUM> may extend between first convex edge <NUM> and second convex edge <NUM>. In such a configuration, rotor metal <NUM> may have a shape that is similar to a bowtie. In other examples, plurality of rotor metals <NUM> may have different or varying shapes.

The orientation of each carriage may vary during use of braiding machine <NUM>. In this configuration, first concave edge <NUM> is located adjacent to carriage <NUM>. Second concave edge <NUM> is located adjacent to carriage <NUM>. As rotor metal <NUM> rotates, carriage <NUM> may interact with second concave edge <NUM> and carriage <NUM> may interact with first concave edge <NUM>. By interacting with carriage <NUM>, carriage <NUM> may be rotated away from gap <NUM> located between rotor metal <NUM> and rotor metal <NUM>. Additionally, carriage <NUM> may be rotated away from gap <NUM> located between rotor metal <NUM> and rotor metal <NUM>.

As shown, each rotor metal of plurality of rotor metals <NUM> is arranged along a perimeter portion of braiding machine <NUM>. The even spacing of plurality of rotor metals <NUM> forms even and consistent gaps <NUM> between each of the plurality of rotor metals <NUM> along the perimeter of braiding machine <NUM>. Gaps <NUM> may be occupied by plurality of carriages <NUM>. In other embodiments, a portion of gaps <NUM> may be unoccupied or empty.

In contrast to radial braiding machines or fully non-jacquard machines, in a lace braiding machine, each rotor metal is not intermeshed with the adjacent rotor metal. Rather, each rotor metal may be selectively independently movable at opportune times. That is, each rotor metal may rotate independently from other rotor metals of braiding machine <NUM> when there is clearance for a motor to rotate. Referring to <FIG>, every other rotor metal is depicted as rotating approximately <NUM> degrees in a clockwise direction from a first position to a second position. In contrast to braiding with a radial braiding machine, every rotor metal does not rotate. In fact, some rotor metals are not permitted to rotate. For example, rotor metal <NUM> rotates from a first position approximately <NUM> degrees clockwise to a second position. Adjacent rotor metal <NUM>, however, may not be permitted to rotate as adjacent rotor metal <NUM> may collide with rotor metal <NUM> in the current position.

The rotation of a rotor metal may assist in rotating carriages along the perimeter of braiding machine <NUM>. Referring to rotor metal <NUM>, second concave edge <NUM> may press against carriage <NUM>. As rotor metal <NUM> contacts carriage <NUM>, rotor metal <NUM> may press or push carriage <NUM> in a clockwise direction. As shown, carriage <NUM> is located between second concave edge <NUM> and the perimeter portion of braiding machine <NUM>. Additionally, carriage <NUM> may rotate clockwise as well. First concave edge <NUM> may press against carriage <NUM> and push or force carriage <NUM> to rotate clockwise. In this configuration, carriage <NUM> may be located between rotor metal <NUM> and ring <NUM>.

Portions of rotor metals may enter into gaps located between each of the rotor metals. In some examples, the convex portions of a rotor metal may be located within the gaps between rotor metals. As shown in <FIG>, second convex edge <NUM> may be partially located within gap <NUM>. Additionally, first convex edge <NUM> may be partially located within gap <NUM>. In this configuration, therefore, rotor metal <NUM> and rotor metal <NUM> may be restricted from rotating because each of the rotor metals may contact rotor metal <NUM>.

Referring to <FIG>, half of the rotor metals have complete a <NUM>-degree rotation. For example, rotor metal <NUM> has completed a <NUM>-degree rotation. In this configuration, second convex edge <NUM> now faces the perimeter of braiding machine <NUM>. First convex edge <NUM> now faces ring <NUM>. Further, carriage <NUM> now occupies gap <NUM>. Additionally, carriage <NUM> now occupies gap <NUM>. In this configuration, carriage <NUM> and carriage <NUM> have exchanged places from the configuration depicted in <FIG>.

As the carriages pass by one another, the strand or thread from the spools located within the carriages may intertwine. As shown in <FIG>, strand <NUM> from the spool of carriage <NUM> may intertwine with strand <NUM> from the spool of carriage <NUM>. Additionally, the strands from other carriages may also intertwine. In this manner, a braided structure may be formed through the interaction and intertwining of various strands from the spools located within the carriages of braiding machine <NUM>.

The number of carriages and spools within braiding machine <NUM> may be varied. In some examples, many gaps <NUM> may remain unoccupied. By not filling a gap with a carriage and spool, different designs and braided structures may be formed. In some examples, by not including spools in certain locations, holes or openings may be formed in a braided structure or component.

Each rotor metal may rotate at opportune times. For example, in the configuration shown in <FIG>, rotor metal <NUM> may rotate. While rotor metal <NUM> begins to rotate, rotor metal <NUM> may not rotate so as to avoid a collision between rotor metal <NUM> and rotor metal <NUM>. When rotor metal <NUM> rotates, rotor metal <NUM> may press against carriage <NUM> and move carriage <NUM> in the same manner as rotor metal <NUM> moved carriage <NUM>. Strand <NUM> may then interact and intertwine with a different strand and form a different braided design. Other carriages may similarly be acted upon to form various braided elements within a braided structure.

Some carriages may individually rotate counterclockwise. In some examples, rotor metal <NUM> and rotor metal <NUM> may rotate counterclockwise. Additionally, every other rotor metal may also rotate counterclockwise. In such a configuration, a braided structure may be formed that is similar in appearance to a braided structure formed on radial braiding machine <NUM>. This type of motion may be considered a non-jacquard motion. A non-jacquard motion may form a non-jacquard braid structure. For example, in some configurations, every other rotor metal from rotor metal <NUM> may be configured to rotate clockwise at opportune times. Every other rotor metal from rotor metal <NUM> may be configured to rotate counterclockwise at opportune times. In this configuration, as rotor metal <NUM> rotates counterclockwise, rotor metal <NUM> may locally rotate carriage <NUM> counterclockwise. Additionally, as rotor metal <NUM> rotates counterclockwise, rotor metal <NUM> may contact carriage <NUM> and locally rotate carriage <NUM> counterclockwise. In such a configuration, however, carriage <NUM> may be rotating clockwise around the perimeter of braiding machine <NUM>. Carriage <NUM> may be rotating counterclockwise around the perimeter of braiding machine <NUM>. In this manner, carriage <NUM> may be rotating in a path similar to path <NUM> of <FIG>. Additionally, carriage <NUM> may be rotating in a path similar to path <NUM> of <FIG>. As such, braiding machine <NUM> may be configured to mimic or recreate the non-jacquard motion of radial braiding machine <NUM> and form non-jacquard structures within a braided portion. In such configurations, braiding machine <NUM> may be configured to form braided structures that are similar to those braided structures formed on radial braiding machine <NUM>.

Although braiding machine <NUM> may be configured to mimic the motion of a radial braiding machine and thereby form non-jacquard portions, it should be recognized that braiding machine <NUM> is not forced to mimic the motion of radial braiding machine <NUM>. For example, plurality of rotor metals <NUM> may be configured to rotate both clockwise and counterclockwise. For example, rotor metal <NUM> may be configured to rotate both clockwise and counterclockwise. In other examples, each rotor metal of plurality of rotor metals <NUM> may be configured to rotate both clockwise and counterclockwise. By rotating clockwise and counterclockwise, braiding machine <NUM> may be able to form designs and unique braided structures within a braided component that radial braiding machine <NUM> may be incapable of forming.

Referring to <FIG> and <FIG>, an individual rotor metal may rotate. As shown, rotor metal <NUM> rotates clockwise and interacts with carriage <NUM> and carriage <NUM>. Carriage <NUM> may be moved to occupy gap <NUM>. Additionally carriage <NUM> may be moved to occupy gap <NUM>. In this configuration, strand <NUM> may twist around strand <NUM>. In this manner, rotor metal <NUM> may assist in forming a jacquard braided structure that may not be formed on radial braiding machine <NUM>. Additionally, other rotor metals may rotate in a similar manner to form intricate patterns and designs that may not be possible on a radial braiding machine.

Referring to <FIG>, an article that is formed using a lace braiding machine is depicted. In contrast to braided portion <NUM> of <FIG>, braided portion <NUM> includes an intricate jacquard braided structure. While braided portion <NUM> is formed of a consistent and repeating non-jacquard braided structure, braided portion <NUM> includes multiple different designs and intricate braided structures. Braided portion <NUM> may include openings within braided portion <NUM> along the braiding direction as well as tightly braided areas with a high density of strands or thread.

Referring to <FIG>, an article of footwear that may be formed as a unitary piece using a lace braiding machine is depicted. Article <NUM> may include various design features that may be incorporated into article <NUM> during the braiding process. In some examples, lace aperture <NUM>, lace aperture <NUM>, lace aperture <NUM>, and lace aperture <NUM> may be formed during the manufacturing process.

Article <NUM> may incorporate areas of high-density braid as well as areas of low-density braid. For example, area <NUM> may be formed with a high-density braided configuration. In some examples, area <NUM> may be a non-jacquard area that is formed during a non-jacquard motion of spools within braiding machine <NUM>. In some examples, high-density areas may be located in areas of article <NUM> that are likely to experience higher levels of force. In some examples, area <NUM> may be located adjacent a sole structure. In other examples, area <NUM> may be located in various areas for design and aesthetic reasons. Additionally, in some examples, lower density braid <NUM> may be located throughout article <NUM>. In some examples, lower density braid <NUM> may be a jacquard area formed during a jacquard motion of spools within braiding machine <NUM>. In some examples, lower density braid <NUM> may extend between and connect areas of high-density braid or non-jacquard areas. In other examples, lower density braid <NUM> may be located in areas of article <NUM> that may be configured to stretch. In other examples, lower density braid <NUM> may be placed in areas for aesthetic and design purposes.

Different techniques may be used to form different densities of braided structures. In some examples, a jacquard area may have a higher density than a non-jacquard area. As discussed previously, varying rate of rotation of the spools as well as the rate of extension of a braided component may assist in varying the density of the braided component.

Article <NUM> may be formed using a seamless braided upper. As discussed previously, braiding machine <NUM> may be used to form different braided shapes and structures. In some examples, the upper of article <NUM> may be formed using a lace braiding machine to form a seamless configuration of higher density areas and lower density areas.

Claim 1:
A method of forming a braided upper using a braiding machine (<NUM>) comprising: connecting a first shoe last (<NUM>) and a second shoe last (<NUM>) to each other by a non-rigid connection mechanism (<NUM>); locating the first shoe last (<NUM>) adjacent a second opening (<NUM>) of a passageway (<NUM>), wherein the passageway (<NUM>) extends through an enclosure (<NUM>) of the braiding machine (<NUM>) and wherein a track (<NUM>) of the braiding machine (<NUM>) extends around the enclosure (<NUM>); passing the first shoe last (<NUM>) through the passageway (<NUM>) from the second opening (<NUM>) to a first opening (<NUM>); passing the first shoe last (<NUM>) from a first side of a braiding point to a second side of the braiding point of the braiding machine (<NUM>); wherein the braiding machine (<NUM>) further includes a plurality of spools (<NUM>) located along the track (<NUM>), the plurality of spools (<NUM>) including a first spool (<NUM>) and a second spool (<NUM>), the first spool (<NUM>) being adjacent to the second spool (<NUM>), wherein as the first spool (<NUM>) moves the second spool (<NUM>) remains stationary; and advancing the first shoe last (<NUM>) through the braiding machine (<NUM>), wherein the connection mechanism (<NUM>) is tensioned such that the second shoe last (<NUM>) is pulled though the braiding machine (<NUM>) and the braiding point, and as each of the plurality of spools (<NUM>) is passed around the track, thread is deposited around the first shoe last (<NUM>).