Patent Description:
The sole structure is secured to a lower portion of the upper and positioned between the foot and the ground. In athletic footwear, for example, the sole structure often includes a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces (i.e., provides cushioning) during walking, running, and other ambulatory activities. The midsole may also include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot, for example. In some configurations, the midsole may be primarily formed from a fluid-filled chamber. The outsole forms a ground-contacting element of the footwear and is usually fashioned from a durable and wear-resistant rubber material that includes texturing to impart traction. The sole structure may also include a sockliner positioned within the void of the upper and proximal a lower surface of the foot to enhance footwear comfort.

Document <CIT> describes a knitted spacer fabric in strip form, comprising two parallel knitted layers with spacer threads running between them, comprises longitudinal zones with different compression resistances determined by the number of spacer threads per unit width or by the thickness of hardness of the spacer threads. Independent claims are also included for article cut from a spacer fabric as above so that the length of the article corresponds to the cross direction, the width corresponds to the machine direction and there are zones of different compression resistance along the length of the article; article cut from a spacer fabric as above so that the length of the article corresponds to machine the direction, the width corresponds to the cross direction and there are zones of different compression resistance over the width of the article.

Document <CIT> describes a double layer and spaced knitted material which forms the lining for the luggage space in a road vehicle. It is worked with longitudinal strips free of pile yarns. The knitted material layers form the surfaces of the double layer material. The strips free of pile yarns are designed to form open pockets between the surface layers.

The claimed invention is defined by the features set forth in the appended independent claims.

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.

The foregoing Summary and the following Detailed Description will be better understood when read in conjunction with the accompanying figures.

The following discussion and accompanying figures disclose various configurations of stabilized spacer textile materials and methods for manufacturing the spacer textile materials. As an example, the spacer textile material, or a portion of the spacer textile material, is disclosed as being incorporated into a fluid-filled chamber. Although the chamber is disclosed with reference to footwear having a configuration that is suitable for running, concepts associated with the chamber may be applied to a wide range of athletic footwear styles, including basketball shoes, cross-training shoes, football shoes, golf shoes, hiking shoes and boots, ski and snowboarding boots, soccer shoes, tennis shoes, and walking shoes, for example. Concepts associated with the chamber may also be utilized with footwear styles that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. In addition to footwear, the chambers may be incorporated into other types of apparel and athletic equipment, including helmets, gloves, and protective padding for sports such as football and hockey. Similar chambers may also be incorporated into cushions and other compressible structures utilized in household goods and industrial products. Additionally, the discussion and figures disclose various configurations of a spacer textile material. Although portions of the spacer textile material are disclosed as being incorporated into the chamber, the spacer textile material may be utilized with a variety of other products or for a variety of other purposes.

An article of footwear <NUM> is depicted in <FIG> as including an upper <NUM> and a sole structure <NUM>. Upper <NUM> provides a comfortable and secure covering for a foot of a wearer. As such, the foot may be located within upper <NUM> to effectively secure the foot within footwear <NUM>. Sole structure <NUM> is secured to a lower area of upper <NUM> and extends between upper <NUM> and the ground. When the foot is located within upper <NUM>, sole structure <NUM> extends under the foot to attenuate ground reaction forces (i.e., cushion the foot), provide traction, enhance stability, and influence the motions of the foot, for example.

For purposes of reference in the following discussion, footwear <NUM> may be divided into three general regions: a forefoot region <NUM>, a midfoot region <NUM>, and a heel region <NUM>. Forefoot region <NUM> generally includes portions of footwear <NUM> corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region <NUM> generally includes portions of footwear <NUM> corresponding with an arch area of the foot. Heel region <NUM> generally corresponds with rear portions of the foot, including the calcaneus bone. Footwear <NUM> also includes a lateral side <NUM> and a medial side <NUM>, which extend through each of regions <NUM>-<NUM> and correspond with opposite sides of footwear <NUM>. More particularly, lateral side <NUM> corresponds with an outside area of the foot (i.e. the surface that faces away from the other foot), and medial side <NUM> corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). Regions <NUM>-<NUM> and sides <NUM>-<NUM> are not intended to demarcate precise areas of footwear <NUM>. Rather, regions <NUM>-<NUM> and sides <NUM>-<NUM> are intended to represent general areas of footwear <NUM> to aid in the following discussion. In addition to footwear <NUM>, regions <NUM>-<NUM> and sides <NUM>-<NUM> may also be applied to upper <NUM>, sole structure <NUM>, and individual elements thereof.

Upper <NUM> is depicted as having a substantially conventional configuration formed from a variety of elements (e.g., textiles, polymer sheet layers, polymer foam layers, leather, synthetic leather) that are stitched, bonded, or otherwise joined together to provide a structure for receiving and securing the foot relative to sole structure <NUM>. The various elements of upper <NUM> define a void <NUM>, which is a generally hollow area of footwear <NUM> with a shape of the foot, that is intended to receive the foot. As such, upper <NUM> extends along the lateral side of the foot, along the medial side of the foot, over the foot, around a heel of the foot, and under the foot. Access to void <NUM> is provided by an ankle opening <NUM> located in at least heel region <NUM>. A lace <NUM> extends through various lace apertures <NUM> and permits the wearer to modify dimensions of upper <NUM> to accommodate the proportions of the foot. More particularly, lace <NUM> permits the wearer to tighten upper <NUM> around the foot, and lace <NUM> permits the wearer to loosen upper <NUM> to facilitate entry and removal of the foot from void <NUM> (i.e., through ankle opening <NUM>). As an alternative to lace apertures <NUM>, upper <NUM> may include other lace-receiving elements, such as loops, eyelets, hooks, and D-rings. In addition, upper <NUM> includes a tongue <NUM> that extends between void <NUM> and lace <NUM> to enhance the comfort and adjustability of footwear <NUM>. In some configurations, upper <NUM> may incorporate other elements, such as reinforcing members, aesthetic features, a heel counter that limits heel movement in heel region <NUM>, a wear-resistant toe guard located in forefoot region <NUM>, or indicia (e.g., a trademark) identifying the manufacturer. Accordingly, upper <NUM> is formed from a variety of elements that form a structure for receiving and securing the foot.

The primary elements of sole structure <NUM> are a midsole <NUM>, a fluid-filled chamber <NUM>, an outsole <NUM>, and a sockliner <NUM>. Midsole <NUM> may be formed from a polymer foam material, such as polyurethane or ethylvinylacetate, that encapsulates chamber <NUM>. In addition to the polymer foam material and chamber <NUM>, midsole <NUM> may incorporate one or more additional footwear elements that enhance the comfort, performance, or ground reaction force attenuation properties of footwear <NUM>, including plates, moderators, lasting elements, or motion control members, for example. Although absent in some configurations, outsole <NUM> is secured to a lower surface of midsole <NUM> and may be formed from a rubber material that provides a durable and wear-resistant surface for engaging the ground. In addition, outsole <NUM> may be textured to enhance the traction (i.e., friction) properties between footwear <NUM> and the ground. Sockliner <NUM> is a compressible member located within void <NUM> and adjacent a lower surface of the foot to enhance the comfort of footwear <NUM>.

Chamber <NUM> is depicted individually in <FIG> as having a configuration that is suitable for footwear applications. When incorporated into footwear <NUM>, chamber <NUM> has a shape that fits within a perimeter of midsole <NUM> and extends through a majority of heel region <NUM>. Chamber <NUM> also extends from lateral side <NUM> to medial side <NUM>. Although the polymer foam material of midsole <NUM> is depicted as extending entirely around chamber <NUM>, the polymer foam material of midsole <NUM> may expose portions of chamber <NUM>. For example, chamber <NUM> may form a portion of (a) a sidewall of midsole <NUM> or (b) an upper or lower surface of midsole <NUM> in some configurations of footwear <NUM>. When the foot is located within upper <NUM>, chamber <NUM> extends under substantially all of a heel of the foot in order to attenuate ground reaction forces that are generated when sole structure <NUM> is compressed between the foot and the ground during various ambulatory activities, such as running and walking. In other configurations where chamber <NUM> has a different shape or structure, chamber <NUM> may extend under other areas of the foot or may extend throughout a length of sole structure <NUM>.

The primary elements of chamber <NUM> are a barrier <NUM> and a tensile member <NUM>. Barrier <NUM> is formed from a polymer material that defines a first or upper barrier portion <NUM>, an opposite second or lower barrier portion <NUM>, and a sidewall barrier portion <NUM> that extends around a periphery of chamber <NUM> and between barrier portions <NUM> and <NUM>. In addition, portions <NUM>-<NUM> (a) form an exterior of chamber <NUM>, (b) define an interior void <NUM> that receives both a pressurized fluid and tensile member <NUM>, and (c) provide a durable and sealed structure for retaining the pressurized fluid within chamber <NUM>. Tensile member <NUM> is located within interior void <NUM> and includes a first or upper layer <NUM>, an opposite second or lower layer <NUM>, and a plurality of connecting members <NUM> that extend between layers <NUM> and <NUM> and are arranged in various substantially parallel rows. Whereas upper layer <NUM> is secured to an inner surface of upper barrier portion <NUM>, lower layer <NUM> is secured to an inner surface of lower barrier portion <NUM>. Examples of chambers that include tensile members are disclosed in (a) <CIT> and entitled Fluid-Filled Chamber With A Textile Tensile Member; (b) <CIT> and entitled Contoured Fluid-Filled Chamber With A Tensile Member; and (c) <CIT>.

Tensile member <NUM> is formed from a spacer textile material. A manufacturing process, which will be discussed in greater detail below, may be utilized to form tensile member <NUM> from at least one yarn. That is, the manufacturing process may knit or otherwise manipulate one or more yarns to (a) form layers <NUM> and <NUM> to have the configuration of knitted elements, (b) extend connecting members <NUM> between layers <NUM> and <NUM>, and (c) join connecting members <NUM> to each of layers <NUM> and <NUM>. Each of connecting members <NUM> may, therefore, be sections or segments of one or more yarns that extend between and join layers <NUM> and <NUM>.

Connecting members <NUM> form a series of rows that are separated by various spaces <NUM>, as depicted in <FIG>, <FIG>. The presence of spaces <NUM> provides tensile member <NUM> with increased compressibility, lesser weight, and more efficient manufacture in comparison to other tensile members that utilize continuous connecting members without spaces. The rows formed by connecting members <NUM> are substantially parallel to each other and equidistant from each other. That is, a distance between two adjacent rows formed by connecting members <NUM> may be the same as a distance between two other adjacent rows formed by connecting members <NUM>. In general, therefore, the rows formed by connecting members <NUM> are substantially parallel to each other and distributed at substantially equal distances across tensile member <NUM>.

A manufacturing process for chamber <NUM> generally involves (a) securing a pair of polymer sheets, which form barrier portions <NUM>-<NUM>, to opposite sides of tensile member <NUM> (i.e., to layers <NUM> and <NUM>) and (b) forming a peripheral bond <NUM> that joins a periphery of the polymer sheets and extends around sidewall barrier portion <NUM>. One or both of the polymer sheets forming barrier portions <NUM>-<NUM> may also be thermoformed, molded, or otherwise shaped during the process. A pressurized fluid is then injected into interior void <NUM> through an inlet <NUM>, which is then sealed. The fluid exerts an outward force upon barrier <NUM>, which tends to separate barrier portions <NUM> and <NUM>. Tensile member <NUM>, however, is secured to each of barrier portions <NUM> and <NUM> in order to retain the intended shape (e.g., generally planar shape) of chamber <NUM> when pressurized. More particularly, connecting members <NUM> extend across the interior void and are placed in tension by the outward force of the pressurized fluid upon barrier <NUM>, thereby preventing barrier <NUM> from expanding or bulging outward. Whereas peripheral bond <NUM> joins the polymer sheets to form a seal that prevents the fluid from escaping, tensile member <NUM> prevents barrier <NUM> from expanding outward or otherwise distending due to the pressure of the fluid. That is, tensile member <NUM> effectively limits the expansion of barrier portions <NUM> and <NUM> to retain the intended shape of chamber <NUM>. Although chamber <NUM> is depicted as having a generally planar shape, chamber <NUM> (i.e., barrier portions <NUM> and <NUM>) may also be contoured, as disclosed in <CIT> and <CIT> which were mentioned above.

In order to facilitate bonding between tensile member <NUM> and barrier <NUM>, polymer bonding layers may be applied to each of layers <NUM> and <NUM>. When heated, the bonding layers soften, melt, or otherwise begin to change state so that contact with barrier portions <NUM> and <NUM> induces material from each of barrier <NUM> and the bonding layers to intermingle or otherwise join with each other. Upon cooling, the bonding layers are permanently joined with barrier <NUM>, thereby joining barrier <NUM> and tensile member <NUM>. In some configurations, thermoplastic threads or strips may be present within layers <NUM> and <NUM> to facilitate bonding with barrier <NUM>, as disclosed in <CIT>, which was mentioned above. An adhesive may also be utilized to assist with securing barrier <NUM> and tensile member <NUM>.

A wide range of polymer materials may be utilized for barrier <NUM>. In selecting materials for barrier <NUM>, engineering properties of the material (e.g., tensile strength, stretch properties, fatigue characteristics, and dynamic modulus) and the ability of the material to prevent diffusion of the fluid contained by barrier <NUM> may be considered. When formed of thermoplastic urethane, for example, barrier <NUM> may have a thickness of approximately <NUM> millimeter, but the thickness may range from <NUM> to <NUM> millimeters or more, for example. In addition to thermoplastic urethane, examples of polymer materials that may be suitable for barrier <NUM> include polyurethane, polyester, polyester polyurethane, and polyether polyurethane. Barrier <NUM> may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in <CIT> and <CIT> A variation upon this material may also be utilized, wherein layers include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. Another suitable material for barrier <NUM> is a flexible microlayer membrane that includes alternating layers of a gas barrier material and an elastomeric material, as disclosed in <CIT> and <CIT> Additional suitable materials are disclosed in <CIT> and <CIT>. Further suitable materials include thermoplastic films containing a crystalline material, as disclosed in <CIT> and <CIT>, and polyurethane including a polyester polyol, as disclosed in <CIT>; <CIT>; and <CIT>.

The fluid within chamber <NUM> may be pressurized between zero and three-hundred-fifty kilopascals (i.e., approximately fifty-one pounds per square inch) or more. In addition to air and nitrogen, the fluid may include octafluorapropane or be any of the gasses disclosed in <CIT>, such as hexafluoroethane and sulfur hexafluoride. In some configurations, chamber <NUM> may incorporate a valve or other structure that permits the wearer to adjust the pressure of the fluid.

An exemplary spacer textile material <NUM> (e.g., a spacer mesh material or spacer-knit textile material) is depicted in <FIG>, <FIG>. Spacer textile material <NUM> may be utilized to form tensile member <NUM>. More particularly, an element having the shape of tensile member <NUM> may be cut or otherwise removed from spacer textile material <NUM> to form tensile member <NUM>. In general, therefore, portions of spacer textile material <NUM> have a configuration that is similar to tensile member <NUM>. Spacer textile material <NUM> includes a first layer <NUM>, a second layer <NUM> that is at least partially coextensive with first layer <NUM>, and a plurality of connecting members <NUM> that extend between and join layers <NUM> and <NUM>. Connecting members <NUM> are arranged to form a series of rows that are separated by various spaces <NUM>. The rows formed by connecting members <NUM> are substantially parallel to each other and distributed at substantially equal distances across tensile member <NUM>. Spaces <NUM> are areas within spacer textile material <NUM> where connecting members <NUM> are absent, typically areas between the rows formed by connecting members <NUM>. Spacer textile material <NUM> also defines a pair of opposite edges <NUM>, which are also edges of layers <NUM> and <NUM>. Each of edges <NUM> are substantially parallel to the rows formed by connecting members <NUM>.

Although tensile member <NUM> may be cut or otherwise removed from spacer textile material <NUM>, a comparison between <FIG> and <FIG> will reveal that (a) connecting members <NUM> are straight in <FIG> and (b) connecting members <NUM> are wavy or otherwise non-linear in <FIG>. As noted above, connecting members <NUM> extend across the interior void of chamber <NUM> and are placed in tension by the outward force of the pressurized fluid upon barrier <NUM>. The tension in connecting members <NUM> imparts, therefore, the straight structure shown in <FIG>. Given that no comparable tension is placed upon spacer textile material <NUM>, connecting members <NUM> are loose, partially collapsed, or otherwise non-tensioned to impart the wavy or otherwise non-linear structure shown in <FIG>.

An advantage of spacer textile <NUM> relates to the presence of two stabilization structures <NUM>. Although stabilization structures <NUM> may have various configurations, as discussed below, stabilization structures <NUM> are depicted in <FIG>, <FIG> as areas of spacer textile <NUM> with a relatively high concentration of connecting members <NUM>. As an example of location, <FIG> and <FIG> depict stabilization structures <NUM> as being located adjacent to edges <NUM>. In comparison with the various rows formed by connecting members <NUM> located in a central area of spacer textile material <NUM>, stabilization structures <NUM> have greater width and a greater concentration or density of connecting members <NUM>. In some configurations, therefore, stabilization structures <NUM> may be rows of connecting members <NUM> with a greater width and a greater concentration. In general, the two stabilization structures <NUM> hold layers <NUM> and <NUM> in proper alignment with each other and resist forces that would otherwise shift layers <NUM> and <NUM>. The manner in which stabilization structures <NUM> retain the proper alignment of layers <NUM> and <NUM> will be discussed in greater detail below.

For purposes of reference in the following discussion, various directions corresponding with a length, height, and width of spacer textile material <NUM> will now be defined. Various axes defining a length direction 67a, a height direction 67b, and a width direction 67c is depicted in <FIG>. Length direction 67a generally corresponds with a length of spacer textile material <NUM> and extends in a direction that is (a) parallel to layers <NUM> and <NUM> and (b) parallel to the various rows formed by connecting members <NUM>. As such, each of the rows formed by connecting members <NUM> are oriented to extend along length direction 67a. Height direction 67b generally corresponds with a height of spacer textile material <NUM> and extends in a direction that is perpendicular to layers <NUM> and <NUM>. According to the claimed invention, individual connecting members <NUM> extend along height direction 67b. Due to the presence of stabilization structures <NUM>, areas where each individual connecting member <NUM> is joined to first layer <NUM> and second layer <NUM> are aligned in height direction 67b. Width direction 67c generally corresponds with a width of spacer textile material <NUM> and extends in a direction that is (a) parallel to layers <NUM> and <NUM> and (b) perpendicular to the various rows formed by connecting members <NUM>. As such, width direction 67c is oriented in a direction that extends between edges <NUM>.

The cross-section of <FIG> depicts a section of spacer textile material <NUM> that extends along height direction 67b and width direction 67c. As a result, <FIG> depicts a cross-section of a height and a width of spacer textile material <NUM>. Additionally, the widths of various rows formed by connecting members <NUM> and the various spaces <NUM> located between connecting members <NUM> are depicted. More particularly, <FIG> depicts multiple row widths 68a, space widths 68b, and stabilization widths 68c. Row widths 68a represent the width of an individual row formed by various connecting members <NUM>. Space widths 68b represent the width of an individual space <NUM> between two adjacent rows formed by connecting members <NUM>. Although the distance associated with each of space widths 68b may vary significantly, space widths 68b are generally greater distances than row widths 68a. Stabilization widths 68c represent the width of each stabilization structure <NUM>. Although the distance associated with each of stabilization widths 68c may vary significantly, stabilization widths 68c are generally greater distances than row widths 68a and space widths 68b. In general, therefore, the widths of stabilization structures <NUM> are greater than the widths of spaces <NUM>, and the widths of spaces <NUM> are greater than the widths of the rows formed by connecting members <NUM>. Although this relationship between the various widths provides a suitable structure to spacer textile material <NUM>, other relationships between the widths may be suitable for other configurations of spacer textile materials.

Based upon the above discussion, the distance associated with row widths 68a is generally less than the distance associated with space widths 68b, and the distance associated with space widths 68b is generally less than the distance associated with stabilization widths 68c. As noted above, the presence of spaces <NUM> provides tensile member <NUM> with increased compressibility, lesser weight, and more efficient manufacture in comparison to other tensile members that utilize continuous connecting members without spaces. Given that tensile member <NUM> comes from spacer textile material <NUM>, the presence of spaces <NUM> provides portions of spacer textile material <NUM> with increased compressibility, lesser weight, and more efficient manufacture in comparison to other spacer textile materials that utilize continuous connecting members without spaces. Moreover, by forming space widths 68b to be larger than row widths 68a, greater compressibility and lesser weight is imparted to spacer textile material <NUM>. Also as noted above, an advantage of spacer textile <NUM> relates to the presence of stabilization structures <NUM>, which retain the proper alignment of layers <NUM> and <NUM>. By forming stabilization widths 68c to be relatively large (e.g., larger than space widths 68b), the ability of each stabilization structure <NUM> to retain alignment of layers <NUM> and <NUM> is enhanced.

In some configurations of spacer textile material <NUM>, the rows formed by connecting members <NUM> have a width formed by a single connecting member <NUM>, thereby having a width of a single section of yarn. The widths of stabilization structures <NUM>, however, may include multiple connecting members <NUM>. In some configurations, the rows formed by connecting members <NUM> rows have a width formed by less than five connecting members <NUM> or the yarn sections, and stabilization structures <NUM> have a width formed by at least five of connecting members <NUM> or the yarn sections. As such, stabilization structures <NUM> have sufficient width to resist misalignment of layers <NUM> and <NUM>. In some configurations, a width of stabilization structures <NUM> may be at least five times or ten times a width of each row formed by connecting members <NUM> to also impart sufficient width to resist misalignment of layers <NUM> and <NUM>.

A general process for manufacturing spacer textile material <NUM> is depicted in <FIG>. In the process, one or more yarns <NUM> are fed into a conventional knitting apparatus <NUM>, which mechanically-manipulates yarns <NUM> to form each of layers <NUM> and <NUM> and connecting members <NUM>. As such, layers <NUM> and <NUM> may be knitted layers, and connecting members <NUM> may be sections of at least one yarn that extend between layers <NUM> and <NUM>. Moreover, the process forms spaces <NUM>, edges <NUM>, and stabilization structures <NUM>. Once formed, spacer textile material <NUM> exits knitting apparatus <NUM> and is collected on a roll <NUM>. After a sufficient length of spacer textile material <NUM> is collected, roll <NUM> may be shipped or otherwise transported to a manufacturer of chamber <NUM>, otherwise utilized to form tensile member <NUM> of chamber <NUM>, or used for other purposes. Although not always performed, spacer textile material <NUM> may be subjected to various finishing operations (e.g., dying, fleecing) prior to being collected on roll <NUM>.

When spacer textile material <NUM> is formed by knitting apparatus <NUM>, layers <NUM> and <NUM> are properly aligned with each other. That is, a point on first layer <NUM> where a particular connecting member <NUM> is joined to first layer <NUM> is aligned with a point on second layer <NUM> where that particular connecting member <NUM> is joined to second layer <NUM>, as depicted in <FIG>. In other words, layers <NUM> and <NUM> are not shifted or misaligned. Although the various connecting members <NUM> may not be straight and exhibit a wavy or crumpled configuration, the points on layers <NUM> and <NUM> are aligned. When spacer textile material <NUM> is collected onto roll <NUM>, connecting members <NUM> may bend, crush, or crumple to an even greater degree, but a point on first layer <NUM> where a particular connecting member <NUM> is joined to first layer <NUM> remains aligned with a point on second layer <NUM> where that particular connecting member <NUM> is joined to second layer <NUM>, as depicted in <FIG>. As such, layers <NUM> and <NUM> do not shift or become misaligned with each other as a result of being collected onto roll <NUM>. Additionally, when tensile member <NUM> is cut or otherwise removed from spacer textile material <NUM>, layers <NUM> and <NUM> remain aligned with each other.

One factor that assists with keeping layers <NUM> and <NUM> aligned following the manufacturing of spacer textile material <NUM> relates to the presence of stabilization structures <NUM> in spacer textile material <NUM>. In general, stabilization structures <NUM> hold layers <NUM> and <NUM> in proper alignment with each other and resist forces that would otherwise shift layers <NUM> and <NUM>. More particularly, the density of connecting members <NUM> in stabilization structures <NUM> limits the ability of layers <NUM> and <NUM> to shift relative to each other. In the absence of stabilization structures <NUM>, layers <NUM> and <NUM> may shift in the manner depicted in <FIG>. More particularly, a point on first layer <NUM> where a particular connecting member <NUM> is joined to first layer <NUM> may be shifted or misaligned with a point on second layer <NUM> where that particular connecting member <NUM> is joined to second layer <NUM> when one or more of stabilization structures <NUM> are not incorporated into spacer textile material <NUM>. It should also be noted that stabilization structures <NUM> may retain the alignment of layers <NUM> and <NUM> during the various finishing operations noted above. Accordingly, stabilization structures <NUM> impart the non-shifted configuration of <FIG> (as well as <FIG>), rather than allowing layers <NUM> and <NUM> to shift, as in the examples of <FIG>.

An advantage of limiting the degree to which layers <NUM> and <NUM> shift relates to the resulting configuration of chamber <NUM>. By retaining the alignment between layers <NUM> and <NUM>, chamber <NUM> is formed with more consistency than those chambers with shifted or misaligned spacer textile materials. For example, if layers <NUM> and <NUM> of tensile member <NUM> were to shift, a shape of chamber <NUM> may be slightly distorted, as in <FIG> which will be discussed in more detail below. Moreover, shifting of layers <NUM> and <NUM> may increase the difficulty of centrally-locating tensile member <NUM> relative to each of barrier portions <NUM>-<NUM>, which may (a) further distort the shape of chamber <NUM> and (b) decrease manufacturing efficiency.

The structure of spacer textile material <NUM> discussed above is intended to provide an example of a suitable configuration for various products, in addition to footwear <NUM>. Various other configurations for spacer textile material <NUM> outside the scope of the claimed invention may also be utilized to impart alignment between layers <NUM> and <NUM>. Referring to <FIG>, for example, spacer textile material <NUM> has a greater number of rows formed by connecting members <NUM>, resulting in an increase in the number of spaces <NUM>. Moreover, while row width 68a and stabilization width 68c remain the same, space width 68b is decreased. A reverse configuration is depicted in <FIG>, wherein spacer textile material <NUM> has a lesser number of rows formed by connecting members <NUM>, resulting in a decrease in the number of spaces <NUM>. Moreover, while row width 68a and stabilization width 68c remain the same, space width 68b is increased. In each of the configurations discussed previously, the rows formed by connecting members <NUM> had a width formed by a single connecting member <NUM>, thereby having a width of a single section of yarn. The rows formed by connecting members <NUM> are, according to the claimed invention, formed from multiple sections of yarn. For example, a row is formed by two connecting members <NUM> in <FIG> and four connecting members <NUM> in <FIG>.

In each of the configurations discussed previously, stabilization structures <NUM> are located adjacent to edges <NUM> and extend along edges <NUM>, thereby being located at a periphery of spacer textile material <NUM>. Referring to <FIG>, however, an additional stabilization structure <NUM> is located in a central area of spacer textile material <NUM>, thereby being centered between edges <NUM>. As another variation, <FIG> depicts a space <NUM> as extending between and separating two stabilization structures <NUM> adjacent to each of edges <NUM>. As such, two stabilization structures <NUM> separated by one space <NUM> are located adjacent to one of edges <NUM>, and two stabilization structures <NUM> separated by another space <NUM> are located adjacent to the other of edges <NUM>.

Forming stabilization structures <NUM> to have a greater concentration or density of connecting members <NUM> is one method of ensuring that layers <NUM> and <NUM> remain aligned following the manufacturing of spacer textile material <NUM>. Referring to <FIG>, for example, stabilization structures <NUM> include joining strands <NUM> that effectively joins layers <NUM> and <NUM>. More particularly, joining strands <NUM> may be stitching that draws layers <NUM> and <NUM> together and effectively secures layers <NUM> and <NUM> to each other within stabilization structures <NUM>. Stitching or otherwise securing layers <NUM> and <NUM> to each other may be utilized, therefore, to supplement the greater concentration or density of connecting members <NUM> and ensure that layers <NUM> and <NUM> remain aligned. Joining strands <NUM> may be any filament, yarn, or thread formed from nylon, polyester, elastane (i.e., spandex), cotton, or silk, for example. A similar result may be obtained through the use of adhesives, staples, or other structures that may limit movement of layers <NUM> and <NUM>. Although joining strands <NUM> may supplement the use of connecting member <NUM> in stabilization structures <NUM>, joining strands <NUM> may be used alone as stabilization structures <NUM>, as depicted in <FIG>.

Claim 1:
A spacer textile material (<NUM>) comprising:
a first layer (<NUM>),
a second layer (<NUM>), and
a plurality of connecting members (<NUM>) extending between and joining the first layer (<NUM>) and the second layer (<NUM>),
the connecting members (<NUM>) forming a series of at least ten rows that are separated by spaces (<NUM>), wherein each individual row is formed from multiple sections of yarn, the rows having a width (68a) that is less than a width of the spaces (68b), wherein the width (68a) of the rows is the width of an individual row formed by various connecting members (<NUM>), and
the connecting members (<NUM>) forming at least one stabilizing row (<NUM>) having a width (68c) that is greater than the width (68b) of the spaces and that is greater than the width (68a) of the rows, and
the least one stabilizing row (<NUM>) having a concentration or a density of connecting members (<NUM>) that is greater than the concentration or the density of the connecting members (<NUM>) at rows of the space textile material (<NUM>), and
wherein the rows formed by the connecting members (<NUM>) are substantially parallel to each other,
characterized in that
the connecting members (<NUM>) extend along a height direction (67b) perpendicular to the first layer (<NUM>) and to the second layer (<NUM>).