Patent Description:
Articles of footwear may include two primary elements: an upper and a sole structure. The upper may be formed from a variety of materials that are stitched or adhesively bonded together to form a void within the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower portion of the upper and is generally positioned between the foot and the ground. In many articles of footwear, including athletic footwear styles, the sole structure often incorporates an insole, a midsole, and an outsole.

<CIT> describes a closure system for an object having a first portion with first eyelets and a second portion with second eyelets. <CIT> discloses an article of footwear comprising an upper and transversal tubular structures made of strands, arranged on said upper. Each tubular structure comprises a tensile member which can be tighten by using a second lace.

The claimed invention is defined by the subject-matter of the independent claim. Specific embodiments are defined by the dependent claims.

Examples useful for the understanding of the invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the examples. The embodiments illustrated (and later described) in <FIG> do not form part of the claimed invention.

Examples include articles of footwear with tubular structures for using in applying tension through one or more regions of the article of footwear, as well as methods for printing the tubular structures onto the articles of footwear. The tubular structure may extend along an upper of the article of footwear. A tensile strand may extend through a tunnel in the tubular structure. Openings in the tubular structure may allow the tensile strand to engage with one or more secondary tensile strands, which may wrap around the tensile strand and extend away from the tubular structure to engage other structures on the upper and/or a sole structure of the article of footwear. As tension is applied along the tensile strand in the tubular structure, the tension may be transferred to the secondary tensile strands, or vice versa.

In some examples, secondary tensile strands (which do not extend through the tunnel of the tubular structure) may extend between two different sections of the tubular structure.

In some examples, the path of the tubular structure may be customized according to custom foot information about a wearer's foot. The customized path may be designed to avoid bony structures and/or provide additional support to other anatomical features (e.g., the arch). The customized path for the tubular structure could be automatically designed or manually configured through, for example, a graphical interface (e.g., a GUI).

Other systems, methods, features, and advantages of the examples will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description.

<FIG> is an isometric view of an example of an article of footwear <NUM>. In the example, article of footwear <NUM> has the form of an athletic shoe. However, in other examples, the provisions discussed herein for article of footwear <NUM> could be incorporated into various other kinds of footwear including, but not limited to, basketball shoes, hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross-training shoes, rugby shoes, baseball shoes as well as other kinds of shoes. Moreover, in some examples, the provisions discussed herein for article of footwear <NUM> could be incorporated into various other kinds of non-sports related footwear, including, but not limited to, slippers, sandals, high-heeled footwear, and loafers.

For purposes of clarity, the following detailed description discusses the features of article of footwear <NUM>, also referred to simply as article <NUM>. However, it will be understood that other embodiments may incorporate a corresponding article of footwear (e.g., a left article of footwear when article <NUM> is a right article of footwear) that may share some, and possibly all, of the features of article <NUM> described herein and shown in the figures.

The embodiments may be characterized by various directional adjectives and reference portions. These directions and reference portions may facilitate in describing the portions of an article of footwear. Moreover, these directions and reference portions may also be used in describing subcomponents of an article of footwear (e.g., directions and/or portions of a midsole structure, an outer sole structure, an upper, or any other components).

For consistency and convenience, directional adjectives are employed throughout this detailed description corresponding to the illustrated embodiments. The term "longitudinal" as used throughout this detailed description and in the claims refers to a direction extending a length of a component (e.g., an upper or sole component). A longitudinal direction may extend along a longitudinal axis, which itself extends between a forefoot portion and a heel portion of the component. Also, the term "lateral" as used throughout this detailed description and in the claims refers to a direction extending along a width of a component. A lateral direction may extend along a lateral axis, which itself extends between a medial side and a lateral side of a component. Furthermore, the term "vertical" as used throughout this detailed description and in the claims refers to a direction extending along a vertical axis, which itself is generally perpendicular to a lateral axis and a longitudinal axis. For example, in cases where an article is planted flat on a ground surface, a vertical direction may extend from the ground surface upward. Additionally, the term "inner" refers to a portion of an article disposed closer to an interior of an article, or closer to a foot when the article is worn. Likewise, the term "outer" refers to a portion of an article disposed further from the interior of the article or from the foot. Thus, for example, the inner surface of a component is disposed closer to an interior of the article than the outer surface of the component. This detailed description makes use of these directional adjectives in describing an article and various components of the article, including an upper, a midsole structure, and/or an outer sole structure.

Article <NUM> may be characterized by a number of different regions or portions. For example, article <NUM> could include a forefoot portion, a midfoot portion, a heel portion and an ankle portion. Moreover, components of article <NUM> could likewise comprise corresponding portions. Referring to <FIG>, article <NUM> may be divided into forefoot portion <NUM>, midfoot portion <NUM>, and heel portion <NUM>. Forefoot portion <NUM> may be generally associated with the toes and joints connecting the metatarsals with the phalanges. Midfoot portion <NUM> may be generally associated with the arch of a foot. Likewise, heel portion <NUM> may be generally associated with the heel of a foot, including the calcaneus bone. Article <NUM> may also include ankle portion <NUM> (which may also be referred to as a cuff portion). In addition, article <NUM> may include lateral side <NUM> and medial side <NUM>. In particular, lateral side <NUM> and medial side <NUM> may be opposing sides of article <NUM>. Furthermore, both lateral side <NUM> and medial side <NUM> may extend through forefoot portion <NUM>, midfoot portion <NUM>, heel portion <NUM>, and ankle portion <NUM>.

As shown in <FIG>, article <NUM> may comprise upper <NUM> and sole structure <NUM>. In some embodiments, sole structure <NUM> may be configured to provide traction for article <NUM>. In addition to providing traction, sole structure <NUM> may attenuate ground reaction forces when compressed between the foot and the ground during walking, running, or other ambulatory activities. The configuration of sole structure <NUM> may vary significantly in different embodiments to include a variety of conventional or nonconventional structures. In some cases, the configuration of sole structure <NUM> can be configured according to one or more types of ground surfaces on which sole structure <NUM> may be used. Examples of ground surfaces include, but are not limited to, natural turf, synthetic turf, dirt, hardwood flooring, as well as other surfaces.

Sole structure <NUM> is secured to upper <NUM> and extends between the foot and the ground when article <NUM> is worn. In different embodiments, sole structure <NUM> may include different components. For example, sole structure <NUM> may include an outsole, a midsole, and/or an insole. In some cases, one or more of these components may be optional.

Upper <NUM> may include a variety of provisions for receiving and covering a foot, as well as securing article <NUM> to the foot. In some embodiments, upper <NUM> includes opening <NUM> that provides entry for the foot into an interior cavity of upper <NUM>. In some embodiments, upper <NUM> may include tongue <NUM> that provides cushioning and support across the instep of the foot. Some embodiments may include fastening provisions, including, but not limited to, laces, cables, straps, buttons, zippers as well as any other provisions known in the art for fastening articles. In the embodiment shown in <FIG>, a particular tensioning system for tensioning one or more regions of upper <NUM> is shown, which is described in further detail below. However, other embodiments could incorporate additional and possibly separate tensioning or fastening systems, including more traditional lacing systems that may be used to close opening <NUM> around a foot. Moreover, for purposes of clarity, the exemplary embodiment does not include a lace, strap, or other fastening feature that might be used to fasten opening <NUM>. It may be appreciated however that some embodiments might incorporate a lace or other similar fastening system at the throat of article <NUM> and/or adjacent to opening <NUM>.

In different embodiments, upper <NUM> may have a variety of different configurations. In particular, upper <NUM> may have any design, shape, size, and/or color. For example, in the exemplary embodiment article <NUM> is a basketball shoe, and, therefore, upper <NUM> may have a high-top configuration that is shaped to provide high support on an ankle. In other embodiments, however, upper <NUM> could be configured as a low-top upper for running or other activities.

Upper <NUM> and sole structure <NUM> may be attached in any manner. Embodiments can utilize any know methods for securing a sole structure to an upper, including various lasting techniques such as board-lasting, slip-lasting, combination-lasting, or strobel-lasting techniques. In <FIG>, bite line <NUM> is the location along the periphery of article <NUM> where upper <NUM> meets and/or joins to sole structure <NUM>.

<FIG> illustrates an exploded isometric view of an embodiment of article of footwear <NUM>, including various components. Referring to <FIG>, article <NUM> may be provided with tensioning system <NUM>. Tensioning system <NUM> may further include tubular structure <NUM>, first tensile strand <NUM>, and plurality of secondary tensile strands <NUM>.

As used herein, the term "tubular structure" refers to any elongated structure with length greater than width and thickness (or diameter for rounded geometries), which further includes an internal tunnel or cavity through its length. In this detailed description and in the claims, the term tubular structure is not intended to be limited to structures with rounded inner and outer cross-sectional geometries. In other words, tubular structures could have outer cross-sectional geometries that are approximately rectangular or polygonal, ovoid or other geometries that need not be circular or approximately circular. In the exemplary embodiment of <FIG>, tubular structure <NUM> may generally comprise an elongated structure, which further includes tunnel <NUM>. Tubular structure <NUM> may further have a cross-sectional geometry that includes rounded section <NUM>, which faces outwardly from article <NUM>, and flattened section <NUM>, which is generally disposed against upper <NUM>.

Tubular structure <NUM> may further include first end <NUM>, second end <NUM> and intermediate portion <NUM> that is disposed between first end <NUM> and second end <NUM>. Intermediate portion <NUM> need not extend the full length between first end <NUM> and second end <NUM>, and may generally characterize a region or segment of tubular structure <NUM> between first end <NUM> and second end <NUM>. Tunnel <NUM> of tubular structure <NUM> may extend continuously through the entire length of tubular structure <NUM>, from first end <NUM> to second end <NUM>. Of course, it is contemplated that in other embodiments, tunnel <NUM> need not extend all the way to first end <NUM> or second end <NUM> of tubular structure <NUM>.

Tubular structure <NUM> may be configured with one or more openings in a surface or sidewall of tubular structure <NUM>. In <FIG>, tubular structure <NUM> includes plurality of openings <NUM>. For example, as shown in <FIG>, opening <NUM>, which may be representative of plurality of openings <NUM>, is disposed in outer surface <NUM> of tubular structure <NUM>. Opening <NUM> may further extend to tunnel <NUM>. In other words, opening <NUM> extends from outer surface <NUM> to an inner surface <NUM> of tubular structure <NUM>. It will be understood that each of the remaining openings in plurality of openings <NUM> may likewise extend from outer surface <NUM> to tunnel <NUM>. Thus, openings <NUM> may provide an access point for components (such as tensile strands) to enter or exit tunnel <NUM>. Although not shown in the Figures, first end <NUM> and second end <NUM> of tubular structure <NUM> may likewise include openings that allow for access to tunnel <NUM>.

The embodiment shown in <FIG> has a common orientation for openings <NUM> along tubular structure <NUM>. Specifically, each of the openings <NUM> is generally oriented toward bite line <NUM> of article <NUM>. However, as discussed further below, other opening orientations are possible, and in some embodiments, different holes could be configured with different orientations.

In different embodiments, one or more dimensions of a tubular structure, as well as the tunnel and openings formed in the tubular structure, could vary. For example, in different embodiments, the outer diameter of a tubular structure could have any value in the range between <NUM> and <NUM>. Likewise, the tube thickness, characterized by the distance between the outer surface and inner surface (e.g., outer surface <NUM> and inner surface <NUM>) could have any value in the range between <NUM> and <NUM>. It may be appreciated that the tunnel diameter may vary in accordance with the tube thickness (i.e., the tunnel diameter is the diameter of the tubular structure minus twice the tube thickness). Moreover, the diameter and tube thickness for a tubular structure may be selected according to various factors including desired tensile strand diameter, desired flexibility of the tubular structure, desired height of the tubular structure relative to the upper as well as possibly other factors.

Additionally, the number and arrangement of openings could vary. For example, some embodiments may include only a single opening, while others could include between two and <NUM> openings. Still other embodiments could include more than <NUM> openings. The number of openings could be selected according to the number of access points to a tunnel required, as well as the desired flexibility of a tubular structure, as additional openings may increase the flexibility of the tubular structure proximate the openings. It may also be appreciated that the openings could be disposed uniformly through the tubular structure, or in any discrete groups or patterns.

The sizes of openings could vary. For example, a circumferential dimension of an opening may characterize how much of the circumference of a tubular structure that the opening covers. Some embodiments can include openings with a circumferential dimension of only a few percent of the total circumference of the tubular structure. Still other embodiments could include openings with a circumferential dimension having a value between <NUM> to <NUM> percent of the circumference of the tubular structure. For example, in other embodiments, openings could be large enough so that only a narrow section of the tubular structure connects adjacent portions of the tubular structure at the opening. An example of a component comprised of discrete tubular structures connected by relatively narrow connecting portions is shown in <FIG> and discussed in further detail below.

A tubular structure can be configured with various physical properties. Exemplary physical properties of the tubular structure that could be varied include rigidity, strength and flexibility or elasticity. In some embodiments, for example, a tubular structure could be configured as relatively rigid with little flexibility. In the embodiment of <FIG>, tubular structure <NUM> may be configured with some flexibility such that one or more portions of tubular structure <NUM> can undergo elastic deformation during tensioning.

Different embodiments could utilize different materials for a tubular structure. Exemplary materials may include, but are not limited to, various kinds of polymers. In embodiments where a tubular structure may be formed by a 3D printing process, the tubular structure could be made of materials including, but not limited to, thermoplastics (e.g., PLA and ABS) and thermoplastic powders, high-density polyurethylene, eutectic metals, rubber, modeling clay, plasticine, RTV silicone, porcelain, metal clay, ceramic materials, plaster and photopolymers, as well as possibly other materials known for use in 3D printing. Such materials may be herein referred to as "printable materials.

Tensioning system <NUM> includes first tensile strand <NUM> and plurality of secondary tensile strands <NUM>. As used herein, the term "tensile strand" refers to any elongated (e.g., approximately two dimensional) element capable of transferring tension across its length. Examples of various kinds of tensile strands that could be used with the embodiments include, but are not limited to, cords, laces, wires, cables, threads, ropes, filaments, yarns as well as possibly other kinds of strands. Tensile strands may be configured with different strengths as well as different degrees of stretch or elasticity.

First tensile strand <NUM> may comprise a cord-like element having an approximately rounded cross section. First tensile strand <NUM> includes first end portion <NUM>, second end portion <NUM>, and intermediate portion <NUM>. Although the length of first tensile strand <NUM> could vary from one embodiment to another, in an exemplary embodiment, first tensile strand <NUM> may be longer than tubular structure <NUM> so that first end portion <NUM> and second end portion <NUM> extend outwardly from first end <NUM> and second end <NUM>, respectively, of tubular structure <NUM>.

In some embodiments, first tensile strand <NUM> may include provisions to prevent either first end portion <NUM> or second end portion <NUM> from being pulled into tunnel <NUM> of tubular structure <NUM>. Such an element may be herein referred to as a "catching element," though the exemplary embodiment of <FIG> is not depicted with any catching elements. Catching elements could include knots formed in a tensile strand or other elements that clamp or tie onto the tensile strand. A catching element may generally have a cross-sectional size and/or shape that prevents the catching element from being pulled into a tubular structure. Instead, the catching element may press against the end of the tubular structure thereby allowing the other end of the tensile strand to be pulled so as to generate tension across the tensile strand.

<FIG> illustrates an enlarged view of a portion of article <NUM> including plurality of secondary tensile strands <NUM>. Referring to <FIG>, plurality of secondary tensile strands <NUM> includes five secondary tensile strands (or just "tensile strands"). Specifically, as seen in <FIG>, plurality of secondary tensile strands <NUM> includes second tensile strands <NUM>, third tensile strand <NUM>, fourth tensile strand <NUM>, fifth tensile strand <NUM>, and sixth tensile strand <NUM>. In other embodiments, tensioning system <NUM> could include fewer than five tensile strands. In still other embodiments, tensioning system <NUM> could include more than five tensile strands.

Referring to <FIG>, a representative second tensile strand <NUM> includes first portion <NUM>, second portion <NUM>, and third portion <NUM>. Moreover, second portion <NUM> may be disposed between first portion <NUM> and third portion <NUM>.

In different embodiments, two or more tensile strands could vary in one or more properties. In some embodiments, a first tensile strand and a second tensile strand could be substantially similar in materials and/or dimensions. In other embodiments, however, a first tensile strand and a second tensile strand could differ in material and/or dimensions. For example, the exemplary embodiment depicts first tensile strand <NUM> that is much longer than any of the plurality of secondary tensile strands <NUM>. Further, as best seen in the enlarged view of <FIG>, first tensile strand <NUM> may have a larger diameter than second tensile strand <NUM>, which is a representative tensile strand of plurality of secondary tensile strands <NUM>. In particular, in some embodiments, each of the tensile strands of plurality of secondary tensile strands <NUM> may have a similar diameter.

In some embodiments, first tensile strand <NUM> may also be made of a different material than second tensile strand <NUM>. For example, in some embodiments, first tensile strand <NUM> could be made of nylon, while second tensile strand <NUM> could be made of a high-strength material such as Vectran. Using this combination of materials could allow for slightly more give and durability in first tensile strand <NUM>, which may be subjected to stresses in many different directions. In other embodiments, however, first tensile strand <NUM> and second tensile strand <NUM> could be made of similar materials that impart similar physical properties including similar strength, stretch, and durability.

Optionally, in some embodiments, a tensile strand may be encased in a coating, such as a PTFE coating, that allows the tensile strand to be pulled or pushed smoothly through a tunnel and/or against a surface such as an upper with minimal resistance. It is also contemplated that in some other embodiments, some portions of plurality of secondary tensile strands <NUM> could be laminated, covered, or embedded within a layer of TPU or other polymer material that may help bond plurality of secondary tensile strands <NUM> to an upper along their length.

Referring back to <FIG>, in the assembled article <NUM>, tubular structure <NUM> extends along a contoured path on outer surface <NUM> of upper <NUM>. Specifically, first end <NUM> of tubular structure <NUM> begins in heel portion <NUM> on medial side <NUM>, extends through midfoot portion <NUM> and forefoot portion <NUM> on medial side <NUM> and then crosses to lateral side <NUM> at the front of article <NUM>. From the front on lateral side <NUM>, tubular structure <NUM> extends through forefoot portion <NUM> and midfoot portion <NUM>, and into heel portion <NUM> on lateral side <NUM>. Second end <NUM> is disposed in heel portion <NUM>. For purposes of illustration, the portions of tubular structure <NUM> on lateral side <NUM> are shown in phantom in <FIG>.

In some embodiments, tubular structure <NUM> may be attached to an underlying portion of upper <NUM>. As an example, the enlarged cross-sectional view in <FIG> illustrates how portion <NUM> of outer surface <NUM> of tubular structure <NUM> may be in contact with, and attached to, upper <NUM>. In some embodiments, tubular structure <NUM> may be attached to upper <NUM> along the entire length of tubular structure <NUM> (e.g., tubular structure may be continuously connected with upper <NUM>). Thus, for example, first end <NUM>, second end <NUM> and intermediate portion <NUM> may all be attached directly to upper <NUM>. In other embodiments, however, tubular structure <NUM> could be attached to upper <NUM> at two or more non-continuous sections.

Generally, tubular structure <NUM> could be attached to upper <NUM> in any manner. Exemplary methods of attachment could include, but are not limited to, adhesive methods, stitching, stapling, the use of various fastening elements as well as possibly other methods. In an exemplary embodiment, tubular structure <NUM> could be formed by a three-dimensional printing process and formed directly onto upper <NUM>. In such a process, tubular structure <NUM> could be made of a printable material capable of bonding with the surface of upper <NUM> during or after printing. Such an exemplary process is discussed in further detail below.

First tensile strand <NUM> may extend through tubular structure <NUM>. Specifically, first tensile strand <NUM> may extend through tunnel <NUM> of tubular structure <NUM>.

Plurality of secondary tensile strands <NUM> may be arranged to engage with first tensile strand <NUM> and provide a means of transferring tension between first tensile strand <NUM> and one or more other regions of article <NUM>. As best seen in <FIG>, second portion <NUM> of second tensile strand <NUM> may wrap around or over first tensile strand <NUM>, thereby engaging first tensile strand <NUM>. Further, first portion <NUM> and third portion <NUM> of second tensile strand <NUM> may be attached to first attachment region <NUM> and second attachment region <NUM>, respectively, on article <NUM>. In other embodiments, one or more ends of second tensile strand <NUM> could be joined to first tensile strand <NUM>, for example, using a knot or intermediate connector.

In the exemplary embodiment of <FIG>, first attachment region <NUM> and second attachment region <NUM> are regions of sole structure <NUM>. Thus, second tensile strand <NUM> acts to connect first tensile strand <NUM> to sole structure <NUM>. In other embodiments, however, a tensile strand could be attached to a region on upper <NUM>. Such arrangements allow second tensile strand <NUM> to transfer tension between first tensile strand <NUM> and one or more attachment regions associated with either upper <NUM> or sole structure <NUM>.

<FIG> illustrates a bottom isometric view of article <NUM>. Referring to <FIG>, the exemplary embodiment provides a configuration for supporting the arch of the foot. Moreover, the additional arch support provided by tensioning system <NUM> allows sole structure <NUM> to be constructed with a narrower midfoot portion <NUM>, which may help reduce the weight of sole structure <NUM> and article <NUM>.

As best seen in <FIG>, each tensile strand in plurality of secondary tensile strands <NUM> is anchored at, or near, bite line <NUM>. In some embodiments, plurality of secondary tensile strands <NUM> may be attached directly to sole structure <NUM>. In other embodiments, plurality of secondary tensile strands <NUM> could be attached on upper <NUM> at a portion of upper <NUM> that is attached to sole structure <NUM>.

<FIG> and <FIG> illustrate an isometric view of article <NUM>, and an enlarged view of a portion of article <NUM>, respectively, as first tensile strand <NUM> is pulled to tighten article <NUM>. Referring to <FIG> and <FIG>, tensioning force <NUM> is applied to first end portion <NUM> and second end portion <NUM> of first tensile strand <NUM>. This results in first tensile strand <NUM> being pulled taut within tubular structure <NUM>. As intermediate portion <NUM> of first tensile strand <NUM> within tubular structure <NUM> is pulled taut, plurality of secondary tensile strands <NUM> is pulled into plurality of openings <NUM> (e.g., second tensile strand <NUM> is pulled into first opening <NUM>). Thus, tension is created across plurality of secondary tensile strands <NUM>, between first tensile strand <NUM> (and tubular structure <NUM>) and sole structure <NUM>. This tension provides increased support to the arch of the foot on medial side <NUM>.

Various other arrangements of secondary tensile strands are possible in other embodiments. In some embodiments, tensile strands may extend from a tubular structure to a bite line (as in <FIG>). In other embodiments, tensile strands could extend between two different portions of a tubular structure, or between two separate tubular structures. Moreover, some embodiments can be configured with a combination of tensile strands that extend to the bite line or across the upper to other portions of a tubular structure. In still other embodiments, one or more portions of a secondary tensile strand could be attached directly to a portion of an upper, using, for example, a laminate layer to bond the tensile strand to the upper, or using various kinds of welds.

<FIG> illustrate views of another embodiment of an article of footwear <NUM> (also referred to as article <NUM>) with tensioning system <NUM>. <FIG> illustrates a top view of article <NUM>, while <FIG> illustrate side views of article <NUM>, corresponding to non-tensioned (<FIG>) and tensioned (<FIG>) configurations of article <NUM>.

Article <NUM> may be provided with some similar provisions to article <NUM> of a previous embodiment. For example, article <NUM> includes upper <NUM> and sole structure <NUM>, which are joined at bite line <NUM>. Upper <NUM> and sole structure <NUM> could be configured in any way as discussed above for upper <NUM> and sole structure <NUM> of the embodiment shown in <FIG>.

For purposes of reference, article <NUM> may be associated with similar portions and/or directional terms as used in discussing article <NUM>. For example, article <NUM> includes forefoot portion <NUM>, midfoot portion <NUM>, heel portion <NUM>, and ankle portion <NUM>. Further, article <NUM> includes lateral side <NUM> and medial side <NUM>.

Article <NUM> further includes tensioning system <NUM>, which may include at least some similar components to tensioning system <NUM> discussed above and shown in <FIG>. Specifically, tensioning system <NUM> includes tubular structure <NUM>, first tensile strand <NUM> and plurality of secondary tensile strands <NUM>. The tubular structure and tensile strands may have any of the properties discussed above for tubular structure <NUM>, first tensile strand <NUM>, and plurality of secondary tensile strands <NUM>.

As seen in <FIG>, tubular structure <NUM> may be arranged on upper <NUM>. Tubular structure <NUM> may include first end <NUM>, second end <NUM>, and various intermediate portions to be discussed in further detail below. First tensile strand <NUM> extends through tunnel <NUM> of tubular structure <NUM>. First end portion <NUM> and second end portion <NUM> of first tensile strand <NUM> exit first end <NUM> and second end <NUM>, respectively, of tubular structure <NUM>.

Tubular structure <NUM> includes plurality of openings <NUM>. Portions of first tensile strand <NUM> may extend outwardly through plurality of openings <NUM> and may be engaged by plurality of secondary tensile strands <NUM> at various portions along tubular structure <NUM>. In contrast to the previous embodiment of <FIG> where secondary tensile strands were provided at a single portion of tubular structure <NUM>, the present embodiment of <FIG> incorporates secondary tensile strands along multiple different portions of tubular structure <NUM>.

Tubular structure <NUM> has a contoured path on upper <NUM>. Starting on lateral side <NUM> of heel portion <NUM>, tubular structure <NUM> extends continuously on lateral side <NUM> through midfoot portion <NUM> and forefoot portion <NUM>, around the front of upper <NUM>, and then on medial side <NUM>, ending in heel portion <NUM>. The contoured path of tubular structure <NUM> incorporates various curved or non-linear portions that facilitate dynamic fit and comfort.

In some embodiments, portions of a tubular structure may be contoured to create dynamic support to one or more portions of a foot. For example, tubular structure <NUM> includes first curved portion <NUM> on lateral side <NUM>, which is approximately disposed through midfoot portion <NUM> of article <NUM>. First curved portion <NUM> is seen to curve away from bite line <NUM>. Second curved portion <NUM> is disposed on medial side <NUM> and similarly curves away from bite line <NUM>. The placement and geometry of these portions may facilitate a dynamic fit for article <NUM>, especially when used in combination with one or more secondary tensile strands.

In some embodiments, portions of a tubular structure may be contoured to enhance comfort, for example, by passing around (rather than over or through) bony regions of an upper. As used herein, the term "bony region" refers to any region or portion of an upper that is in contact with, or proximate, a bony structure of a foot when the article is worn. Exemplary bony structures in the foot include structures of the metatarsal bones, structures of the calcaneus bone, as well as structures associated with the ankle, such as the lateral malleolus, the medial malleolus, and the posterior malleolus. Since applying forces directly against some bony structures of the foot can increase discomfort, it may be desirable to avoid placing a tubular structure across a bony structure (i.e., within a bony region of the upper).

More generally, embodiments can include provisions for contouring a tubular structure to achieve any desired configuration relative to an anatomical portion of a foot. For example, tubular structure may be contoured in a manner that facilitates support to the arch of the foot. As another example, a tubular structure could be configured to pass around pressure points or hotspots on a foot, which may or may not be associated with bony structures.

Referring to <FIG>, the contoured geometry of tubular structure <NUM> includes several portions intended to avoid bony regions. Here, upper <NUM> includes first bony region <NUM> corresponding to the lateral malleolus of a foot, second bony region <NUM> corresponding to the medial malleolus of a foot, third bony region <NUM> corresponding to a first metatarsal bone of a foot and fourth bony region <NUM> corresponding to a phalanx of the big toe. To accommodate these bony structures, third curved portion <NUM> curves around a periphery of first bony region <NUM>, and fourth curved portion <NUM> curves around a periphery of second bony region <NUM>. Further, as seen in <FIG>, tubular structure <NUM> includes looped portion <NUM> that surrounds the entire periphery of third bony region <NUM>. Finally, tubular structure <NUM> curves along the periphery of fourth bony region <NUM> so as to pass between the big toe (hallux) and the rest of the foot.

Secondary tensile strands may be arranged on article <NUM> to facilitate a dynamic fit and/or to enhance the support of the upper adjacent a bony structure. Plurality of secondary tensile strands <NUM> may be further associated with several distinct groups of tensile strands. For example, first group of tensile strands <NUM> is disposed in heel portion <NUM>, second group of tensile strands <NUM> is disposed over instep portion <NUM> (shown in <FIG>) of upper <NUM>, and third group of tensile strands <NUM> is disposed in midfoot portion <NUM> on medial side <NUM>. Each group of secondary tensile strands attaches to first tensile strand <NUM> and provides the ability to vary the tension across these different regions of upper <NUM>. It may be understood that the term "group of tensile strands" may refer to one or more tensile strands. In the embodiment shown in <FIG>, for example, second group of tensile strands <NUM> may comprise a single tensile strand that weaves back and forth across instep portion <NUM>. In other embodiments, second group of tensile strands <NUM> could comprise two or more distinct tensile strands.

As best seen in <FIG>, third group of tensile strands <NUM> may extend from first tensile strand <NUM> down to bite line <NUM>, thereby enhancing support for the arch of the foot on medial side <NUM>. The configuration of third group of tensile strands <NUM> and the support provided may be similar in many respects to the configuration of, and support provided by, plurality of secondary tensile strands <NUM> shown in <FIG>. As with the earlier embodiment, ends of each tensile strand in third group of tensile strands <NUM> may be attached directly to sole structure <NUM>.

Some tensile strands may be configured to extend between different portions of a tubular structure. For example, first group of tensile strands <NUM> includes tensile strands extending from third curved portion <NUM> to fourth curved portion <NUM> of tubular structure <NUM>, wrapping around the back and/or bottom side of heel portion <NUM> between these tubular portions. Similarly, second group of tensile strands <NUM> includes tensile strands extending from first curved portion <NUM> to second curved portion <NUM>, extending over instep portion <NUM> (see <FIG>) in between these tubular portions. Second group of tensile strands <NUM> also includes tensile strands extending from looped portion <NUM> of tubular structure <NUM> to lateral forefoot portion <NUM> of tubular structure <NUM>, which is disposed adjacent to bite line <NUM>. These tensile strands extend over the top of forefoot portion <NUM>.

Second group of tensile strands <NUM> includes second tensile strand <NUM> that extends between first curved portion <NUM> and second curved portion <NUM> of tubular structure <NUM>. Here, first curved portion <NUM> includes first surface <NUM> with first opening <NUM> that extends into tunnel <NUM>, and second curved portion <NUM> includes second surface <NUM> with second opening <NUM> that extends into tunnel <NUM>. Second tensile strand <NUM> includes first portion <NUM> that engages first tensile strand <NUM> proximate second opening <NUM> (e.g., just inside, or outside, of opening <NUM>). Second tensile strand <NUM> also includes second portion <NUM> that engages first tensile strand <NUM> proximate first opening <NUM>. Moreover, in some embodiments, second tensile strand <NUM> continues to weave back and forth between first curved portion <NUM> and second curved portion <NUM>, further engaging additional portions of first tensile strand <NUM> through more openings on the tubular portions. With this configuration, second tensile strand <NUM> is able to transmit tension between two different portions of first tensile strand <NUM>, specifically a portion of first tensile strand <NUM> within first curved portion <NUM> and a portion of first tensile strand <NUM> within second curved portion <NUM>.

In order to accommodate the various path directions of the secondary tensile strands, openings in a tubular structure may be provided with a variety of different orientations. For purposes of reference, a tubular structure may be associated with an axial direction, which extends along the length of the tubular structure, and a circumferential direction (e.g., an angular direction) that extends around the circumference of the tubular structure. To accommodate different path directions and locations for secondary tensile strands, a tubular structure may, therefore, include openings having different circumferential orientations. As used herein, the orientation of an opening refers to a direction normal to a center of the opening. As an example shown in <FIG>, opening <NUM> of tubular structure <NUM> is open toward a top or instep portion <NUM> (see <FIG>) of upper <NUM>, while opening <NUM> of tubular structure <NUM> is open toward bite line <NUM> of article <NUM>. Thus, opening <NUM> and opening <NUM> are clearly seen to have different circumferential orientations along tubular structure <NUM>. Such variable orientations allow for the placement of secondary tensile strands extending in any desired direction across upper <NUM>, including across the top of upper <NUM>, beneath upper <NUM>, and/or to bite line <NUM>.

<FIG> illustrates a side view of article <NUM> as first tensile strand <NUM> is pulled, or tensioned. As seen in comparing <FIG>, during tensioning, at least some portions of tubular structure <NUM> undergo elastic deformation. In particular, the geometry or curvature of tubular structure <NUM> (along the axial direction) is changed with tension. This change in geometry is elastic since releasing the tension results in tubular structure <NUM> returning to its non-tensioned configuration (<FIG>).

The deformations in some portions of tubular structure <NUM> occur as first tensile strand <NUM> attempts to straighten under tension. Thus, in some portions of high curvature, first tensile strand <NUM> may apply forces to tubular structure <NUM> that act to straighten those portions. For example, first curved portion <NUM> of tubular structure <NUM> undergoes an elastic deformation that results in a slightly straighter configuration. This, along with the retraction of first tensile strand <NUM> into openings <NUM> acts to pull second group of tensile strands <NUM>. As second curved portion <NUM> (not shown in <FIG>) may undergo a similar straightening and pulling away from instep portion <NUM>, second group of tensile strands <NUM> may be generally pulled down on instep portion <NUM>, increasing support at instep portion <NUM>. Additionally, third curved portion <NUM> undergoes an elastic deformation that pulls inwardly (e.g., toward a center of first bony region <NUM>) on first group of tensile strands <NUM>. This results in first group of tensile strands <NUM> pulling against the back, sides and bottom of the heel to enhance support.

Different portions of a tubular structure may undergo different changes in geometry. The degree and type of change in geometry may be controlled by various factors including, but not limited to, the non-tensioned geometry of the tube (e.g., straight or curved) and flexibility of the tube, as well as possibly other factors.

Because tubular structure <NUM> is attached directly to upper <NUM>, tubular structure <NUM> applies forces to upper <NUM> as it deforms, which may result in changes in the upper geometry. Therefore, changes in support and fit of the upper as tensioning system <NUM> is adjusted result not only from adjusting the tension of secondary tensile strands but also from changing the upper geometry as tubular structure <NUM> undergoes elastic deformation.

For purposes of characterizing upper <NUM>, upper may be considered as having various base portions. A base portion is a local portion of the region of the upper that may or may not be continuous with adjacent portions or regions. A base portion may further be characterized as having a geometry. As used herein, the geometry of a base portion, or base layer, includes the surface area and the geometry of the surface. Base portions may have flat geometries, may be smoothly curved or may be highly curved. Regions of high curvature in the surface of a base portion or layer may be characterized as folds or pinched portions. Because the layers of an upper may be made of fabrics or textiles having a high degree of flexibility, an upper or portions of the upper may undergo significant changes in geometry, including changing from a relatively flat geometry to a geometry with one or more folds. In some embodiments, the surface area of a base portion could change without significant changes to the surface curvature or contouring. This may occur when the base portion is capable of expanding or compressing in a dimension parallel with the surface of the base portion (e.g., a rubber sheet can expand or compress horizontally inducing a change in surface area without significant changes from a flattened geometry). It may, therefore, be appreciated that as used herein, "change in geometry" could refer to increases or reductions in surface area without significant changes in curvature (e.g., without adding indentations, pinches, or folds to the surface).

As depicted in <FIG>, upper <NUM> may include several distinct base portions. First base portion <NUM> extends in midfoot portion <NUM>, from first curved portion <NUM> of tubular structure <NUM> down to bite line <NUM>. A second base portion <NUM> extends through midfoot portion <NUM>, between first curved portion <NUM> and second curved portion <NUM> (e.g., across instep portion <NUM>). <FIG> depict an initial geometry for first base portion <NUM> and second base portion <NUM>. As tension is applied via first tensile strand <NUM> (shown in <FIG>), tubular structure <NUM> deforms and applies forces to the boundaries of both first base portion <NUM> and second base portion <NUM>. The resulting deformation acts to increase the geometry of second base portion <NUM>, as first curved portion <NUM> and second curved portion <NUM> pull the edges of second base portion <NUM> apart. Thus, the surface area of second base portion <NUM> may generally be increased, and some slight changes in contouring may also occur as second base portion <NUM> accommodates a slightly different portion of the foot. In contrast, as first curved portion <NUM> deforms, first base portion <NUM> contracts slightly, as the upper boundary of first base portion <NUM> is moved closer to a lower boundary at bite line <NUM>. In the exemplary embodiment, this change in the boundary locations of first base portion <NUM> induces small ridge <NUM> (e.g., a local change in the otherwise flat geometry of first base portion <NUM>). Thus, first base portion <NUM> clearly changes in geometry as article <NUM> is tensioned. The resulting changes may provide enhanced fit across upper <NUM> in second base portion <NUM> (i.e., along part of instep portion <NUM>), while relaxing the fit on upper <NUM> in first base portion <NUM>.

It will be appreciated that depending on the configuration of the tubular structure and one or more secondary tensile strands, some portions of upper <NUM> may not undergo any significant changes in geometry (and therefore fit) as tension is applied to first tensile strand <NUM>. Moreover, as discussed above, it is contemplated that base portions could undergo significant changes in geometry without introducing highly curved features (such as ridges, indentations, pinches, or folds) - e.g., by using elastic fabrics or textiles that are pre-stretched in an un-tensioned state of the article, such that deformations in tube geometry result in mere contraction or further expansion without affecting surface curvature.

<FIG> illustrates an exemplary embodiment of another embodiment of an article of footwear <NUM> (or article <NUM>), which illustrates a tubular geometry configured to provide enhanced comfort at a bony region associated with the calcaneus bone. It will be appreciated that article <NUM> may incorporate any of the provisions previously discussed in the previous embodiments and shown in <FIG>. Such similar provisions may be discussed without introduction in discussing this embodiment.

Referring to <FIG>, tubular structure <NUM> has an approximately circular or rounded geometry and passes around periphery <NUM> of bony region <NUM>, which corresponds to the calcaneus bone. In <FIG>, the approximate location of the furthest protruding feature <NUM> of the calcaneus bone is depicted in phantom. Thus, the path of tubular structure <NUM> in heel region <NUM> is selected to avoid applying pressure directly against the calcaneus, especially in the vicinity of protruding feature <NUM>. Secondary tensile strands <NUM> engage first tensile strand <NUM> and extend radially outwardly from a center of bony region <NUM>. Thus, when tensioned, secondary tensile strands <NUM> may help keep tubular structure <NUM> from deforming into bony region <NUM> and thereby causing discomfort.

The embodiments disclosed in <FIG> illustrate tubular structures that are generally continuous with openings placed at various locations along the tubular structure. It may be appreciated that other embodiments are not limited to this specific class of geometries and may incorporate other geometries for tube-like structures that facilitate the operation of a tensioning system along an upper. For example, some other embodiments could incorporate more discrete tubular segments that are joined by relatively narrow connecting portions. Such an alternative embodiment is depicted in <FIG>.

<FIG> depicts an embodiment of article <NUM> including tensioning system <NUM> with tunnel spring structure <NUM>. Here, tunnel spring structure <NUM> extends in a contoured path over upper <NUM>. <FIG> depicts article <NUM> in a tensioned state. Tunnel spring structure <NUM> includes plurality of individual tubular structures <NUM> that are joined by connecting portions <NUM>. For example, first tubular structure <NUM> is connected to second tubular structure <NUM> by intermediate connecting portion <NUM>. More specifically, first tubular structure <NUM> includes first end <NUM> and second end <NUM> and a tunnel portion (not visible) extending between first end <NUM> and second end <NUM>. Likewise, second tubular structure <NUM> includes third end <NUM> and fourth end <NUM> as well as a tunnel portion (not visible) extending between third end <NUM> and fourth end <NUM>. Thus, intermediate connecting portion <NUM> is seen to be attached at second end <NUM> of first tubular structure <NUM> and third end <NUM> of second tubular structure <NUM>, thereby joining the structures. In this embodiment, each separate tubular structure has a tunnel portion and by joining the tubular structures together with connecting portions the tunnel portions together form a tunnel extending from a first end to a second end of the tunnel spring structure <NUM>.

In the embodiment shown in <FIG>, intermediate connecting portion <NUM> may generally have a small circumferential dimension. Specifically, embodiments may include connecting portions with circumferential dimensions in the range between <NUM> and <NUM> percent of the total circumference of each tubular structure.

In contrast to the tubular structures depicted in <FIG>, tunnel spring structure <NUM> is capable of flexing (e.g., contracting or expanding in length) along an axial direction. This flexing can occur as connecting portions <NUM> deform under tension applied across tensile strand <NUM>, thereby allowing adjacent tubular structures to move closer together. Such a configuration may allow for slightly different dynamics on an upper than in cases where the tubular structure has a fixed axial length. It is also to be appreciated that such tunnel spring structures may also be more easily flexed in other directions beyond the axial direction. In other words, the tunnel spring structures may flex and bend more easily than other configurations of a tubular structure. In some cases, tunnel spring structures may also tend to return to a default position after tension is released as the connecting portions of the tunnel spring structure may act to urge adjacent tubular structures apart and toward a default spacing of tubular structures.

Referring to <FIG>, as tension is applied along tensile strand <NUM> (e.g., when a user pulls tensile strand <NUM>), tunnel spring structure <NUM> may deform. In contrast to some other embodiments with openings that do not sufficiently change the structural properties of the tubular structure, the structural properties of tunnel spring structure <NUM> are strongly influenced by the geometry of the connecting portions and the large openings, or gaps, between adjacent tubular structures. For example, as tension is applied along tensile strand <NUM>, the tubular structures in tunnel spring structure <NUM> may collapse toward one another as their respective connecting portions undergo deformation. Thus, in some cases, the spacing between adjacent tubular structures may vary between non-tensioned states (<FIG>) and tensioned states (<FIG>). For example, first tubular structure <NUM> and second tubular structure <NUM> are seen to move closer to one another between the non-tensioned state of <FIG> and the tensioned state of <FIG>, as intermediate connecting portion <NUM> undergoes spring-like deformation.

In some cases, portions of tunnel spring structure <NUM> may be arranged so that as tension is applied to tensile strand <NUM>, the portions may conform more closely to one or more anatomical features of a foot. In the exemplary embodiment of <FIG>, tunnel spring structure <NUM> includes adaptive portion <NUM>, which can be seen as circumscribing the approximate region on upper <NUM> associated with the lateral malleolus <NUM>. In this case, adaptive portion <NUM> is attached to upper <NUM> along a plurality of anchoring portions, which are the points of attachment between each individual tubular structure in tunnel spring structure <NUM> and upper <NUM> (e.g., a first anchoring portion may be defined as tubular structure <NUM>, since first tubular structure <NUM> is directly attached to upper <NUM> and thereby helps to anchor tunnel spring structure <NUM> to upper <NUM>).

Referring now to <FIG>, as tensile strand <NUM> is tensioned, the tubular segments of adaptive portion <NUM> may collapse together and form a curved section of tunnel spring structure <NUM> that more closely conforms to lateral malleolus <NUM> and thereby provides continued support across the ankle on the lateral side without tunnel spring structure <NUM> passing directly over lateral malleolus <NUM>.

<FIG> illustrate still another embodiment of an article of footwear <NUM> (or article <NUM>) incorporating a tubular structure in the form of tunnel spring structure <NUM>. As with previous embodiments, tunnel spring structure <NUM> may be attached directly to upper <NUM> of article <NUM>. Further, tensile strand <NUM> may extend through a tunnel (comprised of the individual tunnel portions of each tubular structure) of tunnel spring structure <NUM>. Tensile strand <NUM> may further engage with lace <NUM>, which may be used to tighten the throat and/or opening of upper <NUM>.

As shown in <FIG>, tunnel spring structure <NUM> includes adaptive portion <NUM> that extends adjacent heel portion <NUM> of article <NUM>. For purposes of reference, the approximate location of calcaneus bone <NUM> is shown in phantom where it would be located when a foot is inserted into article <NUM>. In the resting, or non-tensioned, state of <FIG>, adaptive portion <NUM> has a default geometry in which it curves from a higher location at the back of heel portion <NUM> to a lower location as it moves forward of heel portion <NUM> and toward midfoot portion <NUM>. Moreover, when no tension is applied, at least some of adaptive portion <NUM> may partially overlap, or lie over, with calcaneus bone <NUM> (e.g., some of adaptive portion <NUM> may be disposed outwardly, or distally, of calcaneus bone <NUM>).

As tension is applied along tensile strand <NUM>, which is shown in <FIG>, adaptive portion <NUM> may deform so as to better conform to the anatomical feature of the foot associated with calcaneus bone <NUM>. Specifically, adaptive portion <NUM> changes shape (i.e., takes on a conforming geometry) so as to circumscribe the periphery of the feature associated with calcaneus bone <NUM> without actually overlapping with the feature, which may help avoid discomfort that could be caused by having the tunnel spring structure apply an inwardly (or proximally) directed force against the part of the foot including calcaneus bone <NUM>.

In some embodiments, an adaptive portion may be made to better conform to an anatomical feature during tensioning by controlling the location of two or more anchoring portions as well as the angle of tension applied across the anchoring portions. In the example of <FIG>, adaptive portion <NUM> may be seen to comprise first adaptive segment <NUM> (consisting of several tubular structures and their connecting portions) and second adaptive segment <NUM>. First adaptive segment <NUM> includes multiple anchoring portions, comprised here of individual tubular structures, such as first tubular structure <NUM> and second tubular structure <NUM>. Here, first adaptive segment <NUM> is seen to extend from first tubular structure <NUM> to second tubular structure <NUM>, and includes a corresponding segment of tensile strand <NUM>. Likewise, second adaptive segment <NUM> includes multiple anchoring portions, comprised here of individual tubular structures, such as third tubular structure <NUM> and fourth tubular structure <NUM>. Here, second adaptive segment <NUM> is seen to extend from third tubular structure <NUM> to fourth tubular structure <NUM>, and includes a corresponding segment of tensile strand <NUM>. In the relaxed, or non-tensioned, state of tunnel spring structure <NUM>, first adaptive segment <NUM> and second adaptive segment <NUM> form an angle (i.e., are not collinear). Thus, as tension is applied along tensile strand <NUM>, as in <FIG>, first adaptive segment <NUM> and second adaptive segment <NUM> deform so as to partially straighten and reduce the relative angle between them. This causes the curvature of adaptive portion <NUM> to become more rounded and pulls some tubular structures (e.g., tubular structure <NUM>) away from the region of upper <NUM> directly overlying calcaneus bone <NUM>.

<FIG> illustrates yet another embodiment of article of footwear <NUM> (or article <NUM>) with a tensioning system. In <FIG>, the tensioning system includes multiple different kinds of tubular structures, which are all connected via a common tensile strand <NUM>. For example, in <FIG>, article <NUM> includes tunnel spring structure <NUM> extending along heel portion <NUM>, as well as several segmented tubular structures (such as first segmented tubular structure <NUM> and second segmented tubular structure <NUM>) extending through midfoot portion <NUM> and forefoot portion <NUM>. As seen in <FIG>, segmented tubular structures may be characterized by comprising just two tubular structures connected by a single connecting portion. In some cases, the segmented tubular structures may not tend to deform (especially the connecting portions) under applied tensions.

As seen in <FIG>, tubular structures may not extend completely around a shoe, as is shown in other embodiments. In particular, in some cases, the use of tubular structures for controlling tension and contraction can be applied to localized regions of an article (for example structure <NUM> in heel portion <NUM> and a separate and distinct tubular structure <NUM> in midfoot portion <NUM>). This arrangement may allow for fine tuning of tensioning and upper substrate contraction in various local regions associated with distinct tubular structures. Moreover, it can be appreciated that in any other embodiments disclosed herein and shown in the figures, the exemplary tubular structures could be separated into disjoint sections that are disposed across local regions (e.g., the arch, around the ankle bones, etc.).

The type of tubular structure used may be selected according to the desired properties for the overall tensioning system. For example, spring tunnel structures may be applied over portions or regions where it is desirable to have continuous tubular structures that can collapse and which also tend to return to an initial relaxed, or non-tensioned, state once the tension along a tensile strand has been removed. In contrast, in some cases, segmented tubular structures may be applied in regions where it is desirable to form complex paths for a tensile strand, including forming loops or other paths with crossovers or intersections that may be more difficult to achieve with continuous tubular structures.

It may be appreciated that embodiments can include provisions for anchoring, or otherwise attaching, components of a tensioning system to different parts of an article of footwear. As previously discussed, in some cases tensile strands and/or tubular structures could be partially or fully anchored to a sole structure, or to portions of an upper directly adjacent the sole structure (e.g., at the bite line). However, it is also contemplated that in some other embodiments, components could be mounted to other structures of an article. For example, <FIG> illustrates another embodiment with an article <NUM> that comprises upper <NUM> and sole structure <NUM>, and which further includes heel counter <NUM> and a fastening system with lace stay <NUM> (or eyestay). In the exemplary embodiment of <FIG>, tubular structure <NUM> extends through upper <NUM> and includes primary tensile strand <NUM> engaged with secondary tensile strands <NUM> and tensile strands <NUM>. In this case, secondary tensile strands <NUM> are seen to be anchored on heel counter <NUM>. That is, at least one end of each of secondary tensile strands <NUM> are directly attached to heel counter <NUM>. Likewise, tensile strands <NUM> are seen to be anchored on lace stay <NUM>. That is, at least one end of each of tensile strands <NUM> are directly attached to lace stay <NUM>. This arrangement may facilitate the transfer of tension applied along primary tensile strand <NUM> to other structures, such as heel counter <NUM> and lace stay <NUM>, as well as vice versa (i.e., transferring tension from those structures back to tensile strand <NUM>).

Of course, the embodiment of <FIG> is not intended to be limiting, and in other embodiments any tensile strands and/or portions of a tubular structure could be mounted, anchored, or otherwise attached to any structure associated with an article of footwear. Such structures include, but are not limited to, sole components (e.g., outsoles, midsoles, and/or insoles), upper components (e.g., various panels, meshes, tongues, etc.), fastening components (e.g., laces, lace stays, eyelets, etc.), supporting structures (e.g., heel counters, toe guards, heel cups, pads, etc.) as well as any other structures comprising an article of footwear.

<FIG> illustrates an exemplary process for manufacturing an article with a tensioning system according to the embodiments. It may be appreciated that in some embodiments, one or more steps may be optional, while in other embodiments the process could include additional steps. The method, therefore, may not be limited to the particular steps or order of steps discussed here. It may also be appreciated that one or more steps could be accomplished by one or more of the following: a manufacturer, retail worker, customer, and/or third party.

In first step <NUM>, custom foot geometry information may be received. An exemplary embodiment of this step is depicted in <FIG> and <FIG>, and discussed in further detail below. Next, during step <NUM>, a custom contoured path for a tubular structure could be determined, for example, as shown in <FIG>, and discussed below. Next, during step <NUM>, a print material may be disposed onto an upper to form a tubular structure with the custom contoured path, as shown in <FIG> and discussed below. Finally, during step <NUM>, an article of footwear can be manufactured using the upper with a tubular structure arranged in a customized path, as shown in <FIG>.

<FIG> is a schematic view of some components of footwear customization system <NUM>. Footwear customization system <NUM> may include provisions for customizing a tensioning system on an article. Specifically, footwear customization system <NUM> includes provisions for creating a tubular structure with a customized contoured path that is designed for a unique foot geometry. As seen in <FIG>, footwear customization system <NUM> can include foot geometry capturing system <NUM>, additive manufacturing device <NUM>, and computing system <NUM>.

Foot geometry capturing system <NUM>, or simply capturing system <NUM>, may include provisions for capturing geometric information about a foot, such as the foot of a customer. This geometric information can include size (e.g., length, width, and/or height) as well as three-dimensional information corresponding to a foot (e.g., forefoot geometry, midfoot geometry, heel geometry, and ankle geometry). In at least one embodiment, the captured geometric information for a foot can be used to generate a three-dimensional model of the foot for use in later stages of manufacturing. For purposes of convenience, the term "foot geometry information" is used throughout the detailed description and in the claims to refer to any information related to the size and/or shape of a foot. In particular, foot geometry information can include at least the width and length of the foot. In some cases, foot geometry information may include information about the three-dimensional foot geometry. Foot geometry information can be used to create a three-dimensional model of the foot.

As shown in <FIG>, in some embodiments, foot geometry information about foot <NUM> may be retrieved using capturing system <NUM> to capture two-dimensional and/or three-dimensional information about foot <NUM> (e.g., the foot of a user or customer). Of course, it is also contemplated that in at least some embodiments, foot geometry information could be captured in any other manner, including manually using various conventional measuring devices (e.g., a tape measure, Brannock Device, etc.). Furthermore, in at least some embodiments, rather than capturing or directly measuring foot geometry information, the customized foot information could be retrieved from a database, or provided directly by the user or customer.

Capturing system <NUM> may include one or more sensing systems and/or sensing devices capable of sensing (e.g., capturing) customized foot information. In one embodiment, capturing system <NUM> includes at least two optical sensing devices. Specifically, capturing system <NUM> may include optical sensing device <NUM> and optical sensing device <NUM>, which may act together to capture foot geometry information, including the dimensions and/or shape of foot <NUM>.

Optical sensing devices may be any kind of device capable of capturing image information. Examples of different optical sensing devices that can be used include, but are not limited to, still-shot cameras, video cameras, digital cameras, non-digital cameras, web cameras (web cams), as well as other kinds of optical sensing devices known in the art. The type of optical sensing device may be selected according to factors such as desired data transfer speeds, system memory allocation, form factor of the optical sensing device, desired spatial resolution for viewing a foot, as well as possibly other factors.

Exemplary image sensing technologies that could be used with an optical sensing device include, but are not limited to, semiconductor charge-coupled devices (CCD), complementary metal-oxide-semiconductor (CMOS) type sensors, N-type metal-oxide-semiconductor (NMOS) type sensors as well as possibly other kinds of sensors. In some other embodiments, optical sensing devices that detect non-visible wavelengths (including, for instance, infrared wavelengths) could also be used.

For purposes of illustration, two cameras are depicted in <FIG>. Such a configuration could allow for three-dimensional imaging using a stereoscopic imaging technique. However, other embodiments could utilize any other number of cameras. Moreover, other embodiments could be configured with any other kind of 3D scanning technologies including contact 3D scanning (e.g., coordinate measuring machine), time-of-flight 3D laser scanning, triangulation-based 3D laser scanning as well as possibly other kinds of 3D scanning technologies.

Although optical sensing device <NUM> and optical sensing device <NUM> are shown here in a static configuration, it is contemplated that in some embodiments optical sensing device <NUM> and/or optical sensing device <NUM> could be moved to various positions to capture additional views of foot <NUM>. Optionally, in some embodiments, the method can include having a user (e.g., a customer) move to locate foot <NUM> at different orientations with respect to optical sensing device <NUM> and/or optical sensing device <NUM>.

Alternatively, rather than using devices for capturing three-dimensional geometry of a foot, embodiments could include a foot scanning device to measure pressure across the sole of the foot. For example, <FIG> illustrates an embodiment employing foot scanning device <NUM> that can be used to generate foot pressure information, shown here as foot pressure image <NUM>. In order to obtain foot pressure information, embodiments could use any of the systems, devices, and methods for imaging a foot as disclosed in<CIT> and titled "Foot Imaging and Measurement Apparatus.

Foot geometry information can be used to locate particular anatomical areas on the foot that may be important to consider in designing a path for a tubular structure. Such anatomical areas can include, for example, arch geometry, forefoot, midfoot, and/or heel geometry, as well areas associated with specific bones or bony features (i.e., bony structures).

Referring to <FIG>, footwear customization system <NUM> includes additive manufacturing device <NUM>. The term "additive manufacturing," also referred to as "three-dimensional printing," refers to any device and technology for making a three-dimensional object through an additive process where layers of material are successively laid down under the control of a computer. Exemplary additive manufacturing techniques that could be used include, but are not limited to, extrusion methods such as fused deposition modeling (FDM), electron beam freeform fabrication (EBF), direct metal laser sintering (DMLS), electron beam melting (EBM), selective laser melting (SLM), selective heat sintering (SHS), selective laser sintering (SLS), plaster-based 3D printing, laminated object manufacturing (LOM), stereolithography (SLA), and digital light processing (DLP). In one embodiment, additive manufacturing device <NUM> could be a fused deposition modeling type printer configured to print thermoplastic materials such as acrylonitrile butadiene styrene (ABS) or polyactic acid (PLA).

An example of a printing device using fused filament fabrication (FFF) is disclosed in Crump, <CIT> and titled "Apparatus and Method for Creating Three-Dimensional Objects," referred to hereafter as the "3D Objects" application. Embodiments of the present disclosure can make use of any of the systems, components, devices, and methods disclosed in the 3D Objects application.

Additive manufacturing device <NUM> may be used to manufacture one or more components used in forming an article of footwear. For example, additive manufacturing device <NUM> may be used to form a tubular structure on an upper.

Additive manufacturing device <NUM> may include device housing <NUM>, actuating assembly <NUM>, and extrusion head <NUM> (see <FIG>). Additive manufacturing device <NUM> may also include platform <NUM>. In some cases, extrusion head <NUM> may be translated via actuating assembly <NUM> on a z-axis (i.e., vertical axis), while platform <NUM> of additive manufacturing device <NUM> may move in the x and y directions (i.e., horizontal axis). In other cases, extrusion head <NUM> could have full three-dimensional movement (e.g., x-y-z movement) above a fixed platform.

Embodiments can include provisions for controlling capturing system <NUM> and additive manufacturing device <NUM>, as well as processing information related to the customization process. These provisions can include a computing system <NUM> and a network. Generally, the term "computing system" refers to the computing resources of a single computer, a portion of the computing resources of a single computer, and/or two or more computers in communication with one another. Any of these resources can be operated by one or more human users. In some embodiments, computing system <NUM> may include one or more servers. In some cases, a separate server (not shown) may be primarily responsible for controlling and/or communicating with devices of footwear customization system <NUM>, while a separate computer (e.g., desktop, laptop, or tablet) may facilitate interactions with a user or operator. Computing system <NUM> can also include one or more storage devices including, but not limited to magnetic, optical, magnetooptical, and/or memory, including volatile memory and non-volatile memory.

Computing system <NUM> may comprise viewing interface <NUM> (e.g., a monitor or screen), input devices <NUM> (e.g., keyboard and/or mouse), and software for designing a computer-aided design ("CAD") representation of a three-dimensional model. In at least some embodiments, the CAD representation can provide a representation of an article of footwear as well as representations of elements of a tensioning system, such as a tubular structure.

In some embodiments, computing system <NUM> may be in direct contact with one or more devices or systems of footwear customization system <NUM> via network <NUM>. The network may include any wired or wireless provisions that facilitate the exchange of information between computing system <NUM> and devices of footwear customization system <NUM>. In some embodiments, the network may further include various components such as network interface controllers, repeaters, hubs, bridges, switches, routers, modems, and firewalls. In some cases, the network may be a wireless network that facilitates wireless communication between two or more systems, devices and/or components of footwear customization system <NUM>. Examples of wireless networks include, but are not limited to, wireless personal area networks (including, for example, Bluetooth), wireless local area networks (including networks utilizing the IEEE <NUM> WLAN standards), wireless mesh networks, mobile device networks as well as other kinds of wireless networks. In other cases, the network could be a wired network including networks whose signals are facilitated by twister pair wires, coaxial cables, and optical fibers. In still other cases, a combination of wired and wireless networks and/or connections could be used.

In some embodiments, the captured foot geometry information can be delivered to computing system <NUM> via network <NUM>. Once received, the foot geometry information may be stored as raw data. In the exemplary embodiment shown in <FIG>, the customized foot information may be used to create customized model <NUM>. Customized model <NUM> may be a three-dimensional model that represents the size and/or geometric information about a user's foot. In some embodiments, customized model <NUM> may represent an upper configured to be worn on a user's foot. In other embodiments, a customized model could represent a foot. In the exemplary embodiment, customized model <NUM> represents a foot.

As seen in <FIG>, the customized model <NUM>, or the raw customized foot information captured (or otherwise retrieved) during previous steps, can be used to design a custom contoured path for a tubular structure on an upper. As used herein, the term "custom contoured path" refers to a path or layout for a tubular structure on an upper that extends throughout the upper. As the anatomy of each customer's foot may be unique, a custom contoured path may be designed to provide optimum support while minimizing discomfort by creating a path for a tubular structure that avoids one or more bony regions of an upper.

Customized model <NUM> includes various anatomical regions that may be considered in designing the path of a tubular structure on an upper. For purposes of clarity, first anatomical region <NUM> and second anatomical region <NUM> are shown; however, it may be understood that customized model <NUM> can be characterized by other anatomical regions. In this case, first anatomical region <NUM> may be associated with the first metatarsal bone, while second anatomical region <NUM> may be associated with a protruding feature of the calcaneus bone (i.e., a bony structure).

A user may interact with customized model <NUM> using a CAD system (e.g., CAD software). Such a system may allow the user to design a customized path for a tubular structure around the upper (or foot). Embodiments may utilize any standard CAD or other software tool for designing a particular tubular structure geometry.

As it may be desirable to avoid applying pressure directly to either first anatomical region <NUM> or second anatomical region <NUM>, a path for a tubular structure may be configured to travel around these regions, rather than across or through them. In <FIG> an initial path for tubular structure <NUM> has been generated. Such a path may be generated automatically by the CAD system (e.g., software) running on computing system <NUM>. The system can include provisions allowing a user to modify the geometry, or path, of tubular structure <NUM> on customized model <NUM>. For example, as seen in <FIG>, a user can drag rearward section <NUM> of tubular structure <NUM> up and around second anatomical region <NUM> so as increase comfort at second anatomical region <NUM>. Likewise, as seen in <FIG>, a user can drag medial side section <NUM> of tubular structure <NUM> up and around first anatomical region <NUM> to increase comfort at first anatomical region <NUM>.

It may be appreciated that the embodiment depicted in <FIG> is only intended to be exemplary. In other embodiments, a user may design a tubular structure with any geometry and customized path around a foot (and article). Moreover, some embodiments could include provisions that allow the user to design hole openings (e.g., locations and/or size), as well as the locations of secondary tensile strands.

In some embodiments, some of the design steps may be automated. For example, in some cases, the task of designing a customized contoured path could be automatically done by a customization system. In other words, in some embodiments, the system may automatically generate a customized path or three-dimensional geometry for a tubular structure on an article based on input information such as customized foot geometry and/or pressure distribution information.

Once a desired custom contoured path for tubular structure <NUM> has been designed, a user may submit custom tubular structure design <NUM> to additive manufacturing device <NUM> (see <FIG>) for printing onto an upper. In some cases, information related to tubular structure <NUM> (including the custom contoured path information) can be provided to additive manufacturing device <NUM> in the form of a 3D printing file format. In one embodiment, for example, tubular structure <NUM> and/or information associated with tubular structure <NUM> could be provided to additive manufacturing device <NUM> in an STL file format, which is a Stereolithography file format for 3D printing. In other embodiments, the information could be stored and/or transferred in the Additive Manufacturing File Format (AMF), which is an open standard for 3D printing information. Still other embodiments could store and/or transfer information using the X3D file format. In still other embodiments, any other file formats known for storing 3D objects and/or 3D printing information could be used.

<FIG> illustrates an embodiment of a step of printing tubular structure <NUM> with a custom contoured path onto upper <NUM>. In particular, extrusion head <NUM> may deposit a printable material onto the surface of upper <NUM> to form the tubular structure. A tubular structure with a hollow tunnel could be formed using a variety of different techniques. Any known materials for three-dimensional printing could be used, including any of the printable materials described above.

After tubular structure <NUM> has been printed, first tensile strand <NUM> may be inserted into the tunnel of tubular structure <NUM>, as shown in <FIG>.

<FIG> illustrates another embodiment in which first tensile strand <NUM> is embedded within a tubular structure as it is printed. Specifically, first layer <NUM>, or portion, of tubular structure <NUM> may be initially printed onto upper <NUM>. Then, first tensile strand <NUM> may be placed on first layer <NUM>. After this, the remaining layers of tubular structure <NUM> may be printed onto first layer <NUM> and over first tensile strand <NUM>, such that first tensile strand <NUM> is embedded during the printing process.

<FIG> illustrates an exemplary embodiment of a final product produced by at least one of the processes described above and shown in <FIG>. Referring to <FIG>, upper <NUM> has been reshaped to form an upper and assembled with sole structure <NUM>. As shown, tubular structure <NUM> has a customized path on upper <NUM> that has been created to bypass sensitive anatomical features or regions. Moreover, as part of forming the final article, second tensile strands <NUM> have been run around tensile strand <NUM> and anchored to the article at the bite line between upper <NUM> and sole structure <NUM>.

Additive manufacturing processes may be used to form structures on flat receiving surfaces as well as on contoured or non-flat surfaces. For example, some embodiments depicted in the figures may illustrate methods whereby material is printed onto a flattened surface of an article, such as a material section of an upper that has a flat or unassembled configuration. In such cases, printing material onto the surface may be accomplished by depositing material in thin layers that are also flat. Thus, a print head or nozzle may move in one or more horizontal directions to apply an Nth layer of material and then move in the vertical direction to begin forming the N+<NUM> layer. However, it should be understood that in other embodiments material could be printed onto a contoured or non-flat surface. For example, material could be printed onto a three-dimensional last, where the surface of the last is not flat. In such cases, the printed layers applied to the surface may also be contoured. In order to accomplish this method of printing, a print head or nozzle may be configured to move along a contoured surface and tilt, rotate or otherwise move so that the print head or nozzle is always aligned approximately normal to the surface where printed material is being applied. In some cases, a print head could be mounted to a robotic arm, such as an articulated robotic arm with six degrees of freedom. Alternatively, in still other embodiments, an object with a contoured surface could be reoriented under a nozzle so that contoured layers of printed material could be applied to the object. For example, embodiments could make use of any of the systems, features, components and/or methods disclosed in <CIT> (and filed as<CIT>), titled "Robotic fabricator. " Embodiments could also make use of any of the systems, features, components and/or methods disclosed in <CIT>, titled "Computerized apparatus and method for applying graphics to surfaces. " Thus, it may be appreciated that the present embodiments are not limited to printing processes used for printing to flat surfaces and may be used in conjunction with printing systems that can print to any kinds of surfaces having any kinds of geometry.

The printed structures of the present embodiments may provide enhanced support. In some cases, one or more printed structures may be attached to an underlying component such as a fabric layer of an upper or other article, and may act to enhance support over a portion of the component. This may occur in situations where the printed structure is more rigid than an underlying material (e.g., fabric, leather, etc.). In some cases, printed structures, such as tubular structures, could extend throughout portions of an article to form an external support system, like an exoskeleton, which helps provide increased support through those portions.

The embodiments further provide a comprehensive fit system that delivers a tuned and pressure-free fit for an article. This is accomplished by steering the articulated tunnel structures around bony prominences of the foot. When a tensile strand extending through the tunnel structures is pulled under tension (e.g., by the laces or another tensile element) the tunnel geometry and article-substrate (e.g., fabric layer) contract around predetermined zones of the foot.

Claim 1:
An article of footwear (<NUM>), comprising:
an upper (<NUM>) having a longitudinal direction extending along a length of the upper (<NUM>) and a lateral direction extending along a width of the upper (<NUM>);
a first tubular structure (<NUM>) forming a first tunnel that extends in the longitudinal direction along the upper (<NUM>), the first tubular structure (<NUM>) including a first intermediate portion that is attached to the upper and includes a first surface with a plurality of openings (<NUM>) extending to the first tunnel;
a first tensile strand (<NUM>) extending through the first tunnel of the first tubular structure (<NUM>);
a second tensile strand (<NUM>) extending over a top portion of the upper (<NUM>) and engaging with portions of the first tensile strand (<NUM>) through at least one of the plurality of openings (<NUM>);
wherein said portions of the first tensile strand (<NUM>) are configured to extend outwardly through the plurality of openings (<NUM>) at various portions along the first tubular structure (<NUM>),
wherein said portions of the first tubular structure (<NUM>) are disposed on a lateral side (<NUM>) and on a medial side (<NUM>) of the upper (<NUM>);
wherein the second tensile strand (<NUM>) engages the first tensile strand (<NUM>) at said portions of the first tubular structure (<NUM>); and
wherein applying tension to one of the first tensile strand (<NUM>) or the second tensile strand (<NUM>) also applies tension to the other one of the first and second tensile strands (<NUM>; <NUM>).