Patent Description:
Articles of footwear generally include two major components, a sole which is the primary contact with the ground or playing surface, and an upper for enclosing the wearer's foot. The upper is secured to the sole. The upper is generally adjustable using tensile strands such as laces, cables, strings or other materials to secure the article of footwear comfortably to the foot. Articles of apparel may also be adjustable using tensile strands such as laces, cables, strings or other materials to tighten or close the article of apparel. Protective gear are often attached to a wearer's elbow or knees, for example, using tensile strands such cables or laces, for example.

<CIT> describes that a component for attachment to an article includes an upper component that is made of a thermoplastic material having a first melting temperature and a flange member that is molded onto the upper component and made of a thermoplastic elastomer material having a second melting temperature that is lower than the first melting temperature of the upper component.

<CIT> describes an article of footwear having a tension member that is guided or directed about a path of the footwear via one or more guides that are coupled to the footwear.

<CIT> describes the mechanism of tying of footwear using one or more girth laces, which are led in predetermined directions around the foot across the instep of the shoe and through the sole of the shoe.

<CIT> describes that a tongueless footwear includes a sole, a first side, an opposing second side, a canopy and a fastening system. The canopy is coupled to the first side and configured to extend over the second side thereby providing substantially direct support for the ankle and instep of a user.

<CIT> describes that articles of footwear, including athletic footwear, include one or more of: (a) a sole structure; (b) an upper having lateral and medial side elements engaged with the sole structure, the upper made from a polymer matrix structure that extends through at least a heel region; (c) a size adjustment mechanism located at the heel region; (d) a heel tongue element located adjacent the size adjustment mechanism; (e) a shoe securing mechanism; (f) an instep tongue member; and/or (g) a bootie member located at least partially within the foot-receiving chamber.

<CIT> describes that the shoe construction generally includes a closure component having a set of interleaved, opposed stretchable fingers, and a stretchable cord securing the ends of the fingers together.

<CIT> relates generally to footwear, and in particular to articles of footwear that include a woven strap system disposed along the entirety of the article of footwear,.

Embodiments in <FIG> and <FIG> do not form part of the claimed invention.

The invention is defined by the appended independent claim <NUM>. Additional embodiments are defined in the dependent claims.

The collapsible tunnel systems or the segmented tunnels may be applied to articles of manufacture using three-dimensional printing systems, or by using other additive manufacturing techniques such as welding, applying adhesives, fusing or sewing. Three-dimensional printing systems and methods may be associated with various technologies including fused deposition modeling (FDM), electron beam freeform fabrication (EBF), selective laser sintering (SLS) as well as other kinds of three-dimensional printing technologies. Structures formed from three-dimensional printing.

The embodiments described below are illustrated schematically in the drawings as tubular structures and segmented tubular structures that have certain geometries and relative dimensions, as shown in the drawings. However, embodiments of the tubular structures and the segmented tunnel structures may have different shapes, such as curved, bent, or other nonlinear geometries, and may have any appropriate range of dimensions such as their inner diameters, their outer diameters, their wall thicknesses and their lengths. They may also have cross sections with any geometry, such as circular, oval, rectangular, square, hexagonal, or other polygonal geometry, or may have any combination of the foregoing.

Segmented tunnels may be applied to a base layer by using additive manufacturing techniques such as three-dimensional printing, welding, adhesive application, fusing, or sewing. Thus, although the embodiments described herein are described as being fabricated using three-dimensional printing, other additive manufacturing methods may alternatively be used to fabricate the articles of manufacture described herein.

<FIG> is a schematic diagram of an embodiment of a three-dimensional printing system <NUM>, also referred to in this specification simply as printing system <NUM>. <FIG> also illustrates several exemplary articles <NUM> that may be used with printing system <NUM>. Referring to <FIG>, printing system <NUM> may include printing device <NUM> in communication with CAD system <NUM> over network <NUM>.

Embodiments may use various kinds of three-dimensional printing (or other additive manufacturing) techniques. Three-dimensional printing, or "3D printing," comprises various technologies that may be used to form three-dimensional objects by depositing successive layers of material on top of one another. Exemplary 3D printing technologies that could be used include, but are not limited to, fused filament fabrication (FFF), electron beam freeform fabrication (EBF), direct metal laser sintering (DMLS), electron beam melting (EMB), selective laser melting (SLM), selective heat sintering (SHS), selective laser sintering (SLS), plaster-based 3D printing (PP), laminated object manufacturing (LOM), stereolithography (SLA), digital light processing (DLP) as well as various other kinds of 3D printing or additive manufacturing technologies known in the art.

in the exemplary embodiment shown in <FIG>, printing device <NUM> of printing system <NUM> uses fused filament fabrication to produce three-dimensional parts. An example of a printing device using fused filament fabrication (FFF) is disclosed in Crump, <CIT>, titled "Apparatus and Method for Creating Three-Dimensional Objects" and referred to hereafter as the "3D Objects" application. Embodiments of the present disclosure may make use of one or more of the systems, components, devices, and methods disclosed in the 3D Objects application.

Printing device <NUM> may include housing <NUM> that supports the devices and components used for three-dimensional printing on articles of manufacture. In some embodiments, printing device <NUM> may include printing nozzle assembly <NUM> and platform <NUM> for supporting the article to be printed on. In some embodiments, platform <NUM> may be controlled to move within housing <NUM> in the horizontal plane as well as in a vertical direction. In other embodiments, platform <NUM> may be fixed in one or more directions, and printing nozzle assembly <NUM> may be controlled to move in one or more directions. Moreover, in some cases, printing nozzle assembly <NUM> and/or platform <NUM> may be configured to rotate and/or tilt about one or more axes.

In the exemplary embodiment of <FIG>, CAD system <NUM> may comprise central processing device <NUM>, monitor <NUM>, and input devices <NUM> (such as a keyboard and mouse), and software for designing a computer-aided design ("CAD") representation <NUM> of a printed structure. In at least some embodiments, CAD representation <NUM> of a printed structure may include information related to the materials required to print various portions of the structure as well as information about the geometry of the structure.

In some embodiments, printed structures may be printed directly to one or more articles. The term "articles" is intended to include articles of footwear (e.g., shoes) and articles of apparel (e.g., shirts, pants, etc.), as well as protective gear and other articles of manufacture. As used throughout this disclosure, the terms "article of footwear" and "footwear" include any footwear and any materials associated with footwear, including an upper, and may also be applied to a variety of athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking boots, for example. As used throughout this disclosure, the terms "article of footwear" and "footwear" also include footwear types that are generally considered to be nonathletic, formal, or decorative, including dress shoes, loafers, sandals, slippers, boat shoes, and work boots.

While the disclosed embodiments are described in the context of footwear, the disclosed embodiments may further be equally applied to any article of clothing, apparel, or gear that bears additive components. For example, the disclosed embodiments may be applied to hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knit material, any woven material, any nonwoven material, sports equipment, etc. Thus, as used throughout this disclosure, the term "article of apparel" may refer to any apparel or clothing, including any article of footwear, as well as hats, caps, shirts, jerseys, jackets, socks, shorts, pants, undergarments, athletic support garments, gloves, wrist/arm bands, sleeves, headbands, any knit material, any woven material, any nonwoven material, etc. As used throughout this disclosure, the terms "article of apparel," "apparel," "article of footwear," and "footwear" may also refer to a textile, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymer, rubber, and foam.

In an exemplary embodiment, printing device <NUM> may be configured to print one or more structures directly onto a portion of one of exemplary articles <NUM>. Exemplary articles <NUM> comprise exemplary articles that may receive a printed structure directly from printing device <NUM>, Including article of apparel <NUM>, as well as an upper for article of footwear <NUM>. Printing device <NUM> may be used to apply printed material to flat articles or to articles that may be flattened, as shown in <FIG>. Printing device <NUM> may also be used to print directly onto articles that have a three-dimensional configuration.

In order to apply printed materials directly to one or more articles, printing device <NUM> may be capable of printing onto the surfaces of various kinds of materials. Specifically, in some cases, printing device <NUM> may be capable of printing onto the surfaces of various materials such as a textile, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymer, rubber, and foam, or any combination of them, without the need for a release layer interposed between a substrate and the bottom of the printed material, and without the need for a perfectly or near-perfectly flat substrate surface on which to print. For example, the disclosed methods may include printing a resin, acrylic, thermoplastic materials, or other ink materials onto a fabric, for example a knit material, where the material is adhered/bonded to the fabric and where the material does not generally delaminate when flexed, rolled, worked, or subject to additional assembly processes/steps. Other possible ink materials may include, for example, polyurethane, polyethylene, eutectic materials, molding clay, silicone, and other materials, including heat-curable, UV-curable, and photo-curable materials. As used throughout this disclosure, the term "fabric" may be used to refer generally to materials chosen from any textile, natural fabric, synthetic fabric, knit, woven material, nonwoven material, mesh, leather, synthetic leather, polymers, rubbers, and foam.

Although some embodiments may use printing device <NUM> to print structures directly onto the surface of a material, other embodiments may include steps of printing a structure onto a platform or release paper, and then joining the printed structure to an article in a separate step. In other words, in at least some embodiments, printed structures need not be printed directly to the surface of an article.

Printing system <NUM> may be operated as follows to provide one or more structures that have been formed using a 3D printing process. CAD system <NUM> may be used to design a structure. This may be accomplished using CAD software or other kind of software. The design may then be transformed into Information that can be interpreted by printing device <NUM> (or a related print server in communication with printing device <NUM>}. In some cases, the design may be converted to a 3D printable file, such as a stereolithography file (STL file).

Before printing, an article may be placed onto the top surface <NUM> of platform <NUM> within the housing <NUM> of printing device <NUM>. Once the printing process is initiated (by a user, for example), printing device <NUM> may begin depositing material onto the article. This may be accomplished by moving nozzle <NUM> (using printing nozzle assembly <NUM>) to build up layers of a structure using deposited material. In embodiments where fused filament fabrication is used, material extruded from nozzle <NUM> may be heated so as to increase the pliability of the printable material as it is deposited.

Although some of the embodiments shown in the figures depict a system using filament-fused fabrication printing technologies, it will be understood that still other embodiments could incorporate one or more different 3D printing technologies. For example, printing system <NUM> may use a tack and drag printing method. Moreover, still other embodiments could incorporate a combination of filament-fused fabrication and another type of 3D printing technique to achieve desired results for a particular printed structure or part.

As previously noted, printing device <NUM> may be configured to print directly onto various articles. Similarly, printing device <NUM> may be configured to print on various surface topographies. For example, as shown in <FIG>, platform <NUM> is substantially planar. In other embodiments, platform <NUM> may include one or more protrusions and/or one or more cavities. Moreover, printing device <NUM> may print on surfaces having various shapes. For example, as shown, platform <NUM> is generally rectangular. In other embodiments, platform <NUM> may be circular, triangular, shaped like an upper for an article of footwear, etc. As shown, platform <NUM> has a top surface <NUM> configured to receive exemplary articles <NUM> (such as article of apparel <NUM> or upper for an article of footwear <NUM>) that will have segmented tunnels printed upon them, as described below.

The segmented tunnels may be printed on exemplary articles <NUM> using printable materials. The term "printable material" is intended to encompass any materials that may be printed, ejected, emitted, or otherwise deposited during an additive manufacturing process. Such materials can include, but are 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.

in some embodiments, a printable material may be any material that is substantially moldable and/or pliable above a predetermined temperature, such as a glass-transition temperature and/or a melting temperature. In one embodiment, a printable material has one or more thermal properties such as a glass-liquid transition ("glass transition") temperature and/or a melting temperature. For example, the printable material may be a thermoplastic material having a glass-transition temperature and a melting temperature. As used herein, thermoplastic materials may include, for example, acrylic, nylon, polybenzimidazole, polyethylene, polypropylene, polystyrene, polyvinyl chloride, polytetrafluoroethylene (PTFE), and the like.

Segmented tubular structures may be used on articles of footwear, articles of apparel, or on other articles of manufacture to route tensile strands that may be pulled tight to alter the configuration of the article. Examples of such tensile strands include cables, cords, laces, and strings. The use of such segmented tubular structures may allow a wearer or user of the article to modify the configuration of the article in a controlled manner by applying tensile stress to the tensile strands.

The segmented tubular structures are generally printed on or otherwise attached to a base layer of the article of footwear, article of apparel, or other article of manufacture. The base layer may be, for example, a fabric layer, textile layer, woven layer, knit layer, nonwoven layer, natural leather layer, synthetic layer, plastic layer, or thermoplastic layer.

<FIG> are schematic diagrams illustrating two of the techniques that may be used to print segmented tubular structures on articles of manufacture. To produce tubular structure <NUM> shown in cross section in <FIG>, a section of tensile strand <NUM> is placed on base layer <NUM> of an article. For convenience, the term "tensile strand" is used herein to designate any tensile strand including a cable, cord, lace, string, or other tensile strand. A layer <NUM> of printable material is then printed over directly onto base layer <NUM> and over tensile strand <NUM>. Optionally, in some embodiments, tensile strand <NUM> is encased in a coating <NUM>, such as a PTFE coating, that allows tensile strand <NUM> to be pulled or pushed smoothly through tunnel <NUM> formed by layer <NUM> of printable material with minimal resistance.

To produce the tubular structure shown in the cross section in <FIG>, a layer <NUM> of printable material may first be printed onto base layer <NUM> of an article. Layer <NUM> is optional, and may be omitted in appropriate cases, as described below. Walls <NUM> are then printed on layer <NUM> (or if layer <NUM> is omitted, on base layer <NUM>), and tensile strand <NUM> is then placed within walls <NUM> and on top of layer <NUM>. The tubular structure is then capped by printing curved section <NUM> over the top of tensile strand <NUM> and over the top of walls <NUM>. Optionally, in some embodiments, tensile strand <NUM> is encased in a coating <NUM>, such as a PTFE coating, that allows tensile strand <NUM> to be pulled or pushed smoothly through tunnel <NUM> formed by layer <NUM> of printable material.

A layer such as layer <NUM> (shown in <FIG>) may also be used to produce a tubular structure such as the tubular structure shown in <FIG> by printing a layer of printable material onto the surface of the article prior to placing a tensile strand on the article. Use of a layer such as layer <NUM> may improve the adhesion of the tubular structure (<FIG>) or the tunnel walls (<FIG>). Thus, in cases where the printable material penetrates into the fabric of the article that is being printed upon and/or exhibits firm adhesion to the article, a layer such as layer <NUM> may be omitted. In other cases, where the adhesion of the walls of the tunnel themselves to the article may not be sufficient to prevent the possible separation of the tunnel segment to the article, printing a layer such as layer <NUM> may be an effective way of improving the attachment of the tunnel segment to the article.

<FIG> is a schematic diagram of a perspective view of an embodiment of a segment of a tubular structure <NUM> on a section of a base layer <NUM>. Base layer <NUM> may be a fabric, such as the fabric used for an upper of an article of footwear or the fabric used for an article of apparel. In this embodiment, the lower portion <NUM> of tubular structure <NUM> is printed first on base layer <NUM>. Tensile strand <NUM> is then placed within the lower portion <NUM> of tubular structure <NUM>, and the upper portion <NUM> of tubular structure <NUM> is then printed over the lower portion <NUM> and over tensile strand <NUM>, thus producing the tubular structure <NUM> shown in <FIG>. Tensile strand <NUM> has catching element <NUM>, which is illustrated in <FIG> as a knot, at one end. Catching element <NUM> prevents tensile strand <NUM> from passing entirely through tunnel <NUM> in tubular structure <NUM>. Thus when end <NUM> of tensile strand <NUM> is pulled, tensile strand <NUM> is pulled through tunnel <NUM> in tubular structure <NUM> until catching element <NUM> abuts end <NUM> of tubular structure <NUM>.

The opposite end <NUM> of tensile strand <NUM> may then be laced through one or more additional tunnel segments, as illustrated in <FIG>, which are described below.

Thus, in the embodiment of a tubular structure illustrated in <FIG>, tensile strand <NUM> is completely encased by the printable tubular structure formed by printing layers of printable material on base layer <NUM> and over tensile strand <NUM>, unlike the embodiment shown in <FIG>, in which tensile strand <NUM> is in direct contact with the base layer <NUM> of an article. The embodiment illustrated schematically in <FIG> is also different from the structure of the embodiment illustrated in <FIG>, because the <FIG> embodiment does not have a layer such as layer <NUM> that extends over the article beyond the periphery of the tunnel segment itself.

Optionally, in the embodiment illustrated in <FIG>, tensile strand <NUM> may be coated with layer <NUM> of a material such as PTFE, which may allow tensile strand <NUM> to slip easily through tunnel <NUM> in tubular structure <NUM>.

<FIG> is a schematic illustration of a perspective view of an embodiment of tubular structure <NUM> fabricated by the method described above with respect to <FIG>, as it has been applied to a section of base layer <NUM>. The cross section shows tensile strand <NUM> directly on the top surface of base layer <NUM>, with optional coating <NUM> of a material such as PTFE, which allows tensile strand <NUM> to slip readily through tunnel <NUM> with minimal resistance from the inner surface of wall <NUM> of tubular structure <NUM>. Thus when end <NUM> of tensile strand <NUM> is pulled, tensile strand <NUM> is pulled through tunnel <NUM> until catching element <NUM> abuts end <NUM> of tubular structure <NUM>.

The tubular structures illustrated schematically in <FIG> and <FIG> may be applied sequentially to form collapsible tunnel systems. By collapsing two or more tubular structures, as illustrated in <FIG>, portions of a relatively flexible or bendable structure may be changed, for example, to a more rigid and less bendable structure and/or to have a different configuration or geometry.

<FIG> illustrate the structure and operation of an exemplary collapsible tunnel system comprised of two linear tubular structures. <FIG> is a schematic diagram of an exploded view of a section of base layer <NUM> with a collapsible tunnel system <NUM> that includes first tubular structure <NUM>, second tubular structure <NUM>, and tensile strand <NUM>. <FIG> shows that tensile strand <NUM> may be laced through two sequential tubular structures, first tubular structure <NUM> and second tubular structure <NUM>, to form a segmented structure of collapsible tunnel system <NUM>. Dashed outline <NUM> shows the position of first tubular structure <NUM> on base layer <NUM>, and dashed outline <NUM> shows the position of second tubular structure <NUM> on base layer <NUM>.

<FIG> is a schematic diagram of a perspective view of an example of the embodiment of <FIG> as it is applied to a section of base layer <NUM>. In this configuration, collapsible tunnel system <NUM> has first tubular structure <NUM> and second tubular structure <NUM> that are spaced apart from each other in this first configuration. First tubular structure <NUM> encloses first tunnel <NUM>, and tubular structure <NUM> encloses second tunnel <NUM>. Tensile strand <NUM> may be inserted into one back end <NUM> of first tubular structure <NUM> and laced through first tunnel <NUM> in first tubular structure <NUM> and through second tunnel <NUM> in second tubular structure <NUM> and out of the front end <NUM> of second tubular structure <NUM>. Tensile strand <NUM> has a catching element <NUM> at one end, such that when tensile strand end <NUM> is pulled, first tubular structure <NUM> is forced toward second tubular structure <NUM>. As shown in the cross section of first tubular structure <NUM>, first tubular structure <NUM> completely encloses tensile strand <NUM> within first tunnel <NUM> in first tubular structure <NUM>. Similarly, second tubular structure <NUM> completely encloses tensile strand <NUM> within second tunnel <NUM>. However, in other embodiments, the structure illustrated in <FIG> may be used, such that the tensile strand is in direct contact with the underlying base layer.

<FIG> is a schematic diagram of the collapsible tunnel system <NUM> of <FIG> on base layer <NUM>, as tensile strand <NUM> is pulled at its tensile strand end <NUM> in the direction indicated by arrow <NUM>. Tensile strand <NUM> is laced through a back end <NUM> of first tubular structure <NUM>, through first tunnel <NUM> in first tubular structure <NUM> and out of its front end <NUM>. Tensile strand <NUM> is then laced into the back end <NUM> of second tubular structure <NUM> through second tunnel <NUM> of second tubular structure <NUM> and out of its front end <NUM>. First Tubular structure <NUM> and second tubular structure <NUM> have been brought closer together, by first pulling on tensile strand <NUM> at tensile strand end <NUM> in the direction indicated by arrow <NUM> until catching element <NUM> (illustrated as a knot in <FIG>) is forced against back end <NUM> of first tubular structure <NUM>, and then pulling tensile strand <NUM> further such that front end <NUM> of first tubular structure <NUM> comes closer to back end <NUM> of second tubular structure <NUM>. In this embodiment, the underlying base layer <NUM> now has a fold <NUM> below collapsible tunnel system <NUM>, because the base layer has been pulled forward when first tubular structure <NUM> has been pulled forward as tensile strand <NUM> has been pulled forward.

<FIG> is a schematic diagram of a perspective view with a longitudinal cross section of the embodiment of collapsible tunnel system <NUM> of <FIG> and <FIG>, showing the configuration of the fully collapsed collapsible tunnel system <NUM> after tensile strand <NUM> (shown with an optional PTFE coating <NUM>) has been pulled fully forward through back end <NUM> of tubular structure <NUM> such that catching element <NUM> is forced against back end <NUM>. Tensile strand <NUM> has also been pulled through first tunnel <NUM> and front end <NUM> of first tubular structure <NUM>, then through back end <NUM> of second tubular structure <NUM>, second tunnel <NUM>, and front end <NUM> of second tubular structure <NUM> in the direction shown by arrow <NUM>. In this configuration, front end <NUM> of first tubular structure <NUM> abuts back end <NUM> of second tubular structure <NUM>, and fold <NUM> in underlying base layer <NUM> is essentially closed up, as shown in the cross section above the perspective view. <FIG> shows that, when fully collapsed, collapsible tunnel system <NUM> has a continuous tunnel <NUM> extending though first tubular structure <NUM> and second tubular structure <NUM>, because first tunnel <NUM> in first tubular structure <NUM> and second tunnel <NUM> in second tubular structure <NUM> have merged to form a single continuous tunnel <NUM> through collapsible tunnel system <NUM>.

<FIG> is a schematic diagram of an alternative embodiment of collapsible tunnel system <NUM> on base layer <NUM>. in this embodiment, front end <NUM> of tubular structure <NUM> is configured to fit into back end <NUM> of tubular structure <NUM>, as shown in the longitudinal cross section, as tensile strand <NUM> (shown without the optional PTFE coating) is pulled forward through tunnel <NUM> in tubular structure <NUM> and tunnel <NUM> in tubular structure <NUM> in the direction indicated by arrow <NUM> at front end <NUM> of tensile strand <NUM>. As in the embodiment of <FIG>, tensile strand <NUM> has a catching element <NUM> at the back end of tensile strand <NUM>, which may be used to force tubular structure <NUM> into close engagement with tubular structure <NUM>. Tunnel <NUM> in tubular structure <NUM> and tunnel <NUM> in tubular structure <NUM> have merged, to form a single tunnel <NUM> through collapsible tunnel system <NUM>. In this embodiment, base layer <NUM> is an elastic material that can absorb the change in its longitudinal dimension without producing a fold, as in the embodiment of <FIG>.

For clarity, the examples of embodiments illustrated in <FIG> only show two sequential tubular structures. However, in general, embodiments may have two, three, four, or more sequential tubular structures that form a collapsible tunnel system. Moreover, although the tubular structures are depicted in the figures as being linear cylinders, in general they may be curved or bent, and may have other shapes. Also, the tubular structures may have any appropriate geometries or dimensions. For example, the tubular structures may be cylindrical, or may have square, oval, or rectangular cross sections, and may have any appropriate range of outer diameter, inner diameter, wall thickness, or length.

The examples of collapsible tunnel systems illustrated in <FIG> are shown as having linear tubular structures. However, these embodiments do not necessarily have to use linear structures - depending on the particular application, curved tubular structures or angled tubular structures may alternatively be used. For example, a curved tubular structure may be used around the back of a heel or along the side of the midfoot or forefoot in an article of footwear. In other embodiments, more complex systems using nonlinear tubular structures may be used, as described below.

<FIG> are schematic diagrams that Illustrate the structure and operation of an embodiment of an exemplary nonlinear collapsible tunnel system <NUM> on a section of base layer <NUM>. in this embodiment, which is shown prior to any application of tension in <FIG>, exemplary nonlinear collapsible tunnel system <NUM> includes linear tubular structures such as linear tubular structure <NUM>, linear tubular structure <NUM>, linear tubular structure <NUM>, linear tubular structure <NUM>, linear tubular structure <NUM>, and linear tubular structure <NUM>. This embodiment also includes a curved tubular structure <NUM>. The tubular structures in this embodiment may be fabricated using any of the processes described above with reference to <FIG>, or by another suitable process. Tensile strand <NUM> is laced through each of linear tubular structure <NUM>, linear tubular structure <NUM>, linear tubular structure <NUM>, curved tubular structure <NUM>, linear tubular structure <NUM>, linear tubular structure <NUM>, and linear tubular structure <NUM>. Tensile strand <NUM> has catching elements <NUM> at both ends. Also, although in this example tensile strand <NUM> is shown in the cross section as having a PTFE coating <NUM>, that coating is not necessarily present in all implementations of this embodiment.

Exemplary nonlinear collapsible tunnel system <NUM> is shown in a first configuration on base layer <NUM> in <FIG> when it is in a relaxed state and not under tension, for example prior to tension being applied to tensile strand <NUM>. in this relaxed state, the various linear tubular structures or curved tubular structures spaced apart from each other. Specifically, in the first configuration shown in <FIG>, curved tubular structure <NUM> has one end portion <NUM> at one end and another end portion <NUM> at its opposite end. As shown in <FIG> and <FIG>, curved tubular structure <NUM> also has tunnel <NUM> that extends from end portion <NUM> through curved tubular structure <NUM> to end portion <NUM>. Similarly, as also shown in <FIG> and <FIG>, linear tubular structure <NUM> has an end portion <NUM> at one end, another end portion <NUM> at its opposite end and tunnel <NUM> (see <FIG> and <FIG>) extending through linear tubular structure <NUM> from end portion <NUM> to end portion <NUM>.

Similarly, linear tubular structure <NUM> has end portion <NUM> at one end, end portion <NUM> at its opposite end, and tunnel <NUM> (see <FIG> and <FIG>) extending from end portion <NUM> to end portion <NUM>; linear tubular structure <NUM> has end portion <NUM> at one end, end portion <NUM> at its opposite end, and tunnel <NUM> (see <FIG> and <FIG>) extending from end portion <NUM> to end portion <NUM>; linear tubular structure <NUM> has end portion <NUM> at one end, end portion <NUM> at its opposite end, and tunnel <NUM> (see <FIG> and <FIG>) extending from end portion <NUM> to end portion <NUM>; linear tubular structure <NUM> has end portion <NUM> at one end, end portion <NUM> at its opposite end, and tunnel <NUM> (see <FIG> and <FIG>) extending from end portion <NUM> to end portion <NUM>; and linear tubular structure <NUM> has end portion <NUM> at one end, end portion <NUM> at its opposite end, and tunnel <NUM> (see <FIG> and <FIG>) extending from end portion <NUM> to end portion <NUM>.

Tensile strand <NUM> is laced through tunnel <NUM>, tunnel <NUM>, tunnel <NUM>, tunnel <NUM>, tunnel <NUM>, tunnel <NUM>, and tunnel <NUM>. Tensile strand <NUM> has a catching element <NUM> at each end. In an exemplary embodiment, at least two of linear tubular structure <NUM>, linear tubular structure <NUM>, linear tubular structure <NUM>, and linear tubular structure <NUM> may be anchored to the base layer or anchored to some other structure, such that when loop <NUM> and loop <NUM> in tensile strand <NUM> are pulled in the direction indicated by arrows <NUM> in <FIG>, linear tubular structure <NUM> is forced toward linear tubular structure <NUM>; linear tubular structure <NUM> is forced toward linear tubular structure <NUM>; and curved tubular structure <NUM> is forced toward linear tubular structure <NUM> and linear tubular structure <NUM>. in one exemplary embodiment, all four of linear tubular structure <NUM>, linear tubular structure <NUM>, linear tubular structure <NUM>, and linear tubular structure <NUM> may be anchored to base layer <NUM> or to another structure. In another embodiment, linear tubular structure <NUM> and linear tubular structure <NUM> may be anchored, and in yet another embodiment, linear tubular structure <NUM> and linear tubular structure <NUM> may be anchored.

Thus <FIG> shows nonlinear collapsible tunnel system <NUM> at an intermediate stage, after tension has been applied by pulling on loop <NUM> and loop <NUM> in the direction shown by arrows <NUM>, but before the tunnel structures have fully collapsed. Thus, as tension is applied to tensile strand <NUM> by pulling on loops <NUM>, catching elements <NUM> push linear tubular structure <NUM> against linear tubular structure <NUM> and linear tubular structure <NUM> against linear tubular structure <NUM>, as shown in <FIG>. Curved tubular structure <NUM> has been pushed closer to linear tubular structure <NUM> and linear tubular structure <NUM>.

<FIG> is a schematic diagram illustrating the final configuration of nonlinear collapsible tunnel system <NUM>, after the system has been fully collapsed by pulling on loop <NUM> and loop <NUM>. As shown in <FIG>, in this configuration, end portion <NUM> of curved tubular structure <NUM> abuts against end portion <NUM> of linear tubular structure <NUM>, and end portion <NUM> of curved tubular structure <NUM> abuts against end portion <NUM> of linear tubular structure <NUM>, such that tunnel <NUM> in linear tubular structure <NUM>, tunnel <NUM> in curved tubular structure <NUM>, and tunnel <NUM> in linear tubular structure <NUM> form a continuous tunnel.

in this final configuration, end portion <NUM> of linear tubular structure <NUM> abuts against end portion <NUM> of linear tubular structure <NUM>, such that tunnel <NUM> and tunnel <NUM> also form a continuous tunnel. End portion <NUM> of linear tubular structure <NUM> abuts against end portion <NUM> of linear tubular structure <NUM>, such that tunnel <NUM> and tunnel <NUM> also form a continuous tunnel.

The nonlinear collapsible system shown in <FIG> may also be collapsed, for example, by pulling on the two ends of tensile strand <NUM> as the ends emerge from linear tubular structure <NUM> and linear tubular structure <NUM>. In that case, linear tubular structure <NUM>, curved tubular structure <NUM>, and linear tubular structure <NUM> may need to be anchored such that linear tubular structure <NUM> is forced against linear tubular structure <NUM>. Linear tubular structure <NUM> and linear tubular structure <NUM> are forced against curved tubular structure <NUM>, and linear tubular structure <NUM> is forced against linear tubular structure <NUM>.

As an example, the nonlinear collapsible tunnel system <NUM> of <FIG> may be placed on the lateral and/or medial side of an upper for an article of footwear, as illustrated in <FIG> and <FIG>, which are described below. As described below, the lace of the article of footwear may be laced though loop <NUM> and loop <NUM> as well as through the eyelets on the side of the tongue opening, such that, when the laces are tightened, tension is applied to tensile strand <NUM>, pulling loop <NUM> and loop <NUM> up toward the eyelets, and collapsing nonlinear collapsible tunnel system <NUM> into the fully collapsed configuration shown in <FIG>.

in other embodiments, some of which are illustrated in <FIG>, the tubular structures may be configured in pairs, with a connecting portion attaching each tubular structure to its paired tubular structure to form a segmented tunnel structure. For example, in the embodiment shown in a perspective view in <FIG>, segmented tunnel structure <NUM> has a first tubular structure <NUM> with a tunnel <NUM> (best shown in the crosssectional view within <FIG>) extending from end <NUM> to end <NUM> of first tubular structure <NUM>. it is attached to a second tubular structure <NUM> that has a tunnel <NUM> extending from end <NUM> to end <NUM> of second tubular structure <NUM> by a connecting portion <NUM>. Connecting portion <NUM> is attached at one end <NUM> to first tubular structure <NUM> and at its other end <NUM> to second tubular structure <NUM>. As shown in <FIG>, in some embodiments, connecting portion <NUM> is in the shape of an arc prior to compression, but In other embodiments, connecting portion <NUM> may have other shapes, such as a combination of straight and/or curved sections.

in some embodiments, for example, when connecting portion <NUM> is in the shape of an arch (as illustrated in <FIG>), connecting portion <NUM> functions as a spring that resists contraction of the segmented tubular structure. This property may be used to control and shape the configuration of the underlying portion of an article of footwear, article of apparel, or other article of manufacture as the segmented tunnel structure is collapsed.

<FIG> are plan views of the exemplary embodiment of <FIG>, when the segmented tunnel structure <NUM> is not under compressive stress in <FIG>, and when it is under compression in <FIG>, as shown by the arrows in <FIG>. In this example, first tubular structure <NUM> is spaced from second tubular structure <NUM> by a distance <NUM>, and connecting portion <NUM> forms a generally semi-circular arch. When segmented tunnel structure <NUM> is under compression, as shown in <FIG>, first tubular structure <NUM> is spaced from second tubular structure <NUM> by a distance <NUM>, which is less than the distance <NUM>, and connecting portion <NUM> forms a much narrower arch.

<FIG> are schematic diagrams that illustrate the embodiment of <FIG>, as applied to a base layer <NUM>, with a tensile strand <NUM> passing through tunnel <NUM> in first tubular structure <NUM> by connecting portion <NUM> and through tunnel <NUM> in second tubular structure <NUM>. <FIG> shows the segmented tunnel structure <NUM> in an unstressed configuration on base layer <NUM>. Tensile strand <NUM> has a catching element <NUM> (such as a knot) at one end, such that first tubular structure <NUM> may be forced closer to second tubular structure <NUM> or into contact with second tubular structure <NUM>, when tensile strand <NUM> is pulled at end <NUM> in the direction shown by arrow <NUM> in <FIG> shows the segmented tunnel structure of <FIG> when tensile strand <NUM> has been pulled such that catching element <NUM> is forcing first tubular structure <NUM> toward second tubular structure <NUM>. In <FIG>, first tubular structure <NUM> has been pulled into full contact with second tubular structure <NUM>, such that tunnel <NUM> in first tubular structure <NUM> and tunnel <NUM> in second tubular structure <NUM> form a single continuous tunnel. Connecting portion <NUM> is folded against Itself, and a fold <NUM> is formed in base layer <NUM>, as shown in <FIG>.

A sequential series of segmented tunnel structures may be laced through by a tensile strand. For example, as shown in <FIG>, tensile strand <NUM> is laced through three segmented tunnel structures - through tunnel <NUM> and tunnel <NUM> in segmented tunnel structure <NUM>, through tunnel <NUM> and tunnel <NUM> in segmented tunnel structure <NUM>, and through tunnel <NUM> and tunnel <NUM> in segmented tunnel structure <NUM>. In the unstressed configuration shown in <FIG>, tensile strand <NUM> has not been pulled to force catching element <NUM> against tubular structure <NUM>, and each of the segmented tunnel structures are spaced apart from each other. In this example, connecting portion <NUM>, connecting portion <NUM>, and connecting portion <NUM> all form a generally semi-circular arch when the segmented tunnel structures are in their unstressed condition. Also, in the uncompressed configuration, tubular structure <NUM> is maintained at a distance <NUM> from tubular structure <NUM>; tubular structure <NUM> is maintained at a similar distance from tubular structure <NUM>; and tubular structure <NUM> is maintained at a similar distance from tubular structure <NUM>.

In the configuration shown in <FIG>, catching element <NUM> of tensile strand <NUM> has been pulled in the direction of arrow <NUM> against tubular structure <NUM> of segmented tunnel structure <NUM> forcing tubular structure <NUM> against tubular structure <NUM> of segmented tunnel structure <NUM>, and tubular structure <NUM> against tubular structure <NUM>. In this example, tunnel <NUM> in tubular structure <NUM> and tunnel <NUM> in tubular structure <NUM> abut, such that they form a continuous tunnel through tubular structure <NUM> and tubular structure <NUM>. Similarly, tunnel <NUM> in tubular structure <NUM> and tunnel <NUM> in tubular structure <NUM> of segmented tunnel structure <NUM> abut, such that they form a continuous tunnel through tubular structure <NUM> and tubular structure <NUM>. Connecting portion <NUM>, connecting portion <NUM>, and connecting portion <NUM> are under compressive stress, such that they form a narrower arch than they did in the unstressed configuration shown in <FIG>, and such that distance <NUM> in <FIG> is less than distance <NUM> in <FIG>.

The segmented tunnel structures shown in <FIG> and <FIG> may be disposed in any appropriate configuration for a given application. For example, <FIG> and <FIG> show that a tensile strand <NUM> may be laced through multiple segmented tunnel structures <NUM> in different configurations. As shown in <FIG>, different segmented tunnel structures may be orientated in different directions. For example, they may be disposed in linear, nonlinear, bent, curved, intersecting, closed, and/or open configurations. In <FIG>, for example, when the segmented tunnel structure is not under tension and thus in a relaxed state, central axis <NUM> of segmented tunnel structure <NUM> is oriented in a different direction than central axis <NUM> of segmented tunnel structure <NUM>. Specifically, central axis <NUM> forms an angle <NUM> with central axis <NUM>, where angle <NUM> is different from <NUM> degrees (I. , central axis <NUM> and central axis <NUM> are not collinear). These segmented tunnel structures may thus be used to control the geometry of the base layer upon which they may be attached in a variable manner, depending upon the magnitude of the tension applied to the tensile strand. Additionally, various arrangements of segmented tunnel structures may allow for any kinds of nonlinear paths for a tensile strand so that the tensile strand can be diverted around regions such as certain regions of an article overlying anatomical structures, or so that the tensile strand can otherwise be arranged in any desired three-dimensional arrangement on an article of footwear or other contoured article.

In the exemplary configuration shown in <FIG>, tensile strand <NUM> and segmented tunnel structures <NUM> are disposed in an open configuration. On the other hand, tensile strand <NUM> and segmented tunnel structures <NUM> may be disposed in other configurations, including, for example, the configuration shown in <FIG>, in which tensile strand <NUM> crosses over itself at a crossing point <NUM>. Moreover, because any number and size of segmented tunnel structures may be used with a tensile strand, they may be used to implement any desired geometry of linear, nonlinear, curved, bent, or intersecting paths on an article of apparel, article of footwear, or other article that can be controlled by varying the tension on the tensile stand. In short, there are no inherent limitations to the configurations of segmented tunnel structures that may be used in applying the segmented tunnel structures to articles of footwear, articles of apparel, protective gear, or other articles of manufacture.

<FIG> are examples of the application of tubular structures to articles of manufacture. Thus, <FIG> and <FIG> are schematic diagrams of a perspective lateral view of an article of footwear <NUM> illustrating the application of collapsible tunnel systems, such as the system illustrated in <FIG> and the system illustrated in <FIG>, to an article of footwear. <FIG> illustrates the configuration of the tubular structures in their uncollapsed configuration and <FIG> illustrates the configuration of the tubular structures when they are fully collapsed. The article of footwear <NUM> shown schematically in <FIG> and <FIG> has two collapsible tunnel systems: collapsible tunnel system <NUM> around the ankle opening <NUM> of upper <NUM> and collapsible tunnel system <NUM> on the lateral side <NUM> of upper <NUM> at the midfoot of upper <NUM>.

Collapsible tunnel system <NUM>, which has components similar to the components illustrated in <FIG>, includes a tensile strand <NUM>, two linear tubular structures (linear tubular structure <NUM> and linear tubular structure <NUM>) and catching element <NUM>. it may be used to provide additional support for a hi-top or medium-top article of footwear. In <FIG>, collapsible tunnel system <NUM> is in an uncollapsed state, because tensile strand <NUM> is not pulled tight around ankle opening <NUM>. When a wearer of the article of footwear <NUM> pulls tensile strand <NUM> tight to fasten collapsible tunnel system <NUM> around ankle opening <NUM>, catching element <NUM> on the lateral side of ankle opening <NUM> forces linear tubular structure <NUM> on the lateral side of ankle opening <NUM> against linear tubular structure <NUM>, as shown in <FIG>. This concurrently also changes the geometry of the base layer <NUM> of the upper underlying and intermediate to linear tubular structure <NUM> and linear tubular structure <NUM>. Although not shown in <FIG> or <FIG>, a similar catching element on the medial side of ankle opening <NUM> forces similar tubular structures (also not shown) on the medial side of ankle opening <NUM> against each other.

Collapsible tunnel system <NUM>, which has components similar to the components illustrated in <FIG>, includes a tensile strand <NUM> that has two loops <NUM> at one end and two catching elements <NUM> at its other end. Collapsible tunnel system <NUM> is shown in its uncollapsed state in <FIG>, because tensile strand <NUM> has not been pulled up by shoelace <NUM>. A wearer of the article of footwear <NUM> could lace shoelace <NUM> through loops <NUM>. When shoelace <NUM> is pulled tight and tied in a bow, catching elements <NUM> force curved tubular structure <NUM> against linear tubular structures <NUM> and linear tubular structures <NUM> against linear tubular structures <NUM>, as shown in <FIG>. Thus applying tension to tensile strand <NUM> changes the geometry of the portion of the base layer <NUM> of upper <NUM> in the region intermediate between curved tubular structure <NUM> and linear tubular structures <NUM>. Collapsible tunnel system <NUM> could function as a supportive and/or protective element for article of footwear <NUM>.

<FIG> illustrates another example of the application of a collapsible tunnel system to an article of footwear. In this example, article of footwear <NUM> has two tensile strands that also function as laces to fasten upper <NUM> over a wearer's foot. Tensile strand <NUM> on the lateral side of upper <NUM> is laced through tubular structure <NUM> and tubular structure <NUM> of collapsible tunnel system <NUM>, then into aperture <NUM> on the side of upper <NUM>. Tensile strand <NUM> is then laced through an eyelet <NUM> on the lateral side of tongue opening <NUM>. it is then laced through every other eyelet <NUM> on each side of the tongue opening. A similar tensile strand <NUM> that may be laced through a pair of tubular structures on the medial side of upper <NUM> is also laced through every other eyelet <NUM> on each side of tongue opening <NUM>. Tensile strand <NUM> and tensile strand <NUM> may then be pulled tight and fastened in a bow <NUM> at the top of tongue opening <NUM> to fasten upper <NUM> over a wearer's foot. Thus a part of tensile strand <NUM> and a part of tensile strand <NUM> function as two sides of a conventional shoelace. Collapsible tunnel system <NUM> may be used to allow a wearer to adjust the fit of an article of footwear at the sides of his or her foot.

<FIG> is a schematic diagram of an exemplary application of the segmented tunnel structures shown in <FIG> to an article of apparel, such as a hoodie <NUM>. Each segmented tunnel structure <NUM> shown in <FIG> has two tubular tunnel structures <NUM> joined by a connecting portion <NUM>. A tensile strand <NUM> is laced through tunnels in each of the tubular tunnel structures <NUM>. End <NUM> of tensile strand <NUM> and end <NUM> of tensile strand <NUM> may then be pulled down to close the face opening <NUM> of the hood <NUM> around a wearer's face. End <NUM> and end <NUM> may be pulled through a tubular structure such as tubular structure <NUM> shown in <FIG>. In this example, because the segmented tunnel structures are characterized by a certain level of rigidity, the wearer of the hoodie can tighten the hood down around his or her chin, without simultaneously forcing the circumference of the hood against his or her face.

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 Mozeika et al. , <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.

Claim 1:
A tensioning system attached to a base layer (<NUM>), comprising:
a first segmented tubular structure (<NUM>) comprising a first tubular structure (<NUM>) and a second tubular structure (<NUM>);
wherein the first tubular structure (<NUM>) includes a first tunnel (<NUM>) and wherein the second tubular structure (<NUM>) includes a second tunnel (<NUM>);
wherein the first tubular structure (<NUM>) is attached to the second tubular structure (<NUM>) by a first connecting portion (<NUM>), the first tunnel (<NUM>) being spaced apart from the second tunnel (<NUM>) proximate the first connecting portion (<NUM>);
a second segmented tubular structure (<NUM>) comprising a third tubular structure (<NUM>) and a fourth tubular structure;
wherein the third tubular structure (<NUM>) includes a third tunnel (<NUM>) and wherein the fourth tubular structure (<NUM>) includes a fourth tunnel (<NUM>);
wherein the third tubular structure (<NUM>) is attached to the fourth tubular structure (<NUM>) by a second connecting portion (<NUM>), the third tunnel (<NUM>) being spaced apart from the fourth tunnel (<NUM>) proximate the second connecting portion (<NUM>);
a tensile strand (<NUM>) extending through the first tunnel (<NUM>), the second tunnel (<NUM>), the third tunnel (<NUM>), and the fourth tunnel (<NUM>);
wherein the first segmented tubular structure (<NUM>) is spaced apart from the second segmented tubular structure (<NUM>);
wherein the first tubular structure (<NUM>) and the second tubular structure (<NUM>) are attached to the base layer (<NUM>), and the first connecting portion (<NUM>) is not attached to the base layer (<NUM>); and
wherein the third tubular structure (<NUM>) and the fourth tubular structure (<NUM>) are attached to the base layer (<NUM>), and the second connecting portion (<NUM>) is not attached to the base layer (<NUM>).