ARTICLES OF APPAREL COMPRISING WOUND THREAD LAYERS AND METHODS OF MAKING THE SAME

Description

FIELD

The described embodiments generally relate to articles of apparel and methods of making articles of apparel. In particular, described embodiments relate to articles of footwear comprising a plurality of wound thread layers of different thread types.

BACKGROUND

Footwear can be manufactured from various materials using a wide range of techniques, including weaving and knitting. Individuals are often concerned with the durability, comfort, and/or performance characteristics for an article of footwear. This is true for footwear worn for athletic and non-athletic activities. Footwear worn for athletic activities can undergo particular stresses depending on the activity. Many athletic activities (for example, basketball) require a high degree of agility. This requires footwear that provide a high degree of stiffness when force is applied to the footwear (for example, during a lateral cut or move). The footwear should not fold or break under the athlete during a change in direction. Proper footwear for athletic activities such as basketball should be durable even under high strain events, such as cutting or accelerating. Simultaneously, the footwear should be comfortable and should not be heavy, which can reduce agility. Therefore, a continuing need exists for innovations in footwear and methods of making footwear to suit individuals who participate in athletic activities that require a high degree of lateral agility.

BRIEF SUMMARY

A first embodiment (1) of the present application is directed to an article of footwear, comprising: a forefoot region, a midfoot region, and a heel region; a sole; and an upper comprising: a thread pattern comprising: an anterior-posterior axis aligned with the length of the article of footwear, and a medial-lateral axis extending perpendicularly to the anterior-posterior axis; a perimeter edge coupled to the sole along at least a portion of the perimeter edge; an edge region adjacent the sole; a first thread layer comprising first thread lines extending between points on the perimeter edge, the first thread lines including all thread lines of the first thread layer extending between points on the perimeter edge, the first thread lines being concentrated in at least one of the forefoot region or the heel region; a second thread layer comprising second thread lines extending between points on the perimeter edge, the second thread lines including all thread lines of the second thread layer extending between points on the perimeter edge, the second thread lines being concentrated in the edge region; a third thread layer comprising third thread lines extending to points on a throat portion of the perimeter edge; and a fourth layer comprising fourth thread lines extending between points on the perimeter edge, a first plurality of the fourth thread lines extending at an angle less than or equal to 45 degrees with respect to the anterior-posterior axis.

In a second embodiment (2), the first plurality of the fourth thread lines according to the first embodiment (1) extends substantially parallel to the anterior-posterior axis.

In a third embodiment (3), a second plurality of the fourth thread lines according to any one of embodiments (1)-(2) extends at an angle greater than 45 degrees with respect to the anterior-posterior axis.

In a fourth embodiment (4), the second plurality of the fourth thread lines according to the third embodiment (3) extends substantially parallel to the medial-lateral axis.

In a fifth embodiment (5), the thread pattern according to any one of embodiments (1)-(4) comprises a tensile stiffness, as measured along an anterior-posterior direction in a region on the thread pattern, from about 75 N/mm to about 130 N/mm.

In a sixth embodiment (6), the thread pattern according to any one of embodiments (1)-(5) comprises a tensile stiffness, as measured along a medial-lateral direction in a region (for example, the region according to the fifth embodiment (5)) on the thread pattern, from about 10 N/mm to about 50 N/mm.

In a seventh embodiment (7), the second thread lines according to any one of embodiments (1)-(6) extend from points on the perimeter edge in the edge region that lie in at least the forefoot region and midfoot region.

In an eighth embodiment (8), the first thread lines according to any one of embodiments (1)-(7) are concentrated in the forefoot region, and each of the fourth thread lines according to any one of embodiments (1)-(7) comprises a tensile stiffness greater than that of each of the first thread lines.

In a ninth embodiment (9), each of the third thread lines according to any one of embodiments (1)-(8) comprises a tensile stiffness greater than that of each of the first thread lines according to any one of embodiments (1)-(8).

In a tenth embodiment (10), the first thread lines according to any one of embodiments (1)-(9) are concentrated in the forefoot region, and the article of footwear according to any one of embodiments (1)-(9) further comprises a fifth thread layer comprising fifth thread lines extending between points on the perimeter edge, the fifth thread lines including all thread lines of the fifth layer extending between points on the perimeter edge, the fifth thread lines being concentrated in the heel region.

In an eleventh embodiment (11), the first, second, third, and fourth thread lines according to any one of embodiments (1)-(10) each comprise a first, second, third, and fourth thread type, respectively, and wherein at least one of the first, second, third, and fourth thread types comprises a different tensile stiffness than another of the first, second, third, and fourth thread types.

In a twelfth embodiment (12), the first, second, third, and fourth thread lines according to any one of embodiments (1)-(11) each comprise a first, second, third, and fourth thread type, respectively, and wherein at least one of the first, second, third, and fourth thread types comprises a different denier than another of the first, second, third, and fourth thread types.

In a thirteenth embodiment (13), the first, second, third, and fourth thread lines according to any one of embodiments (1)-(12) each comprise a first, second, third, and fourth thread type, respectively, and wherein at least one of the first, second, third, and fourth thread types comprises a different material than another of the first, second, third, and fourth thread types.

In a fourteenth embodiment (14), the first thread layer according to any one of embodiments (1)-(13) comprises overlapping sub-layers each comprising a different thread line count, and a thread line count of each of the overlapping sub-layers decreases with respect to a thread line count of an immediately adjacent overlapping sub-layer.

In a fifteenth embodiment (15), the first thread lines according to the fourteenth embodiment (14) are concentrated in the forefoot region, and a number of overlapping sub-layers of the first thread layer according to the fourteenth embodiment (14) at a point on the first thread layer progressively decreases in a direction extending parallel to the anterior-posterior axis from a forefoot end of the article of footwear.

In a sixteenth embodiment (16), the fourth thread layer according to any one of embodiments (1)-(15) comprises overlapping sub-layers each comprising a different thread line count, and a thread line count of each of the overlapping sub-layers decreases with respect to a thread line count of an immediately adjacent overlapping sub-layer.

In a seventeenth embodiment (17), a number of overlapping sub-layers of the fourth thread layer according to the sixteenth embodiment (16) at a point on the fourth thread layer progressively increases in a direction extending parallel to the anterior-posterior axis from the forefoot region to the heel region of the article of footwear.

An eighteenth embodiment (18) of the present application is directed to an article of footwear, comprising: a sole; and an upper comprising: a thread pattern comprising: a perimeter edge coupled to the sole along at least a portion of the perimeter edge; and a thread layer comprising thread lines extending between points on the perimeter edge, the thread layer comprising overlapping sub-layers each comprising a different thread line count, a thread line count of each of the overlapping sub-layers decreasing with respect to a thread line count of an immediately adjacent overlapping sub-layer.

In a nineteenth embodiment (19), the thread line count of each of the overlapping sub-layers according to the eighteenth embodiment (18) decreases with respect to the thread line count of the immediately adjacent overlapping sub-layer by the same increment.

In a twentieth embodiment (20), the thread line count of each of the overlapping sub-layers according to any one of embodiments (18)-(19) decreases by at least two with respect to the thread line count of the immediately vertically adjacent sub-layer.

In a twenty-first embodiment (21), each of the overlapping sub-layers according to any one of embodiments (18)-(20) comprises thread lines extending substantially parallel to thread lines of an immediately adjacent overlapping sub-layer.

In a twenty-second embodiment (22), each of the overlapping sub-layers according to any one of embodiments (18)-(21) comprises thread lines that overlay thread lines of an immediately adjacent overlapping sub-layer along entire lengths of the thread lines of the immediately adjacent overlapping sub-layer.

In a twenty-third embodiment (23), the thread line count of each of the overlapping sub-layers according to any one of embodiments (18)-(22) progressively decreases in a direction extending outward from the upper.

In a twenty-fourth embodiment (24), the thread line count of each of the overlapping sub-layers according to any one of embodiments (18)-(22) progressively decreases in a direction extending inward into the upper.

In a twenty-fifth embodiment (25), a number of overlapping sub-layers of the thread layer according to any one of embodiments (18)-(24) at a point on the thread layer progressively increases in a direction extending along the upper away from an edge thread line of the thread layer.

A twenty-sixth embodiment (26) of the present application is directed to an article of footwear, comprising: a sole; and an upper comprising: a thread pattern comprising: a perimeter edge coupled to the sole along at least a portion of the perimeter edge; and a plurality of edge-adjacent thread layers each comprising a different thread type, the thread type of each of the edge-adjacent thread layers comprising a thread type characteristic value that decreases with respect to a same thread type characteristic value of an immediately adjacent edge-adjacent thread layer.

In a twenty-seventh embodiment (27), the thread type characteristic value of each of the edge-adjacent thread layers according to the twenty-sixth embodiment (26) decreases with respect to the same thread type characteristic value of the immediately adjacent edge-adjacent layer by the same increment.

In a twenty-eighth embodiment (28), the plurality of edge-adjacent thread layers according to any one of embodiments (26)-(27) are level-adjacent thread layers that occupy a common level in the thread pattern.

In a twenty-ninth embodiment (29), each of the edge-adjacent thread layers according to any one of embodiments (26)-(28) comprises thread lines extending substantially parallel to thread lines of an immediately adjacent edge-adjacent thread layer.

In a thirtieth embodiment (30), each of the edge-adjacent thread layers according to any one of embodiments (26)-(29) does not comprise a first thread line that overlays a second thread line of an immediately adjacent edge-adjacent thread layer along entire lengths of the first and second thread lines.

In a thirty-first embodiment (31), the thread type characteristic value according to any one of embodiments (26)-(30) comprises a tensile stiffness.

A thirty-second embodiment (32) of the present application is directed to a method of manufacturing an article of footwear, the method comprising: defining a perimeter edge of a thread pattern for a shoe upper; winding one or more first continuous threads around projections to form a first thread layer comprising first thread lines extending between points on the perimeter edge; winding one or more second continuous threads around projections to form a second thread layer comprising second thread lines extending between points on the perimeter edge, the second thread lines being concentrated in an edge region of the thread pattern; winding one or more third continuous threads around projections to form a third thread layer comprising third thread lines extending to points on a throat portion of the perimeter edge; winding one or more fourth continuous threads around a plurality of projections to form a fourth thread layer comprising fourth thread lines extending between points on the perimeter edge; bonding the first, second, third, and fourth thread layers to one another; cutting the first, second, third, and fourth continuous threads along the perimeter edge to form the thread pattern; orienting the thread pattern relative to a sole of the article of footwear such that the first thread lines are concentrated in at least one of a forefoot region or a heel region of the article of footwear and a first plurality of the fourth thread lines extend at an angle less than or equal to 45 degrees with respect to a lengthwise axis of the article of footwear; and coupling at least a portion of the perimeter edge to the sole.

A thirty-third embodiment (33) of the present application is directed to a method of manufacturing an article of apparel, the method comprising: defining a perimeter edge of a thread layer for an article of apparel; winding one or more continuous threads around projections to form a first sub-layer of the thread layer, the first sub-layer comprising first thread lines extending between points on the perimeter edge and comprising a first thread line count; winding the one or more continuous threads around projections to form a second sub-layer that overlaps the first sub-layer, the second sub-layer comprising second thread lines extending between points on the perimeter edge and comprising a second thread line count less than the first thread line count; winding the one or more continuous threads around projections to form a third sub-layer that overlaps the first and second sub-layers, the third sub-layer comprising third thread lines extending between points on the perimeter edge and comprising a third thread line count less than the second thread line count; bonding the first, second, and third sub-layers to one another; and cutting the one or more continuous threads along the perimeter edge to form the thread layer.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1A shows an article of footwear according to some embodiments.

FIG. 1B shows a portion of the article of footwear of FIG. 1A according to some embodiments.

FIGS. 2A-2C show thread layers according to some embodiments.

FIG. 3 shows a thread pattern according to some embodiments.

FIG. 4 shows an apparatus for producing thread layers or thread patterns according to some embodiments.

FIG. 5 shows a thread layer according to some embodiments.

FIG. 6 shows a thread layer according to some embodiments.

FIGS. 7A-7C show thread layers according to some embodiments.

FIG. 8 shows a thread layer according to some embodiments.

FIG. 9 shows a thread layer according to some embodiments.

FIG. 10 shows a thread layer according to some embodiments.

FIG. 11 shows a thread layer according to some embodiments.

FIGS. 12A-12B show thread layers according to some embodiments.

FIG. 13 shows a thread layer according to some embodiments.

FIG. 14 shows a thread layer according to some embodiments.

FIG. 15 shows a shoe upper component according to some embodiments.

FIG. 16 shows a graph of tensile stiffness testing according to some embodiments.

FIG. 17 shows tensile stiffness testing results for various wound components.

FIG. 18 shows tensile stiffness testing results for various wound components.

FIG. 19 shows tensile stiffness testing results for various wound components.

FIG. 20 is an exemplary flowchart of a method according to some embodiments.

FIGS. 21A-21B show a thread layer or thread pattern according to some embodiments.

FIG. 22 is an exemplary flowchart of a method according to some embodiments.

FIG. 23 shows a schematic block diagram of an exemplary computer system with which embodiments can be implemented.

FIGS. 24A-24B show a thread pattern according to some embodiments

DETAILED DESCRIPTION

The present invention(s) will now be described in detail with reference to embodiments thereof as illustrated in the accompanying drawings. References to “some embodiments”, “one embodiment”, “an embodiment”, “an exemplary embodiment”, etc., indicate that the embodiment described can comprise a particular feature, structure, or characteristic, but every embodiment may not necessarily comprise the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

The indefinite articles “a,” “an,” and “the” include plural referents unless clearly contradicted or the context clearly dictates otherwise.

The term “comprising” is an open-ended transitional phrase. A list of elements following the transitional phrase “comprising” is a non-exclusive list, such that elements in addition to those specifically recited in the list can also be present.

As used herein, unless specified otherwise, references to “first,” “second,” “third,” “fourth,” etc. are not intended to denote order, or that an earlier-numbered feature is required for a later-numbered feature. Also, unless specified otherwise, the use of “first,” “second,” “third,” “fourth,” etc. does not necessarily mean that the “first,” “second,” “third,” “fourth,” etc. features have different properties or values.

An article of footwear has many purposes. Among other things, footwear can provide a unique aesthetic look, provide warming or cooling characteristics, provide support for portions of an individual's foot or ankle, and provide other performance characteristics, such as air permeability, moisture wicking properties, and compression properties. Each of these purposes, alone or in combination, provides for comfortable footwear suitable for use athletic competition. The features of an article of footwear (for example, the materials and components used to make footwear, and the way these materials/components are made) can be altered to produce desired characteristics, for example, durability, stiffness, weight, tackiness, texture, haptics, tackiness, and/or air permeability.

An article of footwear, or a portion thereof (for example, an upper of a shoe), can be configured to provide various degrees of durability, stiffness, support, etc. in various regions and with respect to various planes of motion. Accordingly, an article of footwear can be particularly suited to withstand the demands of certain sport-specific movement patterns. For example, it is possible to increase stiffness of a shoe upper along a lateral direction (transverse to the length of an article of footwear) so that the shoe upper does not flex as much in the lateral direction when force is applied to an inside of the upper by an individual's foot. This can protect an individual from injury or shoe failure during explosive lateral cuts, for example, common to basketball. Such an increase in shoe upper stiffness may not be required, for example, for a runner who rarely moves in a significant lateral direction.

While durability, stiffness, and support are concerns, the weight and complexity of the footwear can also be a consideration. For example, stiffness can be increased by adding solid layers of material or incorporating additional reinforcement materials, but this increases the weight of the footwear. Weight increase is particularly detrimental in sports, such as basketball, that require explosive movements. Additionally, the approach of adding solid layers of material or incorporating additional reinforcement materials can increase materials and labor costs associated with production.

Accordingly, a manufacturing process that facilitates the manufacture of laterally reinforced (or generally reinforced) footwear while minimizing the weight of the footwear and the complexity of the manufacturing process can be desirable. For example, various thread layers as described herein can be combined into a thread pattern for an article of apparel (for example, footwear). The thread layers can be configured to selectively impart increased stiffness in particular regions and along particular axes of the article of footwear. For example, the combination of thread layers can be configured to selectively impart increased stiffness along an anterior-posterior direction of the article of footwear while maintaining stiffness along a medial-lateral direction, or vice-versa. In addition, one or more of the thread layers can be configured to create a gradual transition between a first property (for example, a first tensile stiffness) and a second property (for example, a second tensile stiffness) by progressively increasing thread line density, thread line tension (and therefore tensile stiffness), and/or changing materials in a particular direction along the thread pattern.

The articles of footwear described herein can be made by, or can comprise a layer made by, winding one or more continuous threads around anchor points to create a desired thread layer or thread pattern. Winding the continuous thread(s) around the anchor points comprises wrapping a continuous thread around a first anchor point, extending that continuous thread to a second anchor point, wrapping that continuous thread around the second anchor point, and so on. The number and position of the anchor points can be utilized to control characteristics of the thread layer or thread pattern, and therefore characteristics of the footwear or a region of the footwear. Also, the number of times a continuous thread is wound from anchor point to anchor point can be utilized to control characteristics of the thread layer or thread pattern, and therefore characteristics of the footwear or the region of the footwear.

Continuous thread(s) of a thread layer or thread pattern can be bonded within the thread layer or thread pattern. The bonding of continuous thread(s) of a thread layer or thread pattern can consolidate the layer or pattern and set thread lines within the layer or pattern. In some embodiments, bonding continuous thread(s) of a thread layer or thread pattern can be utilized to control characteristics of the layer or pattern. In some embodiments, a continuous thread can be bonded to itself within a thread layer or thread pattern. In some embodiments, a continuous thread can be bonded to itself at points of overlap between different thread lines of the continuous thread (i.e., at thread line intersection points). In some embodiments, different continuous threads of a thread layer or pattern can be bonded together. In some embodiments, different continuous threads can be bonded to each other at points of overlap between the different continuous threads (i.e., at intersection points between the different continuous threads). The bonding of continuous thread(s) can set the continuous thread(s) in tension because the thread(s) can be wound around anchor points in tension. The bonding of thread(s) in tension allows a thread layer or thread pattern to contract once removed from anchor points used to wind the thread layer or thread pattern, which can be utilized to control characteristics of the thread layer or thread pattern.

As used herein, two components (for example, two threads or a thread and another material) described as “bonded to” each other means the first component and second component are bonded to each other, either by direct contact and/or bonding between the two components or via an adhesive, bonding, and/or another thread layer. Two components (for example, two threads or a thread and another material) described as “directly bonded to” each other means the two components are directly bonded to each other via a material of the first component, a material of the second component, or both. For example, where heat and/or pressure is utilized to directly bond the polymeric material of a first thread to a second thread, the first thread is directly bonded to the second thread via the polymeric material of the first thread. In such embodiments, the polymeric material can be thermally fused to the second thread.

In some embodiments, a plurality of different continuous threads can be wound around anchor points to form a plurality of thread layers for a thread pattern. In some embodiments, different continuous threads can be wound in the same configuration (i.e., around the same anchor points and along the same paths). In some embodiments, different continuous threads can be wound in different configurations (i.e., around one or more different anchor points and/or along different paths between one or more anchor points). In some embodiments, continuous threads of different types can define different wound layers for an article of footwear, or portion thereof. In such embodiments, the different layers can provide different characteristics to a thread pattern, and therefore provide different characteristics on the article of footwear.

Continuous thread(s) can be wound around anchor points (for example, projections as discussed herein) in various configurations to provide varying degrees of characteristics for an article of footwear. The number of anchor points, the position of the anchor points, the way continuous threads are wound around the anchor points, and/or the type of threads wound around the anchor points can be utilized to produce footwear or a region of footwear having desired characteristics, such as strength, stiffness, air permeability, comfort, abrasion resistance, fit, texture, haptics, tackiness, and durability. Characteristics of an article of footwear or region of an article of footwear can be varied by changing the arrangement of anchor points and/or the way continuous thread(s) are wound around the anchor points. Characteristics can also be varied by altering the type of continuous thread(s). In some embodiments, a plurality of thread layers and/or thread patterns can be [0074] bonded together in a process for forming a shoe upper material that surrounds all or a portion of a wearer's foot during use. In some embodiments, the upper material that surrounds all or a portion of a wearer's foot during use can comprise a portion that extends across and wraps around at least a portion of the bottom of a wearer's foot. In some embodiments, the upper material need not comprise such a portion. For example, the upper material can be configured for attachment to the sole of a shoe at the sides of a wearer's foot and not beneath. In some embodiments, bonding a plurality of thread layers and/or thread patterns together can create an upper material having a void configured to receive all or a portion of a wearer's foot.

In some embodiments, a plurality of thread layers can form a thread pattern for use in a shoe upper (also referred to herein as an upper for an article of footwear). The thread pattern can comprise a first, second, third, and fourth thread layer each comprising thread lines extending between points on a perimeter edge of the thread pattern. In some embodiments, the thread lines of the first thread layer can be concentrated in at least one of a forefoot region or a heel region of an article of footwear. In some embodiments, the thread lines of the second thread layer can be concentrated in an edge region of the thread pattern. In some embodiments, the thread lines of the third thread layer can extend to points on a throat portion of the perimeter edge. And in some embodiments, thread lines of the fourth thread layer can extend at an angle less than or equal to 45 degrees with respect to an anterior-posterior (AP) axis of the thread pattern that is aligned with the length of the article of footwear.

In some embodiments, a thread layer of a thread pattern for use in an article of apparel, for example an article of footwear, can comprise a gradient. The gradient can be formed from a plurality of overlapping sub-layers that vary in thread line count. For example, in some embodiments, a thread line count of each of the overlapping sub-layers can decrease with respect to a thread line count of an immediately adjacent overlapping sub-layer. In some embodiments, the result can be thread line densities that increase in a direction away from an edge thread line of the thread layer. In such embodiments, the gradient can produce a smooth transition between a first property of the thread pattern and a second property of the thread pattern. In some embodiments, the gradient can be formed from a plurality of edge-adjacent thread layers comprising thread lines with different thread types that gradually change in one or more characteristics of the thread.

FIGS. 1A and 1B show an article of footwear 100 according to some embodiments. In some embodiments, article of footwear 100 can be athletic footwear designed for use in a sport that requires high degrees of lateral agility (e.g., football, basketball, soccer, tennis, etc.). In some embodiments, article of footwear 100 can be a basketball shoe. Article of footwear 100 can comprise a wound component comprising one or more thread layers.

In some embodiments, article of footwear 100 can comprise an upper 120 coupled to a sole 180. Article of footwear 100 and upper 120 can comprise a forefoot end 102, a heel end 104, a medial side 106, and a lateral side 108 opposite medial side 106. As illustrated in FIG. 1A, article of footwear 100 can comprise a forefoot region 110, a midfoot region 112, and a heel region 114. Although regions 110, 112, and 114 are illustrated in connection with article of footwear 100 of FIGS. 1A-1B, regions 110, 112, and 114 can also be used to describe regions of upper 120, sole 180, or other individual components of article of footwear 100. For example, a “forefoot region” of upper 120 (or upper component 1500) can be the portion of upper 120 (or upper component 1500) that lies in forefoot region 110 of article of footwear 100.

As illustrated in FIG. 1A, lengthwise axis L of article of footwear 100 extends from forefoot end 102 to heel end 104 along the longest dimension of article of footwear 100. Planes A and B transect lengthwise axis L at 35% and 70% of the length of axis L, respectively, as measured from forefoot end 102. Both planes A and B are perpendicular to lengthwise axis L and extend through article of footwear 100 from lateral side 108 to medial side 106. Herein, forefoot region 110 is defined as a region forward of plane B, midfoot region 112 is defined as a region between planes A and B, and heel region 114 is defined as a region rearward of plane B.

Upper 120 can be formed of one or more components that are stitched, bonded, or otherwise joined together to form a structure for receiving and securing a foot relative to sole 180. And upper 120 comprises at least a portion defined by a thread pattern 122. Thread pattern 122 can be made by winding continuous threads as discussed herein. Layers of thread pattern 122 are not knitted, woven, braided, or embroidered layers. Thread pattern 122 can be referred to as a thread network of adjacent and overlapping thread lines. Thread pattern 122 can comprise any combination of the thread layers described herein, for example, thread layers 200, 220, 240, 500, 600, 700, 720, 740, 800, 900, 1000, 1100, 1200, 1220, 1300, 1400, and/or 2100.

In some embodiments, thread pattern 122 can comprise a network of individual thread lines that form a substantially continuous material with minimal void space between thread lines. As used herein, “void space” means an opening extending through a thread layer or thread pattern between thread lines of the thread layer or thread pattern. In some embodiments, the substantially continuous material can have a ratio (V:T) of void space (V) to thread material (T) of at least 1:1 measured across all or a portion of an outer surface of a thread layer or thread pattern. In some embodiments, the ratio of void space to thread material can be at least 1:1, 1:2, 1:2.5, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:20, 1:50, or 1:100. In some embodiments, a thread layer or thread pattern can comprise a network of thread lines that form a continuous material with no void space between thread lines. A ratio of void space to thread material can be measured for a thread layer or thread pattern before or after bonding of thread lines. In some embodiments, bonding of thread lines can serve to reduce the amount of void space of a thread layer or thread pattern. For example, thermally bonding thread lines via a polymer material of the thread lines can reduce the amount of void space by filling in void space with thermally melted polymer material. In some embodiments, melted polymer material(s) of a thread layer or thread pattern can fill void spaces between thread lines to form a continuous material without void space between thread lines.

In some embodiments, thread pattern 122 can wrap around all or a portion of the sides, the top, and/or the heel of a wearer's foot. In some embodiments, thread pattern 122 can wrap around at least a portion of the bottom surface (i.e., the sole) of a wearer's foot when worn. For example, an upper with thread pattern 122 can wrap around the bottom surface of a wearer's foot when worn. As another example, thread pattern 122 can wrap around the bottom surface of a wearer's foot by wrapping around a sole for an article of footwear. As another example, thread pattern 122 can wrap around the bottom surface of a wearer's foot by extending through a sole for an article of footwear.

Upper 120 can extend along the lateral side of the foot, along the medial side of the foot, over the foot, around a heel of the foot, and/or under the foot when worn. Upper 120 can define a void 155, which can be a generally hollow area having the general shape of a foot and can be configured to receive the foot. An opening of void 155 can be defined in whole or in part by a collar 156 located in at least a heel portion of upper 120.

In addition, upper 120 can comprise a throat area 150 extending from collar 156 towards a forefoot region of upper 120. Throat area 150 can extend over a dorsal area of a wearer's foot that corresponds generally to the location of a wearer's cuneiform and metatarsal bones. In some embodiments, throat area 150 can define an opening for a tongue 154 that extends between lateral and medial perimeter sides of throat area 150 and moveably opens and closes a portion of void 155 to enhance the adjustability of article of footwear 100. In some embodiments, upper 120 can also comprise one or more eyelets 152 [0085] formed in a perimeter portion of throat area 150 for securing and tensioning a shoelace. More particularly, the shoelace can allow a wearer to tighten or loosen upper 120 around his or her foot. In some embodiments, upper 120 can comprise a heel counter 158. Heel counter 158 can provides cushioning, support, and/or protection for a wearer's heel and/or Achilles tendon.

With reference to FIG. 1A, upper 120 can be coupled to sole 180 at a biteline 160 (i.e., a sole connection area). Together, biteline 160, collar 156, heel counter 158, and a perimeter portion of throat area 150 can define a perimeter portion 162 of upper 120. Perimeter portion 162 can comprise an outer edge defined by biteline 160 and an inner edge defined by collar 156 and a perimeter of throat area 150. Perimeter portion 162 can define a frame having a shape corresponding to at least a portion of a perimeter shape of upper 120. Portions of upper 120 within perimeter portion 162 can comprise the quarter panels, a vamp portion, and a toe box portion of upper 120. Thread pattern 122 can define all or a portion of perimeter portion 162 and/or any portion of upper 120 within perimeter portion 162 of upper 120.

In some embodiments, upper 120 can comprise a fabric layer 174 disposed on the outer surface and/or the inner surface of thread pattern 122. As used herein, the term “outer surface” or “outer side” refers to the surface of a component that faces away from the foot when worn by a wearer. And “inner surface” or “inner side” refers to the surface of a component that faces toward the foot when worn by a wearer.

In some embodiments, fabric layer 174 can be a woven, non-woven, or knitted polymeric layer. In some embodiments, fabric layer 174 can be a woven, non-woven, or layer composed of thermoplastic polyurethane (TPU), polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU) foam, and co-polymers or polymer blends comprising one or more these polymers. In some embodiments, fabric layer 174 can be a bioengineered woven, knitted or layered synthetic spider silk, woven, knitted or layered plant based materials, or woven, knit or layered recycled and/or extruded plastics. In some embodiments, fabric layer 174 can be film or sheet of a polymeric material, such as thermoplastic polyurethane (TPU), polyester, polyamide, polyethylene (PE), PE foam, polyurethane (PU) foam, and co-polymers or polymer blends comprising one or more these polymers. In some embodiments, fabric layer 174 can be a woven, non-woven, or knitted layer for providing cushion and/or thermal insulation for article of footwear 100. In some embodiments, fabric layer 174 can be a sock bootie. In some embodiments, fabric layer 174 can be a discontinuous layer formed of individual spaced-apart fabric elements.

In some embodiments, sole 180 can comprise traction elements, such as tread patterns. In some embodiments, sole 180 can comprise a midsole. In some embodiments, sole 180 can comprise an outsole coupled to a midsole. Sole 180 and portions thereof can comprise material(s) for providing desired cushioning, ride, and stability. Suitable materials for sole 180 include, but are not limited to, a foam, a rubber, ethyl vinyl acetate (EVA), expanded thermoplastic polyurethane (eTPU), expandable polyether block amide (ePEBA), thermoplastic rubber (TPR) and a thermoplastic polyurethane (TPU). In some embodiments, the foam can comprise, for example, an EVA-based foam or a PU-based foam and the foam can be an open-cell foam or a closed-cell foam. In some embodiments, the midsole and/or outsole can comprise elastomers, thermoplastic elastomers (TPE), foam-like plastics, and gel-like plastics.

As shown in FIGS. 1A and 1B, upper 120 can comprise a thread pattern 122. All or a portion of upper 120 can comprise thread pattern 122. As described herein, thread pattern 122 comprises a plurality of thread layers coupled together to define at least a portion of upper 120.

In some embodiments, thread pattern 122 can comprise a plurality of anchor points 134 and a continuous thread 130 fixed at a plurality of anchor points 134. In some embodiments, anchor points 134 can be disposed along a perimeter of upper 120 (for example, in perimeter portion 162). Such anchor points 134 can be referred to as “peripheral anchor points.” However, thread pattern 122 need not comprise anchor points 134, for example, in the case of thread pattern 122 having been cut to remove anchor points 134 before thread pattern 122 is attached to other components of upper 120. In such embodiments, continuous thread 130 is cut into multiple segments that each form a thread line 132 extending between points where thread pattern 122 was cut.

As used herein, “thread” means a material having a length that is substantially larger than its width. A “thread” can be a filament, a fiber, a yarn, a cable, a cord, a fiber tow, a tape, a ribbon, a monofilament, a braid, a string, a plied thread, and other forms of materials which can be spooled and laid down in a thread layer or thread pattern as described herein.

As used herein, “anchor point” means a location to which a thread or group of thread lines is fixedly attached. A thread or thread line can be wrapped, wound, bonded, or otherwise attached at an anchor point. In some embodiments, an anchor point can be a location on an article of footwear. For example, an anchor point can be a hole or opening left behind by a structure (for example, pin, projection, or nub) used to wind continuous thread(s) of a thread layer and/or thread pattern. In some embodiments, a thread layer or thread pattern for an article of footwear does not comprise any anchor point locations because all the anchor point locations present during winding of the thread layer or thread pattern have been removed (for example, cut off). An anchor point can be a structure (for example, pin, projection, or nub) used to wind continuous thread(s) of a thread layer and/or thread pattern. And the anchor point structure can or may not form a portion of a thread layer or thread pattern for an article of footwear.

A continuous thread wrapped or wound around an anchor point need not be wrapped or wound completely (i.e., 360 degrees) around the anchor point. A continuous thread wrapped or wound around an anchor point can be wrapped or wound around only a portion of the anchor point. For example, a continuous thread wrapped or wound around an anchor point can be wrapped or wound around 25% (90 degrees) of an anchor point's perimeter, 50% (180 degrees) of an anchor point's perimeter, 75% (270 degrees) of an anchor point's perimeter, or 100% (360 degrees) of an anchor point's perimeter. In some embodiments, a continuous thread can be wrapped or wound around an anchor point's perimeter more than once before being threaded to the next anchor point. For example, a continuous thread can be wrapped or wound around an anchor point's perimeter one and a half times (540 degrees) or twice (720 degrees) before being threaded to the next anchor point.

Continuous thread 130 can be wrapped around a plurality of anchor points 134 and can comprise a plurality of thread lines 132. In some embodiments, each thread line 132 can extend between two respective anchor points 134. In some embodiments, each thread line 132 can extend between points where thread pattern 122 was cut, but not between two respective anchor points (which have been removed). In some embodiments, one or more of thread lines 132 can extend between an anchor point 134 and a point where thread pattern 122 was cut.

In some embodiments, thread lines 132 can be bonded at points where two or more thread lines 132 overlap in a thread layer (i.e., intersection points 136). In some embodiments, upper 120, and thread pattern 122, can comprise more than one continuous thread. For example, as shown in FIGS. 1A and 1B, thread pattern 122 can comprise a second continuous thread 170. Second continuous thread 170 can have the same or different characteristics as first continuous thread 130. And second continuous thread 170 can be incorporated into thread pattern 122 in the same manner as first continuous thread 130.

While FIGS. 1A and 1B show thread pattern 122 comprising two continuous threads (130 and 170), article of footwear 100 can comprise a thread pattern 122 with any suitable number of continuous threads, such as for example, one, three or more, four or more, five or more, six or more, seven or more, eight or more, nine or more, ten or more, fifteen or more, or twenty or more. Additional continuous threads can be the same as or different from continuous threads 130 and 170. And additional continuous threads can be incorporated into thread pattern 122 in the same manner as continuous threads 130 and 170. In some embodiments, additional continuous threads can be wound around and extended between anchor points 134 in the same fashion as continuous threads 130 and 170.

In some embodiments, each wound continuous thread can define a thread layer of thread pattern 122. For example, a thread layer defined by wound continuous thread 130 can define a first thread layer of thread pattern 122 and a thread layer defined by wound continuous thread 170 can define a second thread layer of thread pattern 122. And different thread layers of a thread pattern can be disposed over each other in areas of overlap between the two thread layers. For example, a first thread layer defined by continuous thread 130 can be disposed over a second thread layer defined by continuous thread 170, or vice versa, in areas of overlap between the two thread layers. Different thread layers defined by different continuous wound threads can provide different characteristics to different areas of upper 120. Thread layers in a thread pattern can define a stack of thread layers for the thread pattern, with one or more layers occupying a respective layer in the stack.

However, a thread layer need not be defined by a single continuous thread. That said, a thread layer a described herein is defined by a single thread type. A thread type can be defined by thread characteristics comprising thread denier (in an unwound or wound state), thread material, ply number (single- or multi-ply, and number of ply), and tensile stiffness (in an unwound or wound state). If any one of these characteristics is different between two threads, the two threads are a different type. If all of these characteristics are the same between two threads, the two threads are the same type. In some embodiments, a group of thread lines of a particular type can define a thread layer of thread pattern 122. For example, thread lines 132 of a particular thread type can make up a first thread layer of thread pattern 122, while thread lines 172 of a different thread type can make up a second thread layer of thread pattern 122. Accordingly, no matter how thread lines are formed on an article of footwear (for example, by an uncut continuous thread, cut continuous thread, or thread segments that were never a continuous thread), a thread layer can be defined by thread type. Thread lines that are of the same thread type can define a thread layer even if they were originally formed by multiple continuous threads. Additionally, thread lines that are of the same thread type can define a single thread layer even if they are separated by other intermediate thread layer(s).

Winding a thread under tension, thus stretching the thread, changes the thread denier and tensile stiffness of the thread. For example, when a thread is stretched, its denier (mass density) may decrease and its tensile stiffness may increase since it becomes increasingly difficult to stretch a thread that is already stretched under tension. Two threads are a different type when any one of the above characteristics of the two threads differ when the threads are compared in an unwound state (e.g., before tension is applied) or in a wound state (e.g., on a shoe).

In some embodiments, the thread denier for a thread type can range from 1 denier to 3000 denier, including subranges. For example, the thread denier for a thread type can range from 1 denier to 3000 denier, 10 denier to 2500 denier, 50 denier to 2000 denier, 100 denier to 1900 denier, 200 denier to 1800 denier, 300 denier to 1700 denier, 400 denier to 1600 denier, 500 denier to 1500 denier, 600 denier to 1400 denier, 700 denier to 1300 denier, 800 denier to 1200 denier, 900 denier to 1100 denier, or 900 denier to 1000 denier. In some embodiments, the first denier of a first thread type can be at least 10% greater than or at least 10% less than the second denier of a second thread type. Any two thread types can have a denier value at least 10% greater than or at least 10% less than the each other.

In some embodiments, the thread material for a thread type can be selected from the group consisting of: textile type, a polymer type, a monofilament type, and a coated thread type comprising a core coated with a sheath. In embodiments where the thread type is a monofilament type, the thread material can comprise the polymer type for the monofilament. In embodiments where the thread type is a coated thread, the thread material can comprise the material of the core (for example, a textile type of the core or the polymer type of the core) and the material of the sheath (for example, the polymer type of the sheath). Suitable polymer types for the sheath and core include those described herein. Suitable textile types include the core materials described herein, for example, polyester, nylon, and cotton.

The ply number for a thread type can be single ply or multi-ply, for example two-ply, three-ply, four-ply, or five-ply. In embodiments where the thread type comprises multiple plies, the plies can be, for example, parallel plies, twisted plies, or braided plies.

In some embodiments, the tensile stiffness for a thread type can range from 0.01 N/mm (Newtons per millimeter) to 5 N/mm, including subranges. For example, the tensile stiffness for a thread type can range from 0.01 N/mm to 5 N/mm, 0.01 N/mm to 2.5 N/mm, 0.01 N/mm to 2 N/mm, 0.01 N/mm to 1 N/mm, 0.01 N/mm to 0.5 N/mm, 0.02 N/mm to 5 N/mm, 0.1 N/mm to 5 N/mm, 0.5 N/mm to 5 N/mm, 1 N/mm to 5 N/mm, 2 N/mm to 5 N/mm, or 2.5 N/mm to 5 N/mm. In some embodiments, the first tensile stiffness of a first thread type can be at least 10% greater than or at least 10% less than the second tensile stiffness of a second thread type. Any two thread types can have a tensile stiffness at least 10% greater than or at least 10% less than the each other. In some embodiments, these tensile stiffness values and percentage differences can be for thread types in an unwound state. In some embodiments, these tensile stiffness values and percentage differences can be for thread types in a wound state.

In some embodiments, a first thread type can be a “stiff” thread type having a tensile stiffness above 0.5 N/mm and a second thread type can be a “stretch” thread type having a tensile stiffness ranging from 0.01 N/mm to 0.5 N/mm. As an example, a “stiff” thread type can have a tensile stiffness ranging from 0.5 N/mm to 5 N/mm. Unless specified otherwise, the tensile stiffness of a thread type is measured according to the following method. A first clamp is fixedly attached to a first end of a segment of a thread having a gauge length, and a second clamp is fixedly attached to a second end of the segment. Then a tensile force is applied across the segment using an INSTRON® machine to stretch the segment through a first displacement (in mm) at 7% strain to a second displacement (in mm) at 17% strain. A second load (in Newtons) at the second displacement and a first load at the first displacement (in mm) are measured. The first load is subtracted from the second load (result 1), and the first displacement is subtracted from the second displacement (result 2). Result 1 is divided by result 2 to yield the tensile stiffness in Newtons/millimeter (N/mm). This method can be implemented for any thread segment (for example, a thread line) by applying the following formula:

Tensile stiffness=(Load @ d2−Load @ d1)/(d2−d1), provided that the strain at d1 and d2 (the first and second displacements, respectively) remain the same with respect to a gauge length of the thread segment as noted above (7% and 17%, respectively). Stretching of the thread segment to the first and second displacements is conducted at a suitable constant rate of extension, for example, 300 mm/min.

The tensile stiffness of a thread changes as it is stretched. For example, depending on the material, the tensile stiffness generally increases up to a point of plastic deformation, from which point it may decrease. Accordingly, in the specific case of determining whether a thread segment (for example, a thread line) is of a “stretch” thread type or a “stiff” thread type, the determination is made in an unwound state. That is, if the above test is used to determine “stiff” or “stretch” type, it is performed on a segment of thread that is initially under no tension (apart from that due to gravity) before it is stretched to the first and second displacements. Winding a thread as disclosed herein can be performed under tension and the thread can stretch, increasing tensile stiffness in a wound state as compared to the unwound state. Therefore, a tensile stiffness test such as the one outlined above can yield different results for a thread segment in a wound state vs. an unwound state, even if the thread segment is the same material in both cases. For testing tensile stiffness of a thread segment in a wound state, the gauge length is the initial length of the stretched thread segment in its wound state. It should be noted that when discussing “tensile stiffness” of a single thread segment, tensile stiffness along a direction parallel to the lengthwise axis of the thread segment is meant.

In some embodiments, a “stiff” thread type can comprise a multi-ply thread.

FIGS. 2A-2C show various thread layers which can be comprised by, for example, article of footwear 100. Thread layers as described herein (for example, thread layers 200, 220, and 240) can each comprise a thread border 250 defined by the space in which thread lines of the thread layer are located. The thread border 250 for a thread layer is the space in which thread lines of the thread layer are located after the thread layer is removed (for example, cut) from anchor points used to wind the thread layer. A plurality of thread lines within a thread layer or thread pattern can comprise a first end located at a first side of the thread border 250 and a second end located at a second side of the thread border 250. For example, thread lines 204 of thread layer 200 can comprise a first end 210 located at a first side of thread border 250 and a second end 212 located at a second side of thread border 250.

FIGS. 2A-2C illustrate thread borders 250a-c for thread layers 200, 220, and 240. For a thread pattern comprising a plurality of thread layers, the thread pattern can comprise a thread pattern border 250 defined by the space occupied by the combination of the individual thread layers. For example, a thread pattern comprising thread layers 200, 220, and 240 comprises a thread pattern border defined by the space occupied by the combination of border 250a and border 250c. Border 250b is wholly contained within border 250a. A thread border 250 can define the perimeter edge of a thread layer. Similarly, the combination of two or more thread borders 250 can define the perimeter edge of a thread pattern. A perimeter edge of a thread pattern as described herein can be defined by cutting the combination of thread layers that comprises the thread pattern, for example, after bonding the combination of thread layers to one another.

As used herein, sides of a perimeter edge or a border refer to top, bottom, right, and left sides of a shape defined by the edge or border. The top, bottom, right, and left sides of the shape are located to the top, bottom, right, and left of a geometrical center of the shape. So, a perimeter edge or border will have a top side defined by the portion of the edge located above the geometrical center, a bottom side defined by the portion of the edge located below the geometrical center, a right side defined by the portion of the edge or border located to the right of the geometrical center, and a left side defined by the portion of the edge or border located to the left of the geometrical center. The top and bottom sides do not overlap. Similarly, the left and right sides do not overlap. The top and left sides overlap at the portion of the edge or border located to the top-left of the geometrical center. The top and right sides overlap at the portion of the edge or border located to the top-right of the geometrical center. The bottom and left sides overlap at the portion of the edge or border located to the bottom-left of the geometrical center. The bottom and right sides overlap at the portion of the edge or border located to the bottom-right of the geometrical center. For purposes of determining the shape defined by the perimeter edge or border, the material having the edge or border is laid in a flat configuration with no portion of the material overlapping itself.

As used herein, a first side of a perimeter edge or border can be the top, bottom, right, or left side of the edge or border and a second side of the perimeter edge can be the top, bottom, right, or left side of the edge or border, provided that the first and second sides are not the same side. Similarly, a third side of a perimeter edge or border can be the top, bottom, right, or left side of the edge or border and a fourth side of the edge or border can be the top, bottom, right, or left side of the edge or border, provided that the third and fourth sides are not the same, and are not the same as the first or second sides.

In some embodiments, one or more thread layers (for example, thread layers 200, 220, and 240) can comprise a thread defining (i) a plurality of thread lines each extending from a first side of a thread border to a second side of the thread border and crossing over each other at points of overlap between two or more of the thread lines, and (ii) a plurality of thread lines each extending from a third side of the thread border to a fourth side of the thread border and crossing over each other at points of overlap between two or more of the thread lines. The thread lines extending from the first side to the second side can extend continuously from the first side to the second side, and the thread lines extending from the third side to the fourth side can extend continuously from the third side to the fourth side.

Thread layer 200 comprises a continuous thread 202 wound around anchor points 290. Thread layer 220 comprises a continuous thread 222 wound around anchor points 290. Thread layer 240 comprises a continuous thread 242 wound around anchor points 290. In some embodiments, anchor points 290 can be different sets of anchor points around which different thread layers are wound. In some embodiments, a plurality of thread layers can wound around the same set of anchor points 290. In such embodiments, separate thread layers can be wound over each other, with one thread layer disposed over one or more other thread layers.

Continuous thread 202 can be wrapped around a plurality of anchor points 290 and comprises a plurality of thread lines 204. Each thread line 204 extends between two respective anchor points 290.

Continuous thread 202 can be wrapped around a plurality of anchor points 290 in tension such that individual thread lines 204 are in tension when wrapped around anchor points 290. In some embodiments, the tension at which thread lines 204 are wound can range from 0 centinewtons (cN) to 25 cN, including subranges. For example, in some embodiments, the tension at which thread lines 204 are wound can range from 0.01 cN to 25 cN, from 0.1 cN to 25 cN, from 1 cN to 25 cN, from 5 cN to 25 cN, from 10 cN to 25 cN, or from 15 cN to 25 cN. In some embodiments, the tension at which thread lines 204 are wound can range from 2 cN to 10 cN. In some embodiments, the tension at which thread lines 204 are wound can range from 2 cN to 6 cN. In some embodiments, the tension at which thread lines 204 are wound can range from 4 cN to 8 cN. In some embodiments, the tension at which thread lines of a first thread type are wound can be at least 10% greater than or at least 10% less than the tension at which thread lines of a second thread type are wound. Thread lines of any two thread types can be wound at a thread tension at least 10% greater than or at least 10% less than each other.

The number of thread lines 204 for thread layer 200 fixed at an anchor point 290 is defined by the “thread line communication number” of an anchor point 290. As used herein, “thread line communication number” means the number of thread lines extending from an anchor point to different anchor points. Two thread lines extending between the same two anchor points (i.e., overlaying thread lines) only counts as “1” for purposes of calculating a thread line communication number for the anchor points. For example, a thread line communication number of five means that an anchor point has five thread lines extending from it with each of the five thread lines leading to another, different anchor point. As another example, a thread line communication number of six means that an anchor point has six thread lines extending from it with each of the six thread lines leading to another, different anchor point.

Similarly, the number of thread lines fixed at an anchor point 290 for a thread pattern comprising a plurality of thread layers is defined by the “thread line communication number” of an anchor point 290 for the thread pattern. For a thread pattern, the “thread line communication number” of an anchor point 290 is the total number of thread lines, for the plurality of layers, extending from an anchor point to different anchor points.

Anchor points 290 can have a thread line communication number of “X” or more for a thread layer or a thread pattern. In some embodiments, two or more respective anchor points 290 can have a thread line communication number of “X” or more. In some embodiments, all the anchor points 290 for a thread layer or a thread pattern can have a thread line communication number of “X” or more. “X” can be, for example, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50, within a range having any two of these values as end points. For example, in some embodiments “X” can be in a range of 2 to 50, 3 to 50, 4 to 50, 5 to 50, 6 to 50, 7 to 50, 8 to 50, 9 to 50, 10 to 50, 15 to 50, 20 to 50, 25 to 50, 30 to 50, 35 to 50, 40 to 50, or 45 to 50. In some embodiments, “X” can be greater than 50. In some embodiments, “X” can range from 2 to 100, 10 to 100, 20 to 100, 10 to 200, 20 to 200, 50 to 200, 10 to 300, 20 to 300, or 50 to 300.

A thread layer, for example thread layer 200, can comprise any suitable number of thread lines. In some embodiments, a thread layer can comprise 10 or more thread lines. In some embodiments, a thread layer can comprise 20 or more thread lines. In some embodiments, a thread layer can comprise 50 or more thread lines. In some embodiments, a thread layer can comprise 100 or more thread lines. In some embodiments, a thread layer can comprise 200 or more thread lines. In some embodiments, a thread layer can comprise 300 or more thread lines. In some embodiments, a thread layer can comprise 500 or more thread lines. In some embodiments, a thread layer can comprise a number of thread lines in a range of 10 to 300. For example, a thread layer can comprise 10 to 300, 50 to 300, 100 to 300, or 150 to 300 thread lines. In some embodiments, a thread layer can comprise 10 to 500 thread lines. In some embodiments, a thread layer can comprise 100 to 500 thread lines. In some embodiments, a thread layer can comprise 100 to 1000 thread lines.

In some embodiments, thread lines 204 can be bonded at anchor points 290. In such embodiments, thread lines 204 can be bonded at anchor points 290 via an adhesive, a bonding layer, thermal (conductive or convective) heat (for example, in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, a mechanical fastener (for example, a clip), hook and loop fasters, needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement, felting, knotting, chemical bonding with a catalyst of biomaterial, adhesive spraying (for example, CNC adhesive spray deposition), or by pushing one thread line through the other thread line(s).

In some embodiments, thread lines 204 can be directly bonded together at anchor points 290. In some embodiments, thread lines 204 can be directly bonded together at anchor points 290 via a polymeric material of continuous thread 202. For example, heat and/or pressure can be applied to directly bond thread lines 204 at anchor points 290. In embodiments where heat and/or pressure is utilized to directly bond the polymeric material of thread lines 204, the thread lines 204 can be thermally fused together at one or more anchor points 290. In embodiments comprising direct bonding of thread lines 204 at anchor points 290, thread lines 204 can be directly bonded at anchor points 290 without the use of an adhesive or bonding layer.

In some embodiments, thread lines 204 can be bonded together via a bonding layer. In some embodiments, thread lines 204 can be bonded together at anchor points 290 via a bonding layer. In such embodiments, the bonding layer can be, for example, a laminated layer, an adhesive layer, a stitched layer, a cured layer, a screen-printed layer, or a blown fiber layer. In some embodiments, the blown fiber layer can comprise polymeric fibers that can bond thread lines 204.

In some embodiments, thread lines 204 can be bonded together without the use of a bonding layer. For example, in some embodiments, thread lines 204 can be directly bonded together via, for example, but not limited to, direct local bonding via material(s) of thread lines 204, needle punching, hydro-entanglement, and ultrasonic/vibratory entanglement.

In some embodiments, thread lines 204 can be bonded at points where two or [0125] more thread lines 204 overlap in thread layer 200 (i.e., intersection points 206). Thread lines 204 can be bonded at intersection points 206 via an adhesive, a bonding layer, thermal (conductive or convective) heat (for example, in a heat press or oven), IR (infrared) heating, laser heating, microwave heating, steam, a mechanical fastener (for example, a clip), hook and loop fasters, needle-punching, hydro-entanglement, ultrasonic/vibratory entanglement, felting, knotting, chemical bonding with a catalyst of biomaterial, adhesive spraying (for example, CNC adhesive spray deposition), or by pushing one thread line through the other thread line(s). Intersection points 206 for thread lines can be referred to as “overlap points” or “points of overlap.”

In some embodiments, thread lines 204 can be directly bonded together at intersection points 206. In some embodiments, thread lines 204 can be directly bonded together at intersection points 206 via the polymeric material of continuous thread 202. In embodiments comprising direct bonding of thread lines 204 at intersection points 206, thread lines 204 can be bonded at intersection points 206 without the use of an adhesive or bonding layer. For example, heat and/or pressure can be applied to thread layer 200 to directly bond thread lines 204 at intersection points 206. In embodiments where heat and/or pressure is utilized to directly bond the polymeric material of thread lines 204, the thread lines 204 can be thermally fused together at one or more intersection points 206.

In some embodiments, a bonding layer can bond thread lines 204 together at a plurality of intersection points 206 within thread layer 200. In such embodiments, the bonding layer can be, for example, a laminated layer, an adhesive layer, a stitched layer, a cured layer, a screen-printed layer, or a blown fiber layer comprising polymeric fibers that can bond thread lines 204.

In some embodiments, thread lines 204 can be bonded together according to any of the bonding methods disclosed in U.S. application Ser. No. 18/640,605, filed Apr. 19, 2024 and titled “Articles of Apparel Comprising Composite Wound Component and Methods of Making the Same,” the disclosure of which is incorporated herein by reference in its entirety.

In some embodiments, bonding of continuous thread(s) for a thread layer or thread pattern can set the thread layer or thread pattern such that the thread layer or thread pattern forms a portion of an article of footwear. In some embodiments, bonding of continuous thread(s) for a thread layer or thread pattern can set the thread layer or thread pattern so that the thread layer or thread pattern can be shaped into a structure that forms a portion of an upper for an article of footwear. In some embodiments, after bonding of continuous thread(s) for a thread layer or thread pattern, the thread layer or thread pattern can be cut to define a shape utilized to form a portion of an upper for an article of footwear. For example, in some embodiments, a thread layer or thread pattern can be cut to define a perimeter shape for a portion of an upper for an article of footwear. As another example, in some embodiments, a thread layer or thread pattern can be cut to define a shape for at least one of a biteline, a collar, or a throat of an upper for an article of footwear.

In some embodiments, continuous thread 202 can comprise overlaying thread lines 204. As used herein, “overlaying thread lines” means two or more thread lines that follow the same path between two respective anchor points. Overlaying thread lines need not be overlaid directly over each other. Two or more thread lines are considered overlaying as long as they extend between the same two anchor points.

In some embodiments, the thread lines 204 of thread layer 200 are not woven, knitted, or braided together. In such embodiments, thread lines 204 can be referred to as “non-woven,” “non-knitted,” and “non-braided” thread lines. Additionally or alternatively, in some embodiments, the thread lines 204 of thread layer 200 are not be embroidered threads stitched to a base layer. In such embodiments, thread lines 204 can be referred to as “non-embroidered” thread lines.

Each thread layer 200, 220, 240 (or a thread pattern) can be defined by one or more threads comprising a plurality of thread lines crossing over each other at points of overlap between two or more of the thread lines. Each thread line of a thread layer can extend continuously across the thread layer (or thread pattern) (for example, between one side of a thread border 250 and another side of the thread border 250). Thread lines extending continuously across the thread layer (or thread pattern) are not woven, knitted, or braided threads. Similarly, thread lines extending continuously across the thread layer (or thread pattern) are not embroidered threads stitched to a base layer. Rather, the thread lines, and therefore the thread layer(s), are formed by winding thread around anchor points as described herein.

In some embodiments, thread lines extending continuously across the thread layer (or thread pattern) can extend continuously without forming a knitted structure, a woven structure, or a braided structure between opposing ends of the thread lines. In some embodiments, thread lines extending continuously across the thread layer (or thread pattern) can extend continuously without forming a knitted structure, a woven structure, or a braided structure along a distance greater than or equal to at least 90% of the length of the thread lines measured between opposing ends of the thread lines. In some embodiments, thread lines extending continuously across the thread layer (or thread pattern) can extend continuously without forming an embroidered structure between opposing ends of the thread lines. In some embodiments, thread lines extending continuously across the thread layer (or thread pattern) can extend continuously without forming an embroidered structure along a distance greater than or equal to at least 90% of the length of the thread lines measured between opposing ends of the thread lines.

In some embodiments, continuous thread 202 can be a polymer thread. In some embodiments, a polymer thread can be composed entirely of one or more polymeric materials. In some embodiments, a polymer thread can comprise a polymeric material coated around a core (which can or may not be composed of a polymeric material), or a polymeric core coated by another material (which can or may not be a polymeric material). In such embodiments, the core can be encapsulated by the coating material. In some embodiments, a polymer thread can comprise a non-polymer core coated, covered, or encapsulated with a polymeric material. In some embodiments, a polymer thread can comprise a polymer core coated, covered, or encapsulated with a non-polymeric material. In some embodiments, a polymer thread can be a braided thread with one or more braids composed of a polymeric material. In some embodiments, the polymeric material(s) of a polymer thread can be thermoplastic material(s).

Suitable polymeric materials for polymer threads discussed herein comprise, but are not limited to, ELASTANE® (a polyether-polyurea copolymer), thermoplastic polyurethane (TPU), a rubber, and silicone. In some embodiments, the TPU can be recycled TPU. In some embodiments, the polymeric material can be a photo-reactive (infrared or ultraviolet light reactive) polymeric material, such as a photo-reactive TPU. In some embodiments, the polymeric material can be soluble (for example, water-soluble). In embodiments comprising polymer threads with a coated core, suitable materials for the core comprise, but are not limited to, TPU, ELASTANE®, polyester, nylon, ultra-high molecular weight polyethylene (for example, DYNEEMA® (a type of ultra-high molecular weight polyethylene)), carbon fiber, KEVLAR® (a type of para-aramid), bioengineered woven, knit or layered materials (for example, synthetic spider silk), woven, knit or layered plant based materials, cotton, wool, natural or artificial silk, and blends of one or more of these materials. In some embodiments, polymer threads can be thermoplastic polyurethane coated polyester threads. In some embodiments, continuous thread 202 can be a non-polymer thread composed of non-polymer materials, such as carbon fiber, cotton, wool, or silk. In some embodiments, continuous thread 202 can be a thread composed of a biomaterial, such as mango yarn or bio-silk. In some embodiments, polymer threads can be a thermoplastic melt yarn, polymer yarn with non-melt core, and other similar types of yarn.

In some embodiments, the polymeric material for polymer threads can comprise a melting temperature in a range of greater than or equal to 110° C. to less than or equal to 150° C. In such embodiments, the polymeric material can be referred to as a “low melting temperature polymeric material.”

In some embodiments, continuous thread 202 can be a plied thread. In some embodiments, the plied thread can be plied while winding thread 202.

Thread patterns as described herein can comprise any number of thread layers. For example, a thread pattern can comprise two or more, three or more, four or more, five or more, six or more, seven or more, eight or more, nine or more, ten or more, fifteen or more, or twenty or more thread layers. For example, a thread pattern can comprise thread layer 200, thread layer 220, thread layer 240, thread layer 500, thread layer 600, thread layer 700, thread layer 720, thread layer 740, thread layer 800, thread layer 900, thread layer 1000, thread layer 1100, thread layer 1200, thread layer 1220, thread layer 1300, thread layer 1400, thread layer 2100, and a combination of two or more of these thread layers.

Continuous threads of any thread layer (for example, thread layers 220 and 240) can be wound around and extended between anchor points 290 in the same fashion as described above for continuous thread 202. Further, thread lines of the continuous threads of any thread layer (for example, thread layers 220 and 240) can be bonded in the same manner as described above for thread layer 200.

Like continuous thread 202, continuous threads for other thread layers (for example, threads 222 and 242) can comprise a plurality of thread lines (for example, thread lines 224 and 244) extending between two respective anchor points. While FIGS. 2A-2C show thread layers each comprising a single continuous thread, in some embodiments, thread layers 200, 220, and/or 240 can comprise multiple continuous threads of the same thread type.

In embodiments comprising a thread pattern with a plurality of thread layers, the plurality of thread layers can be layered over each other. For example, thread layer 200 can define a first layer of a thread pattern and a second thread layer 220 can define a second layer of the thread pattern. Different thread layers of a thread pattern can be disposed over each other in areas of overlap between the two thread layers. For example, a first thread layer 200 can be disposed over second thread layer 220, or vice versa, in areas of overlap between the two thread layers.

In embodiments comprising a thread pattern with a plurality of thread layers, the plurality of thread layers can be bonded to each other in the thread pattern. In some embodiments, one or more of the layers can be directly bonded to each other via the polymeric material of a continuous thread defining thread lines for at least one of the layers. In some embodiments, one or more of the layers can be bonded via a bonding layer. In such embodiments, the bonding layer can be, for example, a laminated layer, an adhesive layer, a stitched layer, a cured layer, a screen-printed layer, or a blown fiber layer. In some embodiments, the bonding layer can be a non-woven bonding layer.

In some embodiments, one or more thread layers of a thread pattern can serve to bond other thread layers of the thread pattern together. In such embodiments, these one or more thread layers can be wound using a polymeric thread, which when heated, bonds other layers of the thread pattern together at anchor points and/or intersection points between thread lines. For example, in a thread pattern comprising three thread layers, one of the three thread layers (for example, the middle thread layer) can be a wound using a polymeric thread that serves to bond all three thread layers together. In some embodiments, one or more thread layers of a thread pattern can be defined by one or more wound continuous threads coated or impregnated with an adhesive. In some embodiments, the adhesive can be activated with the application of heat. In some embodiments, the adhesive can be a dissolvable adhesive that, when contacted with a solvent, such as water, fully or partially dissolves to bond thread layers together.

The thread layers described herein, for example, thread layers 500, 600, 700, 720, 740, 800, 900, 1000, 1100, 1200, 1220, 1300, 1400, and/or 2100, can be formed, layered, and/or bonded in the same fashion, and can comprise the same or similar characteristics, as described above for thread layers 200, 220, and 240.

FIG. 3 illustrates a thread pattern 300 which can be comprised by, for example, article of footwear 100. Thread pattern 300 can comprise multiple thread layers, for example, first thread layer 310, second thread layer 320, and third thread layer 330. Like thread layers 200, 220, and 240, thread layers 310, 320, 330 can each comprise thread lines extending between anchor points 290 or points on a thread border. In some embodiments, thread lines of first thread layer 310, second thread layer 320, and third thread layer 330 can comprise different thread types, depending on the thread layer. In some embodiments, thread lines of first thread layer 310, second thread layer 320, and third thread layer 330 can comprise different materials, depending on the thread layer.

In some embodiments, first thread layer 310, second thread layer 320, and third thread layer 330 can be wound sequentially. For example, first thread layer 310 can be wound around anchor points 290 first, followed by second thread layer 320 being wound around anchor points 290, and then third thread layer 330 being wound around anchor points 290. While FIG. 3 shows three thread layers 310, 320, 330, thread pattern 300 can comprise any number of thread layers, such as two, four, five, six, seven, eight, nine, ten, eleven, or twelve thread layers. For example, thread pattern 300 or thread pattern 1520 can comprise two or more of, three or more of, four or more of, or five or more of thread layers 500, 600, 700, 720, 740, 800, 900, 1000, 1100, 1200, 1220, 1300, 1400, and 2100.

As shown in FIG. 3, thread pattern 300, and any thread pattern described herein, can have an anterior-posterior (AP) axis extending along the thread pattern. The AP axis is an axis aligned with the length of article of footwear 100 on which the thread pattern is intended to be coupled and bisects the lateral and medial sides of footwear 100. Thread pattern 300 can also have a medial-lateral (ML) axis. The ML axis extends perpendicularly to the AP axis at all points of the ML axis.

Thread pattern 300 can comprise different regions, numbered 1-5 in FIG. 3. These regions can serve as test points for tensile stiffness along different directions. For example, tensile stiffness of thread pattern 300 along an AP direction can be tested at any one of regions 1-5. Likewise, tensile stiffness of thread pattern 300 along an ML direction can be tested at any one of regions 1-5. As used herein with reference to a region of a thread pattern, the term “AP direction” refers to a direction along the thread pattern at the region that is more aligned (i.e., closer to parallel) with the AP axis than with the ML axis of the thread pattern. As used herein with reference to a region of a thread pattern, the term “ML direction” refers to a direction along the thread pattern at the region that is more aligned (i.e., closer to parallel) with the ML axis than with the AP axis of the thread pattern. As an example, an AP direction can extend at an angle less than 45 degrees with respect to the AP axis. Likewise, as an example, an ML direction can extend at an angle less than 45 degrees with respect to the ML axis. A non-limiting example of a more specific AP or ML direction as disclosed herein can include a direction substantially parallel to the AP or ML axis, respectively. As used herein, a direction that is “substantially” parallel to an axis or “substantially” along an axis means the direction extends at an angle less than or equal to 10 degrees with respect to the axis. Tensile stiffness testing will be discussed in more detail with respect to FIGS. 16-19.

While FIG. 3 shows thread pattern 300 comprising the anchor points 290 used to wind thread pattern 300, thread pattern 300 can be a reduced version of that shown in FIG. 3. That is, thread pattern 300 can be a portion of that shown in FIG. 3 that has been cut to a particular shape for integration with a shoe upper.

FIG. 4 shows a CNC machine 400 for winding continuous threads according to some embodiments. In some embodiments, CNC machine 400 can comprise a robotic arm 405 for winding a thread layer 420 comprising thread lines 422 around anchor points 290, which can be projections (for example, pins) coupled to or integrally formed with support plate 402. Thread layer 420 in FIG. 4 is a representative exemplary thread layer. CNC machine 400 can also be used to wind a thread pattern comprising a plurality of thread layers.

Robotic arm 405 can comprise a thread spool 410 for threading and winding thread lines 422 of thread layer 420 around anchor points 290. In some embodiments, CNC machine 400 can comprise a thread tensioner 412 configured to apply a desired tension to thread(s) that are wound around anchor points 290. CNC machine 400 can comprise a controller 415 configured to wind a desired thread layer 420 around anchor points 290 using a thread model and input data. In some embodiments, controller 415 can control tensioner 412 to wind thread(s) at desired tensions. Controller 415 can comprise components of computer system 2300 discussed herein.

In some embodiments, CNC machine 400 can comprise a winding assembly comprising a plurality of thread spools 410 for threading and winding a plurality of different threads for a thread pattern. In some embodiments, the winding assembly can comprise a plurality of tensioners 412 configured to apply a desired tension to threads from different thread spools 410. In some embodiments, CNC machine 400 with the winding assembly can wind a plurality of threads from a plurality of thread spools 410 simultaneously when winding a thread pattern. In some embodiments, the winding assembly can be used to simultaneously wind “overlaying thread lines” from a plurality of thread spools 410.

In some embodiments, CNC machine 400 can comprise two or more robotic arms 405 for winding a plurality of threads simultaneously. In such embodiments, the two or more robotic arms 405 can wind different threads in different regions of a thread pattern simultaneously.

In some embodiments, the input to controller 415 can comprise one or more files specifying a winding pattern of thread layer 420. In some embodiments, the one or more files can comprise a file describing the positions of anchor points 290 in two dimensions (2D) or three dimensions (3D), depending on the structure of support plate 402. In such embodiments, each of anchor points 290 can be associated with a unique identifier (e.g., a number or alphanumeric code) that is specified in the file. In some embodiments, the one or more files can be JSON files, but the one or more files are not limited to a particular format. In some embodiments, one or more processors of or in communication with controller 415 (for example, processor device 2304) can interpret the contents of the one or more files into CNC G-code commands that control the movement of robotic arm(s) 405. In some embodiments, the contents of the one or more files can also comprise instructions to change a continuous thread to another continuous thread, for example, to transition between winding a first thread layer and winding a second thread layer. In some embodiments, the contents of the one or more files can also comprise instructions to control tensioner(s) 412 to wind thread(s) at desired tension(s).

In some embodiments, tensioner 412 can be a mechanical tensioning device with digitally controlled impedance that is used to dynamically control how tight a thread is fed through a winding machine (for example, CNC machine 400). In some embodiments, thread can be run through tensioner 412 before it exits thread spool 410, thereby giving an exact tension as it is fed out. In some embodiments, thread can be run through tensioner 412 after it exits a thread spool to give the thread a desired tension. In some embodiments, the tension value for thread can be changed dynamically by adjusting the voltage in tensioner 412. In some embodiments, tensioner 412 can be a manually adjustable tensioner. In some embodiments, tensioner 412 can comprise a spring configured to adjust the amount of tension applied to thread(s). The spring can be manually controlled or digitally controlled.

Once thread layer 420 is mechanically set by, for example, bonding thread lines 422 to one another, thread layer 420 can be removed from support plate 402. In some embodiments, removing thread layer 420 from support plate 402 can comprise lifting thread layer 420 from anchor points 290. In some embodiments, removing thread layer 420 from support plate 402 can comprise cutting a portion of thread layer 420 from support plate 402. In some embodiment, the cutting process can comprise a laser cutting process.

While FIG. 4 shows a CNC machine 400, in some embodiments, a thread layer or thread pattern can be wound around anchor points on a support plate (for example, anchor points 290 of support plate 402) manually.

Additionally, while FIG. 4 shows a flat support plate 402 and CNC machine 400 comprising a robotic arm 405, alternative configurations of CNC machine 400 are contemplated. For example, in some embodiments, support plate 402 can be in the form of one or more rotating objects (for example, wheel(s), a drum, a rotating plate, etc.) as disclosed in U.S. patent application Ser. No. 18/400,574, filed Dec. 29, 2023 and titled “Circular Winding Apparatus and Method,” and U.S. patent application Ser. No. 18/400,620, filed Dec. 29, 2023 and titled “Rotational Winding Apparatus and Method,” the disclosures of which are incorporated by reference herein in their entireties. In such embodiments, CNC machine 400 can comprise one or more translating components (for example, a thread guide) that wind a continuous thread around anchor points of a rotating object as the object rotates, as disclosed in U.S. patent application Ser. Nos. 18/400,574 and 18/400,620.

FIGS. 1A-1B, 2A-2C, 3, and 4 have been used to describe various thread layers and thread patterns that can be comprised by article of footwear 100, along with their methods of manufacture. The following description describes particular configurations of thread layers and thread patterns that impart desired characteristics to article of footwear 100 according to embodiments of the present application. In particular, thread layers and thread patterns as described herein reinforce article of footwear 100 in areas where greater stiffness is required based on the movement patterns of sports that require frequent explosive changes in direction (for example, basketball). For example, thread layers and thread patterns as described herein reduce “spillover,” particularly “lateral spillover,” which may occur when an individual engages in a lateral cut. Spillover refers to portions of upper 120 shifting and extending beyond the perimeter of sole 180 when the individual changes direction and applies a force to the inside of upper 120 via his or her foot. Spillover can reduce stability during changes of direction, as there is a risk of article of footwear 100 rolling over. This can cause ankle injury. Additionally, spillover can reduce agility by reducing the responsiveness of article of footwear 100.

FIGS. 5-14 show various thread layers according to embodiments of the present application that can be combined in a thread pattern, for example thread pattern 300. The thread pattern can then be integrated into an upper for an article of footwear. The various thread layers shown in FIGS. 5-14 can be combined in any combination (thread pattern). The combinations of thread layers described with respect to FIGS. 5-14 can be comprised by article of footwear 100 and can reinforce article of footwear 100, for example, against lateral spillover.

FIG. 5 shows an example thread layer 500 according to some embodiments. Thread layer 500 can be a toe bumper layer. Thread layer 500 can be configured to cover an individual's toes and increase the stability of a shoe upper when an individual decelerates.

FIG. 5 shows perimeter edge 520. Perimeter edge 520 can be the edge of a resulting thread pattern that comprises thread layer 500 (along with other thread layers). Perimeter edge 520 can be defined by cutting the combination of thread layers that comprises thread layer 500 to form the resulting thread pattern, for example, after bonding the combination of thread layers to one another. Perimeter edge 520 can demarcate a shape for the resulting thread pattern that will be integrated into a shoe upper. In some embodiments, perimeter edge 520 can be coupled to a sole (for example, sole 180), either directly or indirectly, along at least a portion of perimeter edge 520. As shown in FIG. 5, perimeter edge 520 can comprise a throat portion 522. Throat portion 522 can define a portion of the resulting thread pattern that will accommodate a tongue of a shoe upper. Throat portion 522 can lie within throat area 150 of upper 120, described with respect to FIGS. 1A-1B.

In some embodiments, thread layer 500 can be formed from a continuous thread 502 that is wound around anchor points 290. Thread layer 500 can comprise thread lines 504 that extend between points on perimeter edge 520.

As noted herein, thread layer 500 can be defined based on the thread type of continuous thread 502 (or threads used to create thread lines 504). Accordingly, thread lines 504 can therefore comprise all thread lines of thread layer 500 having the same thread type extending between points on perimeter edge 520. In some embodiments, when the thread pattern comprising thread layer 500 is coupled to a sole to form an article of footwear, thread lines 504 can be concentrated in the forefoot region (for example, forefoot region 110) of the article of footwear.

As used herein, thread lines being “concentrated” in a particular region means that the region comprises a greater number of the thread lines than any other region as defined herein. For example, in the case that thread layer 500 is formed by 100 thread lines 504, thread lines 504 are concentrated in forefoot region 110 in the following exemplary scenarios: 1) forefoot region 110 comprises 34 thread lines 504, midfoot region 112 comprises 33 thread lines 504, and heel region 114 comprises 33 thread lines 504; 2) forefoot region 110 comprises 51 thread lines 504, midfoot region 112 comprises 49 thread lines 504, and heel region 114 comprises 0 thread lines 504. Thread lines 504 are not concentrated in forefoot region 110 in the following exemplary scenarios: 1) forefoot region 110 comprises 33 thread lines 504, midfoot region 112 comprises 33 thread lines 504, and heel region 114 comprises 34 thread lines 504; 2) forefoot region 110 comprises 49 thread lines 504, midfoot region 112 comprises 50 thread lines 504, and heel region 114 comprises 1 thread line 504.

Thread lines of a thread layer being concentrated in a combination of regions means that each of the regions in the combination comprises a greater number of the thread lines than any other region not within the combination. For example, in the case a thread layer is formed by 100 thread lines, the thread lines are concentrated in forefoot region 110 and heel region 114 in the following exemplary scenarios: 1) forefoot region 110 comprises 34 thread lines, midfoot region comprises 32 thread lines, and heel region comprises 34 thread lines; 2) forefoot region 110 comprises 50 thread lines, midfoot region comprises 0 thread lines, and heel region comprises 50 thread lines. The thread lines are not concentrated in forefoot region 110 and heel region 114 in the following exemplary scenarios: 1) forefoot region 110 comprises 34 thread lines, midfoot region comprises 33 thread lines, and heel region comprises 33 thread lines; 2) forefoot region 110 comprises 49 thread lines, midfoot region comprises 49 thread lines, and heel region comprises 2 thread lines.

A region is considered to comprise a thread line when more than 50% of the thread line is contained in the region.

In some embodiments, thread layer 500 comprises no thread lines 504 extending to throat portion 522 of perimeter edge 520.

Thread lines 504 of thread layer 500 can comprise a particular thread type. In some embodiments, the thread type for thread lines 504 can comprise a material comprising a polymer monofilament. In such embodiments, the polymer monofilament can comprise a denier and polymer material as described herein. In some embodiments, the thread type for thread lines 504 can be “stretch” thread type. In some embodiments, the thread type for thread lines 504 can have a tensile stiffness ranging from 0.01 N/mm to 0.5 N/mm in a wound state. In some embodiments, the thread type for thread lines 504 can be “stiff” thread type. In some embodiments, the thread type for thread lines 504 can have a tensile stiffness ranging from 0.5 N/mm to 5 N/mm in a wound state.

FIG. 6 shows an example thread layer 600 according to some embodiments. Thread layer 600 can be an edge thickness layer. Thread layer 600 can be configured to increase thread density at the edges of a thread pattern comprising thread layer 600. The thread pattern can be incorporated into a shoe upper (for example, upper 120) to provide a high degree of tensile stiffness in the shoe upper at portions that couple to a sole. The high tensile stiffness of the shoe upper can prevent detachment of the shoe upper during board lasting operations or from a sole (for example, sole 180) after the shoe upper has been stitched to the sole.

FIG. 6 shows perimeter edge 620. Like perimeter edge 520, perimeter edge 620 can be the edge of a resulting thread pattern that comprises thread layer 600 (along with other thread layers). Perimeter edge 620 can be defined by cutting the combination of thread layers that comprises thread layer 600 to form the resulting thread pattern, for example, after bonding the combination of thread layers to one another. Perimeter edge 620 can demarcate a shape for the resulting thread pattern that will be integrated into a shoe upper. In some embodiments, perimeter edge 620 can be coupled to a sole (for example, sole 180), either directly or indirectly, along at least a portion of perimeter edge 620. Unlike perimeter edge 520, perimeter edge 620 can comprise a neck portion 622 that defines a portion of the resulting thread pattern that will receive an ankle of a wearer. Accordingly, FIGS. 5 and 6 show various configurations for the perimeter edge of the resulting thread pattern, but it should be understood that the thread layers illustrated with either configuration can be formed according to the other unless otherwise noted.

As shown in FIG. 6, the resulting thread pattern can comprise an edge region 630 configured to be adjacent a sole. The edge region 630 can be defined as the region within 1 inch (2.54 centimeters) of exterior portions of perimeter edge 620 directly or indirectly coupled to sole 180, for example, portions other than neck portion 622 and a throat portion 624 of the resulting thread pattern.

In some embodiments, thread layer 600 can be formed from a continuous thread 602 that is wound around anchor points 290. Thread layer 600 can comprise thread lines 604 that extend between points on perimeter edge 620.

As noted herein, thread layer 600 can be defined based on the thread type of continuous thread 602 (or threads used to create thread lines 604). Accordingly, thread lines 604 can therefore comprise all thread lines of thread layer 600 having the same thread type extending between points on perimeter edge 620. In some embodiments, thread lines 604 can be concentrated in the edge region 630 of the resulting thread pattern. In some embodiments, when the thread pattern comprising thread layer 600 is coupled to a sole to form an article of footwear, thread lines 604 can extend from points on perimeter edge 620 in edge region 630 that lie in at least the forefoot region (for example, forefoot region 110) and midfoot region (for example, midfoot region 112) of the article of footwear. In some embodiments, thread lines 604 can extend from points on perimeter edge 620 in edge region 630 that lie in the forefoot region (for example, forefoot region 110), midfoot region (for example, midfoot region 112), and heel region (for example, heel region 114) of the article of footwear.

In some embodiments, thread layer 600 comprises no thread lines 604 extending to throat portion 624 and/or neck portion 622 of perimeter edge 620.

Thread lines 604 of thread layer 600 can comprise a particular thread type. In some embodiments, the thread type for thread lines 604 can comprise a material comprising polyester, ELASTANE®, and thermoplastic polyurethane (TPU). For example, in some embodiments, the material can comprise polyester wrapped around an ELASTANE® core, with TPU wrapped around this pairing. As another example, the material can comprise polyester wrapped around an ELASTANE® core, with a TPU filament running in parallel to the polyester/ELASTANE® core after having been wound in parallel to the polyester/ELASTANE® core. In some embodiments, the material can comprise a nylon and/or polyester core (either mono- or multi-filament) covered in a sheath of TPU. In some embodiments, the material can comprise polyester and ELASTANE® alone. In some embodiments, the thread type for thread lines 604 can be a “stretch” thread type. In some embodiments, the thread type for thread lines 604 can have a tensile stiffness ranging from 0.01 N/mm to 0.5 N/mm in a wound state.

FIGS. 7A-7C show example thread layers 700, 720, and 740 according to some embodiments. In some embodiments, thread layers 700, 720, and 740 can be separate thread layers, one or more of which can be comprised by a thread pattern. In some embodiments, any combination of thread layers 700, 720, and 740 (for example, thread layers 700 and 720) can be integrated into a single thread layer comprising the same thread type. Thread layers 700, 720, 740 can be eyestay reinforcement layers. Thread layers 700, 720, 740 can be configured to provide a high thread density adjacent throat portion 522 or 624 of perimeter edge 520 or 620 of a resulting thread pattern. The thread pattern can be incorporated into a shoe upper (for example, upper 120), thus providing high degrees of strength of the shoe upper around eyelets (for example, eyelets 152) of the shoe upper. The high strength of the shoe upper around its eyelets can prevent deformation or ripping of the shoe upper when forces are exerted on the eyelets via laces.

In some embodiments, thread layer 700 shown in FIG. 7A can be formed from a continuous thread 702 that is wound around anchor points 290. Thread layer 700 can comprise thread lines 704 that extend between points on perimeter edge 520. As noted herein, thread layer 700 can be defined based on the thread type of continuous thread 702 (or threads used to create thread lines 704). Accordingly, thread lines 704 can therefore comprise all thread lines of thread layer 700 having the same thread type extending between points on perimeter edge 520.

In some embodiments, at least a portion of thread lines 704 can extend to points on throat portion 522 of perimeter edge 520. In some embodiments, at least a portion of thread lines 704 can be splayed out such that they extend from throat portion 522 to other portions of perimeter edge 520. In some embodiments, at least a portion of thread lines 704 can be splayed out such that they extend from throat portion 522 to other portions of perimeter edge 520 and are separated by approximately equal intervals along the other portions of perimeter edge 520.

In some embodiments, thread layer 720 shown in FIG. 7B can be formed from a continuous thread 722 that is wound around anchor points 290. Thread layer 720 can comprise thread lines 724 that extend between points on perimeter edge 520. As noted herein, thread layer 720 can be defined based on the thread type of continuous thread 722 (or threads used to create thread lines 724). Accordingly, thread lines 724 can therefore comprise all thread lines of thread layer 720 having the same thread type extending between points on perimeter edge 520.

In some embodiments, at least a portion of thread lines 724 can extend to points on throat portion 522 of perimeter edge 520. In some embodiments, at least a portion of thread lines 724 can extend adjacent throat portion 522 and parallel to a side of throat portion 522. In some embodiments, at least a portion of thread lines 724 can be splayed out such that they extend from throat portion 522 to other portions of perimeter edge 520. In some embodiments, at least a portion of thread lines 724 can be splayed out such that they extend from throat portion 522 to other portions of perimeter edge 520 and are separated by approximately equal intervals along the other portions of perimeter edge 520.

In some embodiments, thread layers 700 and 720 can both be comprised by a resulting thread pattern. In some embodiments, either thread layer 700 or thread layer 720 can be comprised by a resulting thread pattern.

In some embodiments, thread layer 740 shown in FIG. 7C can be formed from a continuous thread 742 that is wound around anchor points 290. Thread layer 740 can comprise thread lines 744 that extend between points on perimeter edge 620. As noted herein, thread layer 740 can be defined based on the thread type of continuous thread 742 (or threads used to create thread lines 744). Accordingly, thread lines 744 can therefore comprise all thread lines of thread layer 740 having the same thread type extending between points on perimeter edge 620.

In some embodiments, at least a portion of thread lines 744 can extend to points on throat portion 624 of perimeter edge 620. In some embodiments, at least a portion of thread lines 744 can extend adjacent throat portion 624 and parallel to a side of throat portion 624. In some embodiments, at least a portion of thread lines 744 can be splayed out such that they extend from throat portion 624 to other portions of perimeter edge 620. In some embodiments, at least a portion of thread lines 744 can be splayed out such that they extend from throat portion 624 to other portions of perimeter edge 620 and are separated by approximately equal intervals along the other portions of perimeter edge 620. In some embodiments, at least a portion of thread lines 744 can extend between points on neck portion 622 and points on throat portion 624 of perimeter edge 620.

In embodiments in which thread layers 700, 720, and 740 are separate layers, thread lines 704 of thread layer 700, thread lines 724 of thread layer 720, and thread lines 744 of thread layer 740 can each comprise a particular thread type. In some embodiments, the thread type for thread lines 704, 724, and 744 can comprise a material comprising polyester, ELASTANE®, and thermoplastic polyurethane (TPU). For example, in some embodiments, the material can comprise polyester wrapped around an ELASTANE® core, with TPU wrapped around this pairing. As another example, the material can comprise polyester wrapped around an ELASTANE® core, with a TPU filament running in parallel to the polyester/ELASTANE® core after having been wound in parallel to the polyester/ELASTANE® core. In some embodiments, the material can comprise a nylon and/or polyester core (either mono- or multi-filament) covered in a sheath of TPU. In some embodiments, the material can comprise just polyester and TPU alone. In some embodiments, the material can comprise nylon and TPU alone. In some embodiments, the material can comprise polyester and ELASTANE® alone. In some embodiments, the material can comprise TPU alone. In some embodiments, the thread types for thread lines 704, 724, and/or 744 can be a “stretch” thread type. In some embodiments, the thread types for thread lines 704, 724, and/or 744 can have a tensile stiffness ranging from 0.01 N/mm to 0.5 N/mm in a wound state. In some embodiments, the thread types for thread lines 704, 724, and/or 744 can be a “stiff” thread type. In some embodiments, the thread types for thread lines 704, 724, and/or 744 can have a tensile stiffness ranging from 0.5 N/mm to 5 N/mm in a wound state. In some embodiments, the thread types for thread lines 704 and 744 can be “stretch” thread type. In some embodiments, the thread types for thread lines 704 and 744 can have a tensile stiffness ranging from 0.01 N/mm to 0.5 N/mm in a wound state. In some embodiments, the thread type for thread lines 704 can be “stretch” thread type while the thread types for thread lines 724 and/or 744 can be “stiff” thread type. In some embodiments, the thread type for thread lines 704 can have a tensile stiffness ranging from 0.01 N/mm to 0.5 N/mm in a wound state while the thread types for thread lines 724 and/or 744 can have a tensile stiffness ranging from 0.5 N/mm to 5 N/mm in a wound state.

In embodiments in which the thread layers 700, 720, and 740 are a single layer, the thread lines 704, 724, and 744 can all comprise the same material, according to any of the materials described above.

FIG. 8 shows an example thread layer 800 according to some embodiments. Thread layer 800 can be a heel counter layer. Thread layer 800 can be configured to provide a high thread density at portions of a thread pattern (comprising thread layer 800) that will lie in heel region 114. The thread pattern can be incorporated into a shoe upper (for example, upper 120) to provide a high degree of stiffness to the shoe upper near the heel. The high degree of stiffness of the shoe upper near the heel can increase the stability of the shoe upper when an individual accelerates forward.

In some embodiments, thread layer 800 can be formed from a continuous thread 802 that is wound around anchor points 290. Thread layer 800 can comprise thread lines 804 that extend between points on perimeter edge 620.

As noted herein, thread layer 800 can be defined based on the thread type of continuous thread 802 (or threads used to create thread lines 804). Accordingly, thread lines 804 can therefore comprise all thread lines of thread layer 800 having the same thread type extending between points on perimeter edge 620. In some embodiments, when the thread pattern comprising thread layer 800 is coupled to a sole to form an article of footwear, thread lines 804 can be concentrated in the heel region (for example, heel region 114) of the article of footwear.

In some embodiments, thread layer 800 comprises no thread lines 804 extending to throat portion 624 and/or neck portion 622 of perimeter edge 620.

Thread lines 804 of thread layer 800 can comprise a particular thread type. In some embodiments, the thread type for thread lines 804 can comprise a material comprising a polymer monofilament. In such embodiments, the polymer monofilament can comprise a denier and polymer material as described herein. In some embodiments, the thread type for thread lines 804 can be “stiff” thread type. In some embodiments, the thread type for thread lines 804 can have a tensile stiffness ranging from 0.5 N/mm to 5 N/mm in a wound state.

In some embodiments, thread layer 500 (toe bumper layer) and thread layer 800 (heel counter layer) can comprise a single thread layer. That is, in some embodiments, thread lines 504 of thread layer 500 and thread lines 804 of thread layer 800 can comprise the same thread type.

FIG. 8 shows that thread layer 800 is comprised by a thread pattern comprising perimeter edge 620, rather than perimeter edge 520. Thread layer 800 need not be comprised by a thread pattern comprising perimeter edge 520, as no neck portion 622 is included and the thread pattern having perimeter edge 520 may not comprise a portion that will wrap around a wearer's heel.

FIGS. 9-14 show various example thread layers 900, 1000, 1100, 1200, 1220, 1300 and 1400 for providing stiffness to a thread pattern used in a shoe upper. In some embodiments, a single one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 can be incorporated into a thread pattern with one or more of thread layers 500, 600, 700, 720, 740, and 800. In some embodiments, multiple of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 can be incorporated into a thread pattern with one or more of thread layers 500, 600, 700, 720, 740, and 800.

Thread lines of any one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 comprise a particular thread type. In some embodiments, the thread type for any one or more of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 can comprise a material comprising a polyester and TPU quad wrap thread. In some embodiments, the thread type for any one or more of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 can comprise a core/sheath thread comprising a nylon core coated with a TPU sheath. In some embodiments, the thread type can comprise a material comprising polyester, ELASTANE®, and TPU. For example, in some embodiments, the material can comprise polyester wrapped around an ELASTANE® core, with TPU wrapped around this pairing. As another example, the material can comprise polyester wrapped around an ELASTANE® core, with a TPU filament running in parallel to the polyester/ELASTANE® core after having been wound in parallel to the polyester/ELASTANE® core. In some embodiments, the thread type(s) for thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 can be “stiff” thread type(s) having a tensile stiffness above 0.5 N/mm, for example, a tensile stiffness ranging from 0.5 N/mm to 5 N/mm in an unwound state. In some embodiments, the thread type(s) for thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 can have a tensile stiffness ranging from 0.5 N/mm to 5 N/mm in a wound state.

Each of FIGS. 9-14 shows an anterior-posterior (AP) axis and a medial-lateral (ML) axis. In a resulting article of footwear, the AP axis extends along the thread pattern containing the thread layer, and is aligned with the length of the article of footwear (for example, lengthwise axis L of article of footwear 100) and bisects the lateral and medial sides of footwear 100. The ML axis extends along the thread pattern containing the thread layer and perpendicularly to the AP axis at all points on the ML axis.

Each of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 comprise thread lines that extend at an angle less than or equal to 45 degrees with respect to the AP axis. The stiffening of a thread pattern provided by thread layer 900, 1000, 1100, 1200, 1220, 1300, and/or 1400 along the AP axis can be beneficial for footwear used in sports such as basketball. In particular, stiffening of the thread pattern along the AP axis can reduce lateral spillover. Since the thread pattern cannot elongate as much along the AP axis, this prevents or inhibits shifting of portions of the thread pattern along a medial-lateral direction of an article of footwear, thereby reducing lateral spillover. Instead, when a lateral load is applied to an upper comprising the thread pattern by a wearer's foot, the increased stiffness along the AP axis can transfer the lateral load across at least a portion of the length of an article of footwear, providing greater resistance to the lateral load.

In some embodiments, the angle of all thread lines in any of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 can be uniformly rotated 90 degrees relative to the AP axis. In such embodiments, the stiffening of a thread pattern as described herein can be instead provided along the ML axis. In some embodiments, the thread type(s) for thread lines of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 can be “stiff” thread type(s). In some embodiments, the thread type(s) for thread lines of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 can have a tensile stiffness ranging from 0.5 N/mm to 5 N/mm in a wound state.

FIG. 9 shows an example thread layer 900 according to some embodiments. In some embodiments, thread layer 900 can be formed from a continuous thread 902 that is wound around anchor points 290. Thread layer 900 can comprise thread lines 904 that extend between points on perimeter edge 520. As noted herein, thread layer 900 can be defined based on the thread type of continuous thread 902 (or threads used to create thread lines 904). Accordingly, thread lines 904 can therefore comprise all thread lines of thread layer 900 having the same thread type extending between points on perimeter edge 520.

As shown in FIG. 9, in some embodiments, all thread lines 904 of thread layer 900 can extend at an angle Θ less than or equal to 45 degrees with respect to the AP axis. In some embodiments, greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 904 of thread layer 900 can extend at an angle Θ less than or equal to 45 degrees with respect to the AP axis. Thread layer 900 can comprise a first plurality 910 of thread lines 904 that extend at a first angle Θ(1) with respect to the AP axis. Thread layer 900 can comprise a second plurality 912 of thread lines 904 that extend at a second angle Θ(2) with respect to the AP axis, the second angle being greater than the first angle.

FIG. 10 shows an example thread layer 1000 according to some embodiments. In some embodiments, thread layer 1000 can be formed from a continuous thread 1002 that is wound around anchor points 290. Thread layer 1000 can comprise thread lines 1004 that extend between points on perimeter edge 520. As noted herein, thread layer 1000 can be defined based on the thread type of continuous thread 1002 (or threads used to create thread lines 1004). Accordingly, thread lines 1004 can therefore comprise all thread lines of thread layer 1000 having the same thread type extending between points on perimeter edge 520.

As shown in FIG. 10, in some embodiments, all thread lines 1004 of thread layer 1000 can extend at an angle Θ less than or equal to 45 degrees with respect to the AP axis. In some embodiments, greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 1004 of thread layer 1000 can extend at an angle Θ less than or equal to 45 degrees with respect to the AP axis. Thread layer 1000 can comprise a first plurality 1010 of thread lines 1004 that extend at a first angle Θ(1) with respect to the AP axis. Thread layer 1000 can comprise a second plurality 1012 of thread lines 1004 that extend at a second angle Θ(2) with respect to the AP axis, the second angle being a mirror image of the first angle.

FIG. 11 shows an example thread layer 1100 according to some embodiments. In some embodiments, thread layer 1100 can be formed from a continuous thread 1102 that is wound around anchor points 290. Thread layer 1100 can comprise thread lines 1104 that extend between points on perimeter edge 520. As noted herein, thread layer 1100 can be defined based on the thread type of continuous thread 1102 (or threads used to create thread lines 1104). Accordingly, thread lines 1104 can therefore comprise all thread lines of thread layer 1100 having the same thread type extending between points on perimeter edge 520.

As shown in FIG. 11, in some embodiments, thread layer 1100 can comprise a first plurality 1110 of thread lines 1104 that extend at a first angle Θ(1) with respect to the AP axis. In some embodiments, Θ(1) can be less than or equal to 45 degrees. In some embodiments, thread layer 1100 can comprise a second plurality 1111 of thread lines 1104 that extend at a second angle Θ(2) with respect to the AP axis. In some embodiments, Θ(2) can be less than or equal to 45 degrees. Additionally, in some embodiments, the second angle can be a mirror image of the first angle. Thread layer 1100 can comprise a third plurality 1112 of thread lines 1104 that extend at a third angle Θ(3) with respect to the AP axis, the third angle being greater than the first and second angles. In some embodiments, Θ(3) can be greater than or equal to 45 degrees. In some embodiments, the third plurality 1112 of thread lines 1104 can extend substantially parallel to the ML axis. As used herein, thread lines extending “substantially” parallel to an axis or other thread line(s) means the thread lines extend at angles less than or equal to 10 degrees with respect to the axis or other thread line(s).

In some embodiments, the first and second pluralities 1110, 1111 of thread lines 1104 can comprise greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 1104 of thread layer 1100. In some embodiments, the third plurality 1112 of thread lines 1104 can comprise less than 50 percent, less than 40 percent, less than 30 percent, less than 20 percent, or less than 10 percent of all the thread lines 1104 of thread layer 1100.

FIG. 12A shows an example thread layer 1200 according to some embodiments. In some embodiments, thread layer 1200 can be formed from a continuous thread 1202 that is wound around anchor points 290. Thread layer 1200 can comprise thread lines 1204 that extend between points on perimeter edge 520. As noted herein, thread layer 1200 can be defined based on the thread type of continuous thread 1202 (or threads used to create thread lines 1204). Accordingly, thread lines 1204 can therefore comprise all thread lines of thread layer 1200 having the same thread type extending between points on perimeter edge 520.

As shown in FIG. 12A, in some embodiments, thread layer 1200 can comprise a first plurality 1210 of thread lines 1204 that extend at a first angle Θ(1) with respect to the AP axis. In some embodiments, Θ(1) can be less than or equal to 45 degrees. Thread layer 1200 also comprises a second plurality 1212 of thread lines 1204 that extend at a second angle Θ(2) with respect to the AP axis, the second angle being greater than the first angle. In some embodiments, Θ(2) can be greater than or equal to 45 degrees. In some embodiments, the first plurality 1210 of thread lines 1204 can extend substantially parallel to the AP axis. In some embodiments, the second plurality 1212 of thread lines 1204 can extend substantially parallel to the ML axis.

In some embodiments, the first plurality 1210 of thread lines 1204 can comprise greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 1204 of thread layer 1200. In some embodiments, the second plurality 1212 of thread lines 1204 can comprise less than 50 percent, less than 40 percent, less than 30 percent, less than 20 percent, or less than 10 percent of all the thread lines 1204 of thread layer 1200. In some embodiments, the second plurality 1212 of thread lines 1204 can comprise greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 1204 of thread layer 1200. In some embodiments, the first plurality 1210 of thread lines 1204 can comprise less than 50 percent, less than 40 percent, less than 30 percent, less than 20 percent, or less than 10 percent of all the thread lines 1204 of thread layer 1200.

As shown in FIG. 12A, in some embodiments, the first plurality 1210 of thread lines 1204 can comprise a gap 1214 that comprises no thread lines 1204 of the first plurality 1210. In some embodiments, gap 1214 can be aligned with the AP axis. In such embodiments, the AP axis can be located within gap 1214. Gap 1214 can comprise a width (as measured along a direction parallel to the ML axis) and a length (as measured along a direction parallel to the AP axis) that is greater than its width. In some embodiments, gap 1214 can comprise a width of at least 1 centimeter. In some embodiments, gap 1214 can comprise a width of at least 2 centimeters. In some embodiments, gap 1214 can run through a geometric center of a thread pattern that comprises thread layer 1200.

FIG. 12B shows an example thread layer 1220 according to some embodiments. In some embodiments, thread layer 1220 can be formed from a continuous thread 1222 that is wound around anchor points 290. Thread layer 1220 can comprise thread lines 1224 that extend between points on perimeter edge 520. As noted herein, thread layer 1220 can be defined based on the thread type of continuous thread 1222 (or threads used to create thread lines 1224). Accordingly, thread lines 1224 can therefore comprise all thread lines of thread layer 1220 having the same thread type extending between points on perimeter edge 520.

As shown in FIG. 12B, in some embodiments, thread layer 1220 can comprise a first plurality 1230 of thread lines 1224 that extend at a first angle Θ(1) with respect to the AP axis. In some embodiments, Θ(1) can be less than or equal to 45 degrees. Thread layer 1220 can comprise a second plurality 1232 of thread lines 1224 that extend at a second angle Θ(2) with respect to the AP axis, the second angle being greater than the first angle. In some embodiments, Θ(2) can be greater than or equal to 45 degrees. In some embodiments, the first plurality 1230 of thread lines 1224 can extend substantially parallel to the AP axis. In some embodiments, the second plurality 1232 of thread lines 1224 can extend substantially parallel to the ML axis.

In some embodiments, the first plurality 1230 of thread lines 1224 can comprise greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 1224 of thread layer 1220. In some embodiments, the second plurality 1232 of thread lines 1224 can comprise less than 50 percent, less than 40 percent, less than 30 percent, less than 20 percent, or less than 10 percent of all the thread lines 1224 of thread layer 1220. In some embodiments, the second plurality 1232 of thread lines 1224 can comprise greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 1224 of thread layer 1220. In some embodiments, the first plurality 1230 of thread lines 1224 can comprise less than 50 percent, less than 40 percent, less than 30 percent, less than 20 percent, or less than 10 percent of all the thread lines 1224 of thread layer 1220.

As shown in FIG. 12B, thread layer 1220 can be the same as thread layer 1200, except that thread layer 1220 comprises no gap 1214.

FIG. 13 shows an example thread layer 1300 according to some embodiments. In some embodiments, thread layer 1300 can be formed from a continuous thread 1302 that is wound around anchor points 290. Thread layer 1300 can comprise thread lines 1304 that extend between points on perimeter edge 520. As noted herein, thread layer 1300 can be defined based on the thread type of continuous thread 1302 (or threads used to create thread lines 1304). Accordingly, thread lines 1304 can therefore comprise all thread lines of thread layer 1300 having the same thread type extending between points on perimeter edge 520.

As shown in FIG. 13, in some embodiments, all thread lines 1304 of thread layer 1300 can extend at an angle Θ less than or equal to 45 degrees with respect to the AP axis. In some embodiments, greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 1304 of thread layer 1300 can extend at an angle Θ less than or equal to 45 degrees with respect to the AP axis. In some embodiments, all thread lines 1304 of thread layer 1300 can extend substantially parallel to the AP axis. In some embodiments, greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 1304 of thread layer 1300 can extend substantially parallel to the AP axis.

FIG. 14 shows an example thread layer 1400 according to some embodiments. In some embodiments, thread layer 1400 can be formed from a continuous thread 1402 that is wound around anchor points 290. Thread layer 1400 can comprise thread lines 1404 that extend between points on perimeter edge 520. As noted herein, thread layer 1400 can be defined based on the thread type of continuous thread 1402 (or threads used to create thread lines 1404). Accordingly, thread lines 1404 can therefore comprise all thread lines of thread layer 1400 having the same thread type extending between points on perimeter edge 520.

As shown in FIG. 14, in some embodiments, all thread lines 1404 of thread layer 1400 can extend at an angle less than or equal to 45 degrees with respect to the AP axis. In some embodiments, greater than 50 percent, greater than 60 percent, greater than 70 percent, greater than 80 percent, or greater than 90 percent of all the thread lines 1404 of thread layer 1400 can extend at an angle less than or equal to 45 degrees with respect to the AP axis.

Thread layer 1400 can be the same as thread layer 1300 except for the addition of a first plurality 1410 and a second plurality 1412 of thread lines 1404. The first and second pluralities 1410, 1412 of thread lines 1404 can extend diagonally to the AP axis. In some embodiments, the first and second pluralities 1410, 1412 can extend diagonally to the AP axis at respective angles that are mirror images of one another, as described for the first and second pluralities 1010, 1012 of thread lines 1004 with respect to FIG. 10. In some embodiments, the first plurality 1410 and second plurality 1412 of thread lines 1404 can intersect in a forefoot region of a thread pattern that comprises thread layer 1400, the intersection points of the thread lines being concentrated in the forefoot region.

A line intersecting an axis forms two angles, an acute and an obtuse angle. It should be understood that any angles Θ between a thread line and an axis discussed herein refer to the acute angle formed between the thread line and the axis. In the case where the thread line does not overlap an axis (for example, a thread line may run substantially parallel to an axis), the angle Θ between the thread line and the axis is measured as the angle between an extension of the thread line and an extension of axis, at the point where the extensions intersect.

Additionally, groups of thread lines that extend at “an” angle, “a first” angle, “a second angle,” etc. have been identified herein. It should be understood that reference to “an” angle, “a first” angle, “a second” angle, etc. does not mean that all of the thread lines in the group extend at the same angle. Instead, such terms mean that each of the thread lines in the group extends at an angle that satisfies the identified condition (for example, an angle less than or equal to 45 degrees). Further, a thread line extends at an angle with respect to an axis when at least a portion of the lengthwise axis of the thread line extends at the angle with respect to the axis.

Since the AP axis and the ML axis extend along a thread pattern that comprises the thread layer shown, angle conditions identified herein should be consistent in both a flat state and a lasted state. In a lasted state, the AP and ML axes curve to follow the lasted thread pattern. The thread lines of the lasted thread pattern also curve, substantially preserving angle relationships that existed in a flat state.

FIG. 15 shows an upper component 1500 according to some embodiments. Upper component can comprise a thread pattern 1520 comprising perimeter edge 520, an ankle support 1530, and a bootie 1540. Thread pattern 1520 shown in FIG. 15 can be in a lasted state. That is, thread pattern 1520, along with bootie 1540, can have been conformed to a shoe last such that its shape is curved to match the shape of a resulting article of footwear. Ankle support 1530 can be a woven or non-woven fabric and/or polymer component configured to support a wearer's ankle. Bootie 1540, which can correspond to fabric layer 174, can provide additional support and comfort to the wearer.

While FIG. 15 shows thread pattern 1520 comprising perimeter edge 520, it should be understood that thread pattern 1520 can comprise perimeter edge 620. In such embodiments, ankle support 1530 need not be included and thread pattern 1520 can comprise thread layer 800 (“heel counter” layer).

Thread pattern 1520 can comprise any combination of thread layers 500 (toe bumper layer), 600 (edge thickness layer), 700, 720, 740 (eyestay reinforcement layers), 800 (heel counter layer), 900, 1000, 1100, 1200, 1220, 1300, and 1400 (stiffening layers), alone or in combination with additional layers. For example, in some embodiments, thread pattern 1520 can comprise thread layers 500, 600, and 700, in combination with any one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400. In some embodiments, thread pattern 1520 can comprise thread layers 500, 600, 700, and 720, in combination with any one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400. In some embodiments, thread pattern 1520 can comprise thread layers 500, 600, 740, and 800, in combination with any one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400. In some embodiments, thread pattern 1520 can comprise any of the above combinations, with another one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 added. In some embodiments, thread pattern 1520 can comprise the above combination, with an additional one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 added (three stiffening layers total). In some embodiments, thread pattern 1520 can comprise any of the above combinations, minus thread layer 500. In some embodiments, thread pattern 1520 can comprise any of the above combinations, minus thread layer 600. In some embodiments, thread pattern 1520 can comprise any of the above combinations, minus thread layer 700, 720, and/or 740. In some embodiments, thread pattern 1520 can comprise one or more of a particular thread layer having the features disclosed herein for the particular thread layer. In some embodiments, thread pattern 1520 can comprise one or more thread layers 500, one or more thread layers 600, one or more thread layers 700, one or more thread layers 720, one or more thread layers 740, one or more thread layers 800, one or more thread layers 900, one or more thread layers 1000, one or more thread layers 1100, one or more thread layers 1200, one or more thread layers 1220, one or more thread layers 1300, and/or one or more thread layers 1400 in any of the combinations of thread layers disclosed herein.

The thread lines of the thread layers that make up thread pattern 1520 comprise a different thread type for each of the thread layers. That is, each of the thread types of the thread layers differ from one another within a thread pattern 1520. In some embodiments, the difference can comprise a different tensile stiffness. In some embodiments, the difference can comprise a difference in material. In some embodiments, the difference can comprise a different denier. In some embodiments, the difference can comprise a different number of plies. In some embodiments, the difference can comprise a difference in tensile stiffness but not material. In some embodiments, the difference can comprise a difference in denier but not material. In some embodiments, the difference can comprise a difference in material but not denier. In some embodiments, the difference can comprise a difference in ply (single- or multi-ply, and number of ply), but not in material and/or denier (total denier if multi-ply).

In some embodiments, each of the thread lines of a stiffening layer 900, 1000, 1100, 1200, 1220, 1300, 1400 can comprise a tensile stiffness greater than that of each of thread lines 504 of thread layer 500. In some embodiments, each of the thread lines of a stiffening layer 900, 1000, 1100, 1200, 1220, 1300, 1400 can comprise a tensile stiffness greater than that of each of thread lines 504 of thread layer 500 and greater than that of each of thread lines 704, 724, and/or 744 of an eyestay reinforcement thread layer 700, 720, and/or 740. In some embodiments, each of the thread lines 704, 724, and/or 744 of an eyestay reinforcement thread layer 700, 720, and/or 740 can comprise a tensile stiffness greater than that of each of thread lines 504 of thread layer 500.

In some embodiments, any of thread layers 500, 600, 700, 720, 740, 800, 900, 1000, 1100, 1200, 1220, 1300, and 1400 can be combined (for example, can be formed using the same thread type). As a non-limiting example, in some embodiments, thread layers 500 and 600 can be formed using the same thread type such that they comprise a single thread layer. As another non-limiting example, in some embodiments, thread layers 500 and 800 can be formed using the same thread type such that they comprise a single thread layer. As another non-limiting example, in some embodiments, thread layers 600 and 700, 740, and/or 720 can be formed using the same thread type such that they comprise a single thread layer. As another non-limiting example, in some embodiments, thread layers 500, 600, and 700, 740, and/or 720 can be formed using the same thread type such that they comprise a single thread layer. As another non-limiting example, thread layers 600, and 700, 740, and/or 720, along with a stiffening thread layer 900, 1000, 1100, 1200, 1220, 1300, or 1400 can be formed using the same thread type such that they comprise a single thread layer. The disclosure for individual thread layers herein applies to associated portions of a combined thread layer.

As shown in FIG. 15, upper component 1500 can comprise regions 1-5, corresponding to regions 1-5 shown in FIG. 3, for tensile stiffness testing. The boxes 1552 delineating each of the regions 1-5 are used in the testing process to mark points of stretch-inducing force application, as described with respect to FIG. 16. The width and height of each box 1552 (the “gauge length” for each test) can each range from 20 mm to 30 mm. Region 1 is on the AP axis in the forefoot region of upper component 1500. Region 2 is in the forefoot region of upper component 1500 offset from the AP axis on the medial side or the lateral side of the AP axis. Region 3 is in the forefoot region of upper component 1500 offset from the AP axis on the medial side or the lateral side of the AP axis opposite Region 2. Region 4 is in the midfoot region of upper component 1500 offset from the AP axis on the medial side or the lateral side of the AP axis. Region 5 is in the midfoot region of upper component 1500 offset from the AP axis on the medial side of the lateral side of the AP axis opposite Region 4.

FIG. 16 shows a graph of data for a method of tensile stiffness testing according to some embodiments. Each line 1602 shown in FIG. 16 corresponds to a region/direction of a tested thread pattern (for example, region 3 of thread pattern 1520, tested along an AP direction). Each line 1602 represents displacement (stretching) of a region (for example, Region 3) when a force (N) is applied and removed to the region.

Tensile stiffness values of a thread pattern disclosed herein were measured according to the following method. To measure AP stiffness, a first clamp was fixedly attached to thread pattern 1520 at the toe edge of a box 1552 corresponding to a region (for example, Region 3). Likewise, a second clamp was fixedly attached to thread pattern 1520 at the heel edge of box 1552 corresponding to the region. Then a tensile force was applied across the region along an AP direction using an INSTRON® machine. Similarly, to measure ML stiffness, the first and second clamps were applied to thread pattern 1520 at the lateral and medial side edges of the box 1552, and a force was applied across Region 3 along an ML direction. In FIG. 16, the slope of a line 1602 represents the AP or ML tensile stiffness (in Newtons/millimeter (N/mm)) of an associated region.

The tensile testing performed was a cyclic load test. A force was applied across a region and relaxed for multiple cycles, and the data on tensile stiffness was recorded on the fifth cycle. The maximum strain applied during each cycle was about 10%. That is, each region 1-5 was stretched to about a 10% increase in length/width from its initial length/width. The strain rate during force application was 300 mm/min.

FIG. 17 shows tensile stiffness data for tested thread patterns at different regions and along different directions. The x-axis designates the different regions/directions. The regions correspond to regions 1-5 depicted in FIGS. 3 and 15. For example, “1 AP” refers to the tensile stiffness of a tested thread pattern at Region 1, as measured along an anterior-posterior direction. As another example, “3 ML” refers to the tensile stiffness of a tested thread pattern at Region 3, as measured along a medial-lateral direction.

FIG. 17 shows tensile stiffness data for a first tested thread pattern 1710, a second tested thread pattern 1720, a third tested thread pattern 1730, a fourth tested thread pattern 1740, and a fifth tested thread pattern 1750.

Each of first, second, and third tested thread patterns 1710, 1720, and 1730 comprised the same combination of thread layers. First tested thread pattern 1710 was in a flat (unlasted) state as shown in FIG. 3. Second tested thread pattern 1720 comprised first tested thread pattern 1710 lasted and attached to an ankle support (for example, like thread pattern 1520 attached to ankle support 1530 as shown in FIG. 15). Third tested thread pattern 1730 comprised second tested thread pattern 1720, attached to the ankle support and additionally to a bootie (for example, bootie 1540 shown in FIG. 15). The bootie provides another layer of material that is stretched during testing in addition to the material of second tested thread pattern 1720.

Fourth and fifth tested thread patterns 1740, 1750 comprised the same combination of thread layers as first, second, and third thread patterns 1720, 1720, and 1730, except for the addition of a stiffening thread layer (for example, thread layer 1300 shown in FIG. 13). Fourth tested thread pattern 1740 was in a flat (unlasted) state as shown in FIG. 3. Fifth tested thread pattern 1750 comprised fourth tested thread pattern 1740 lasted and attached to an ankle support (for example, like thread pattern 1520 attached to ankle support 1530 as shown in FIG. 15). No bootie was attached to fifth tested thread pattern 1750.

FIG. 17 shows that in each of numbered regions 1-5, fourth and fifth tested thread patterns 1740, 1750 comprise higher tensile stiffness along an AP direction than any other of first, second, and third tested thread patterns 1710, 1720, 1730 (with bootie). For example, fourth and fifth tested thread patterns 1740, 1750 comprise a tensile stiffness, as measured along an AP direction, from about 75 N/mm to about 130 N/mm in each of regions 1-5. More specifically, fourth and fifth tested thread patterns 1740, 1750 comprise a tensile stiffness, as measured along an AP direction, from about 80 N/mm to about 120 N/mm in each of regions 1-5.

FIG. 17 also shows that in each of numbered regions 1-5, fourth and fifth tested thread patterns 1740, 1750 comprise lower tensile stiffness along an ML direction, as compared to an AP direction. For example, fourth and fifth tested thread patterns 1740, 1750 comprise a tensile stiffness, as measured along an ML direction, from about 5 N/mm to about 60 N/mm in each of regions 1-5. More specifically, fourth and fifth tested thread patterns 1740, 1750 comprise a tensile stiffness, as measured along an ML direction, from about 10 N/mm to about 50 N/mm in each of regions 1-5. In some embodiments, in each of regions 1-5, the tensile stiffness of fourth and fifth tested thread patterns 1740, 1750 along an AP direction can be greater than or equal to 150%, 175%, 200%, 250%, or 300% of the tensile stiffness along an ML direction. In some embodiments, in each of regions 1-5, the tensile stiffness of fourth and fifth tested thread patterns 1740, 1750 along an AP direction can be greater than or equal to 150% to less than or equal to 500% of the tensile stiffness along an ML direction, or greater than or equal to 150% to less than or equal to 300% of the tensile stiffness along an ML direction, or greater than or equal to 175% to less than or equal to 500% of the tensile stiffness along an ML direction, or greater than or equal to 175% to less than or equal to 300% of the tensile stiffness along an ML direction.

In each of numbered regions 1-5, nearly all of first-fifth tested thread patterns 1710-1750 comprise a higher tensile stiffness along an AP direction, as compared to an ML direction. However, this trend is particularly pronounced for fourth and fifth tested thread patterns 1740 and 1750. As shown by fourth and fifth tested thread patterns 1740 and 1750, in some embodiments, tensile stiffness along an anterior-posterior direction, which can be important for sports such as basketball, can be increased in a targeted manner without substantially increasing tensile stiffness along a medial-lateral direction (see comparable ML tensile stiffness data for first-third tested thread patterns 1710-1730). Accordingly, unneeded material (and weight) need not be added to achieve the overall tensile stiffness required for sports such as basketball that demand rapid changes in direction. Additionally, maintaining lower tensile stiffnesses in ML directions can provide some compliance in an upper material, which can facilitate comfort in fitting in lacing. The lower tensile stiffnesses in ML directions can allow the upper to stretch a required amount to fit a wearer's foot, while the higher tensile stiffnesses in AP directions can “lock down” the upper as a whole and prevent it from shifting laterally with respect to the sole to cause lateral spillover.

In some embodiments, the addition of a stiffening thread layer (for example, one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400 disclosed herein) can increase tensile stiffness of any thread pattern according to the same or similar magnitude changes shown in FIG. 17, in one or more of Regions 1-5 and along a desired direction. For example, FIG. 17 shows increases in tensile stiffness along AP directions in particular regions of fourth tested thread pattern 1740 (unlasted), as compared to first tested thread pattern 1710 (unlasted), that could be achieved in any unlasted thread pattern that comprises a stiffening thread layer as compared to a thread pattern that is otherwise the same, but does not. Likewise, FIG. 17 shows increases in tensile stiffness along AP directions in particular regions of fifth tested thread pattern 1750 (lasted), as compared to second tested thread pattern 1720 (lasted), that could be achieved in any lasted thread pattern that comprises a stiffening thread layer as compared to a thread pattern that is otherwise the same, but does not.

The amount of tensile stiffness increase along particular directions can be scaled according to the number and orientations of thread lines in the stiffening thread layer. Accordingly, any desired tensile stiffness increase along particular directions can be achieved. Of note, tensile stiffness of a thread pattern, measured as disclosed with respect to FIGS. 15-16, tends to be increased more along directions that are closer to parallel to thread lines of an added stiffening thread layer, with a maximum increase tending to occur along directions parallel to the thread lines. Therefore, the same or similar magnitude changes in tensile stiffness shown in FIG. 17 can be achieved in any desired direction depending on the orientation of the thread lines. FIGS. 9-12B and 14 show stiffening thread layers configured to increase tensile stiffness along the AP and ML axes in certain regions, in that vectors approximating various thread lines of these stiffening thread layers have substantial non-zero components along both the AP and ML axes. Some increase of tensile stiffness along ML directions can be useful to ensure an upper comprising one or more of these stiffening layers cannot stretch excessively in ML directions, which could also contribute to lateral instability in an article of footwear.

FIG. 18 shows tensile stiffness data for fourth tested thread pattern 1740 and fifth tested thread pattern 1750. FIG. 18 illustrates an additional benefit of the thread pattern of fourth and fifth tested thread patterns 1740, 1750 comprising a stiffening thread layer, namely, that tensile stiffness of the thread pattern, as measured along an AP direction, does not significantly decrease when the thread pattern is lasted to form fifth tested thread pattern 1750. For example, in no region does the tensile stiffness, as measured along an AP direction, decrease by more than 15% from a flat to a lasted state. Indeed, at regions 2, 4, and 5, the tensile stiffness of the thread pattern, as measured along an AP direction, increases from a flat to a lasted state.

FIG. 19 shows tensile stiffness data for tested thread patterns at different regions and along different directions. Each of the lines on the graph of FIG. 19 represents a tested thread pattern. Each of the tested thread patterns represented in FIG. 19 comprised the same combination of thread layers, and each comprised the same stiffening thread layer, for example, one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400. However, the stiffening layer comprised different numbers of thread lines for each of the tested thread patterns shown in FIG. 19. As illustrated by FIG. 19, in some embodiments, tensile stiffness along AP and/or ML directions can be scaled at one or more regions of a thread pattern by increasing or decreasing the number of thread lines in a stiffening layer, with a higher number of thread lines corresponding to higher tensile stiffnesses. In some embodiments, the same effect can be achieved by increasing the tension, and thus tensile stiffness, of the thread lines in the stiffening layer.

FIG. 20 shows a method 2000 of making an article of footwear (for example, article of footwear 100) according to some embodiments.

Unless stated otherwise, the steps of method 2000 need not be performed in the order set forth herein. Additionally, unless specified otherwise, the steps of method 2000 need not be performed sequentially. The steps can be performed in a different order or simultaneously. As one example, step 2020 can be performed after step 2030. Additionally, method 2000 need not comprise all steps shown in FIG. 21. As one example, method 2000 need not comprise step 2030 or 2040.

Step 2010 comprises defining a perimeter edge (for example, perimeter edge 520 or 620) of a thread pattern (for example, thread pattern 1520) for a shoe upper (for example, upper 120).

Step 2020 comprises winding one or more first continuous threads (for example continuous thread 502 and/or continuous thread 802) around projections to form a first thread layer (for example, thread layer 500 and/or thread layer 800) comprising first thread lines (for example, thread lines 504 and/or thread lines 804) extending between points on the perimeter edge.

Step 2030 comprises winding one or more second continuous threads (for example, continuous thread 602) around projections to form a second thread layer (for example, thread layer 600) comprising second thread lines (for example, thread lines 604) extending between points on the perimeter edge. In some embodiments, the second thread lines can be concentrated in an edge region (for example, edge region 630) of the thread pattern.

Step 2040 comprises winding one or more third continuous threads (for example, continuous threads 702, 722, and/or 742) around projections to form a third thread layer (for example, thread layers 700, 720, and/or 740) comprising third thread lines (for example, thread lines 704, 724, and/or 744) extending to points on a throat portion (for example, throat portion 522 or 624) of the perimeter edge.

Step 2050 comprises winding one or more fourth continuous threads (for example, continuous thread 902, 1002, 1102, 1202, 1222, 1302, or 1402) around a plurality of projections to form a fourth thread layer (for example, thread layer 900, 1000, 1100, 1200, 1220, 1300, or 1400) comprising fourth thread lines (for example, thread lines 904, 1004, 1104, 1204, 1224, 1304, or 1404) extending between points on the perimeter edge.

Step 2060 comprises bonding the first, second, third, and fourth thread layers to one another, for example, via heat, pressure, and/or any of the bonding methods disclosed herein. When the first, second, third, and fourth thread layers are bonded to one another, the first, second, third, and fourth thread lines can be bonded to other first, second, third, and/or fourth thread lines at intersection points.

Step 2070 comprises cutting the first, second, third, and fourth continuous threads along the perimeter edge to form the thread pattern.

Step 2080 comprises orienting the thread pattern relative to a sole (for example, sole 180) of the article of footwear (for example, article of footwear 100). In some embodiments, step 2080 can comprise orienting the thread pattern relative to the sole such that the first thread lines are concentrated in at least one of a forefoot region (for example, forefoot region 110) or a heel region (for example, heel region 114) of the article of footwear. In some embodiments, step 2080 can comprise orienting the thread pattern relative to the sole such that a first plurality of the fourth thread lines extend at an angle less than or equal to 45 degrees with respect to a lengthwise axis (for example, lengthwise axis L) of the article of footwear. In some embodiments, step 2080 can comprise orienting the thread pattern relative to the sole such that the first plurality of the fourth thread lines extend substantially parallel to the lengthwise axis of the article of footwear. In some embodiments, step 2080 can comprise orienting the thread pattern relative to the sole such that a second plurality of the fourth thread lines extend at an angle greater than or equal to 45 degrees with respect to a lengthwise axis of the article of footwear. In some embodiments, step 2080 can comprise orienting the thread pattern relative to the sole such that the second plurality of the fourth thread lines extend substantially perpendicular to the lengthwise axis of the article of footwear.

Step 2090 comprises coupling at least a portion of the perimeter edge to the sole. In some embodiments, step 2090 can comprise coupling at least the portion of the perimeter edge to the sole via stitching and/or board lasting. The perimeter edge can be coupled to the sole directly (for example, the perimeter edge contacts the sole) or indirectly (via an intervening component such as a bootie or other shoe upper component).

In some embodiments, method 2000 can further comprise winding one or more fifth continuous threads (for example, continuous thread 802) around a plurality of projections to form a fifth thread layer (for example, thread layer 800) comprising fifth thread lines (for example, thread lines 804) extending between points on the perimeter edge. In such embodiments, method 2000 can comprise bonding the fifth thread layer to the first, second, third, and fourth thread layers for example, via heat, pressure, and/or any of the bonding methods disclosed herein. The fifth thread lines can be bonded to the first, second, third, and/or fourth thread lines, and to each other, at intersection points. In some embodiments, step 2080 can comprise orienting the thread pattern relative to the sole such that the fifth thread lines are concentrated in a heel region (for example, heel region 114) of the article of footwear.

FIGS. 21A-21B show thread layer 2100 according to some embodiments. In some embodiments, thread layer 2100 can comprise a sub-layer gradient. In such embodiments, the sub-layer gradient of thread layer 2100 can be configured to provide a gradual transition from a first property of a thread pattern or the thread layer to a second property of the thread pattern or thread layer.

In some embodiments, thread layer 2100 can comprise a plurality of sub-layers. In some embodiments, thread layer 2100 can comprise sub-layers 2110, 2120, and 2130, respectively. Sub-layers 2110, 2120, and 2130 can each comprise thread lines extending between points on perimeter edge 520. For example, sub-layer 2110 can comprise thread lines 2112, sub-layer 2120 can comprise thread lines 2122, and sub-layer 2130 can comprise thread lines 2132. Sub-layers 2110, 2120, and 2130 can be part of the same thread layer 2100, and as such, thread lines 2112, 2122, and 2132 can comprise the same thread type.

Thread layer 2100 can provide a gradual transition from the first property to the [0257] second property by comprising varying thread line densities in a particular direction. For example, in some embodiments, thread layer 2100 can comprise thread line densities that increase in a direction away from an edge thread line 2114 of thread layer 2100. Edge thread line 2114 can mark the edge of thread layer 2100 on a shoe upper. In some embodiments, the thread line densities can gradually increase in the direction away from the edge thread line 2114. For example, a first region 2140 of thread layer 2100 can contain a smaller number of thread lines than a second region 2150 of thread layer 2100, which can contain a smaller number of thread lines than a third region 2160 of thread layer 2100. Each of the first, second, and third regions 2140, 2150, 2160 can be the same volume and shape. First region 2140 can abut the edge of thread layer 2100 (as marked by the extreme of edge thread line 2114), second region 2150 can abut first region 2140 and be distal from the edge, and third region 2160 can abut second region 2150 and be further distal from the edge.

In some embodiments, the weight of thread layer 2100, measured in grams per square meter (GSM), can gradually increase from the first region 2140 to the second region 2150, and from the second region 2150 to the third region 2160. In such embodiments, the gradual increase in weight can be a result of the different number of thread lines in each region.

In some embodiments, sub-layers 2110, 2120, and 2130 can be wound immediately adjacent one another. In some embodiments, sub-layers 2110, 2120, and 2130 can overlap one another. That is, thread lines of sub-layers 2110, 2120, and 2130 can intersect and/or overlay one another. In some embodiments, sub-layers 2110, 2120, and 2130 can contact one another.

As used herein, a “sub-layer” refers to a group of thread lines that occupy a common level in the stack of a thread layer. As shown in FIG. 21B, sub-layer 2110 can be made up of thread lines 2112 that occupy a common level X comprising a thread line count of N. Likewise, sub-layer 2120 can be made up of thread lines 2122 that occupy a common level Y comprising a thread line count of N-a. Sub-layer 2130 can be made up of thread lines 2132 that occupy a common level Z comprising a thread line count of (N-a)-b. In some embodiments, the level a thread line occupies can be determined by the highest number of thread lines the thread line overlaps at any single point on the thread line. For example, a thread line 2122 that overlaps a single thread line 2112 at any single point on the thread line 2122 occupies level Y corresponding to sub-layer 2120. In the process of determining the level a thread line occupies, thread lines above the thread line on the vertical axis V (shown in FIG. 21B) are ignored. Axis V extends outward from thread layer 2100 in a direction configured to extend outward from a shoe upper.

As shown in FIG. 21B, in some embodiments, each of sub-layers 2110, 2120, 2130 can comprise a different thread line count. In some embodiments, a thread line count of sub-layers 2120, 2130 can decrease with respect to a thread line count of an immediately adjacent overlapping sub-layer. For example, the thread line count of sub-layer 2120 can decrease with respect to the thread line count of sub-layer 2110 by a number a. Likewise, the thread line count of sub-layer 2130 can decrease with respect to the thread line count of sub-layer 2120 by a number b. In some embodiments, a and b can be the same. In some embodiments, a and b can be different. In some embodiments, a and b can both be at least two. In some embodiments, a and/or b can be one.

While FIGS. 21A-21B show only three sub-layers 2110, 2120, and 2130, in some embodiments, thread layer 2100 can comprise more sub-layers, such as four, five, six, seven, eight, nine, or ten sub-layers. In such embodiments, a thread line count of each sub-layer above sub-layer 2110 can decrease with respect to a thread line count of an immediately adjacent overlapping sub-layer as described for sub-layers 2110, 2120, and 2130.

In some embodiments, one or more of sub-layers 2110, 2120, and 2130 can comprise thread lines extending substantially parallel to thread lines of an immediately adjacent overlapping sub-layer. For example, in some embodiments, sub-layer 2130 can comprise multiple thread lines 2132 extending substantially parallel to multiple thread lines 2122 of sub-layer 2120. In some embodiments, each of sub-layers 2110, 2120, and 2130 can comprise thread lines extending substantially parallel to thread lines of an immediately adjacent overlapping sub-layer.

In some embodiments, one or more of sub-layers 2110, 2120, and 2130 comprises thread lines that overlay thread lines of an immediately adjacent overlapping sub-layer along entire lengths of the thread lines of the immediately adjacent overlapping sub-layer. For example, in some embodiments, sub-layer 2130 can comprise multiple thread lines 2132 that overlay multiple thread lines 2122 of sub-layer 2120. In some embodiments, each of sub-layers 2110, 2120, and 2130 comprises thread lines that overlay thread lines of an immediately adjacent overlapping sub-layer along entire lengths of the thread lines of the immediately adjacent overlapping sub-layer.

Thread lines of sub-layers 2110, 2120, and 2130 need not be aligned as shown in FIGS. 21A-21B. In some embodiments, one or more of sub-layers 2110, 2120, and 2130 (and optionally additional sub-layers) can comprise thread lines extending at an angle greater than 45 degrees with respect to thread lines of an immediately adjacent overlapping sub-layer. In some embodiments, one or more of sub-layers 2110, 2120, and 2130 (and optionally additional sub-layers) can comprise thread lines extending substantially perpendicular to thread lines of an immediately adjacent overlapping sub-layer. As used herein, thread lines extending “substantially” perpendicular to an axis or other thread line(s) means the thread lines extend at angles from 70 degrees to 110 degrees with respect to the axis or other thread line(s). In such embodiments, thread layer 2100 can comprise sub-layers forming gradients in multiple directions.

The order of sub-layers 2110, 2120, and 2130 shows in FIGS. 21A-21B does not imply an order of winding the sub-layers. In some embodiments, the thread line count of each of sub-layers 2110, 2120, and 2130 can progressively decrease in a direction of axis V (extending outward from a shoe upper), as shown in FIG. 21B. In some embodiments, the thread line count of each of sub-layers 2110, 2120, and 2130 can progressively decrease in a direction opposite axis V (extending inward into a shoe upper).

In some embodiments, a number of overlapping sub-layers 2110, 2120, and 2130 of thread layer 2100 at a point on thread layer 2100 progressively increases in a direction extending along axis U (shown in FIG. 21B). When thread layer 2100 is incorporated into a shoe upper, axis U extends along the shoe upper away from edge thread line 2114 of thread layer 2100.

The features of thread layer 2100 related to forming a gradient can be applied with any thread layer described herein, for example, thread layer 500, 600, 700, 720, 740, 800, 900, 1000, 1100, 1200, 1220, 1300, or 1400. For example, in some embodiments, a gradient can be implemented in thread layer 500 (toe bumper layer). In such embodiments, a number of overlapping sub-layers thread layer 500 at a point on thread layer 500 can progressively decrease in a direction extending parallel to the AP axis of a thread pattern (for example thread pattern 1520) comprising thread layer 500 from a forefoot end (for example, forefoot end 102) of the article of footwear. In some embodiments, the thread line density of thread layer 500 can decrease along the AP axis from the forefoot end of the article of footwear.

In some embodiments, a gradient can be implemented in one of thread layers 900, 1000, 1100, 1200, 1220, 1300, and 1400. In such embodiments, a number of overlapping sub-layers of one of these thread layers at a point on the thread layer can progressively increase in a direction extending parallel to the AP axis of a thread pattern (for example thread pattern 1520) comprising the thread layer from a forefoot region (for example, forefoot region 110) to a heel region (for example, heel region 114) of the article of footwear. In some embodiments, the thread line density of the thread layer can increase along the AP axis from the from the forefoot region to the heel region.

In some embodiments, a gradient as described in reference to thread layer 2100 can be created by a group of adjacent and overlapping thread layers, rather than different sub-layers within a single thread layer. In such embodiments, a thread pattern 2100a comprising adjacent thread layers 2110a, 2120a, and 2130a arranged in the same manner as sub-layers 2110, 2120, and 2130 can create the gradient. In such embodiments, the thread layers 2110a, 2120a, and 2130a can comprise different thread types with a characteristic value that progressively changes with respect to the same thread type characteristic value from layer to layer. For example, in some embodiments, the thread layers 2110a, 2120a, and 2130a can comprise different thread types with a tensile stiffness that progressively changes from layer to layer. In such embodiments, the tensile stiffness can progressively increase or decrease by at least 10% for each of thread layers 2110a, 2120a, and 2130a. In some embodiments, thread layers 2110a, 2120a, and 2130a can comprise thread lines of different materials that comprise such tensile stiffness differences even in an unwound state. In some embodiments, thread layers 2110a, 2120a, and 2130a can comprise the same material, but tensile stiffness can progressively increase or decrease by varying the tension at which thread lines of thread layers 2110a, 2120a, and 2130a are wound.

In such embodiments, thread layers 2110a, 2120a, 2130a, etc. overlap in the same manner as described herein for sub-layers 2110, 2120, 2130, etc. In such embodiments, each layer can occupy a different level in the stack of a thread pattern. As shown in FIG. 21B, layer 2110a can be made up of thread lines 2112a that occupy a common level X comprising a thread line count of N. Likewise, layer 2120a can be made up of thread lines 2122a that occupy a common level Y comprising a thread line count of N-a. And layer 2130a can be made up of thread lines 2132a that occupy a common level Z comprising a thread line count of (N-a)-b. In some embodiments, the level a thread line occupies can be determined by the highest number of thread lines the thread line overlaps at any single point on the thread line. For example, a thread line 2122a that overlaps a single thread line 2112a at any single point on the thread line 2122a occupies level Y corresponding to layer 2120a. In the process of determining the level a thread line occupies, thread lines above the thread line on the vertical axis V (shown in FIG. 21B) are ignored. Axis V extends outward from thread pattern 2100a in a direction configured to extend outward from a shoe upper.

As shown in FIG. 21B, in some embodiments, each of adjacent layers 2110a, 2120a, 2130a can comprise a different thread line count. In some embodiments, a thread line count of layers 2120a, 2130a can decrease with respect to a thread line count of an immediately adjacent overlapping layer. For example, the thread line count of layer 2120a can decrease with respect to the thread line count of layer 2110a by a number a. Likewise, the thread line count of layer 2130a can decrease with respect to the thread line count of layer 2120a by a number b. In some embodiments, a and b can be the same. In some embodiments, a and b can be different. In some embodiments, a and b can both be at least two. In some embodiments, a and/or b can be one.

Similarly, thread pattern 2100a can provide a gradual transition from the first property to the second property by varying thread line density and thread type in a particular direction. For example, in some embodiments, thread pattern 2100a can comprise thread line densities that increase in a direction away from an edge thread line 2114a of thread pattern 2100a, along with a gradual change in thread line type. Edge thread line 2114a can mark the edge of thread pattern 2100a on a shoe upper. In some embodiments, the thread line densities can gradually increase in the direction away from the edge thread line 2114a, along with a corresponding decrease in the thread type characteristic that progressively changes from layer to layer.

FIG. 22 shows a method 2200 of making an article of apparel (for example, article of footwear 100) according to some embodiments. As used herein, “apparel” can be any item that is worn or adorns an individual, including both clothing and accessories. Clothing can comprise, but is not limited to pants, shorts, leggings, socks, a shoe (which can refer any type of footwear, including a sneaker, a cleat, a boot, a slipper, a flip-flop, a sandal, etc.), a shoe upper, a shoe sole, a jacket, a coat, a hat, a sleeve, a sweater, a shirt, a bra, a jersey, a bootie, a glove, an arm sleeve, a knee sleeve, an elbow sleeve, a wrist sleeve, an ankle sleeve. Accessories can comprise, but are not limited to a headband, a waistband, a belt, a wristband, a bracelet, a watch band, a shoulder wrap, a tape, a shin guard, a hat, a tie, a scarf, a purse, a handbag, a wallet, a knapsack, or a backpack. In particular embodiments, any article of apparel described herein can be an article of footwear (for example, article of footwear 100), an upper for an article of footwear, or a sole for an article of footwear.

Unless stated otherwise, the steps of method 2200 need not be performed in the order set forth herein. Additionally, unless specified otherwise, the steps of method 2200 need not be performed sequentially. The steps can be performed in a different order or simultaneously. As one example, steps 2220, 2230, and 2240 can be performed in that order or in reverse order. Additionally, method 2200 need not comprise all steps shown in FIG. 22. As one example, method 2200 need not comprise step 2240.

Step 2210 comprises defining a perimeter edge (for example, perimeter edge 520 or 620) of a thread layer (for example, thread layer 2100) for the article of apparel.

Step 2220 comprises winding one or more continuous threads around projections to form a first thread layer (for example, sub-layer 2110) comprising first thread lines (for example, thread lines 2112) extending between points on the perimeter edge. In some embodiments, the first sub-layer can comprise a first thread line count (for example, N).

Step 2230 comprises winding the one or more continuous threads around projections to form a second sub-layer (for example, sub-layer 2120) that overlaps the first sub-layer, the second-sub layer comprising second thread lines (for example, thread lines 2122) extending between points on the perimeter edge. In some embodiments, the second sub-layer can comprise a second thread line count less than the first thread line count.

Step 2240 comprises winding the one or more continuous threads around projections to form a third sub-layer (for example, sub-layer 2130) that overlaps the first and second sub-layers, the third sub-layer comprising third thread lines (for example, thread lines 2132) extending between points on the perimeter edge. In some embodiments, the third sub-layer can comprise a thread line count less than the second thread line count.

Step 2250 comprises bonding the first, second, and third sub-layers to one another, for example, via heat, pressure, and/or any of the bonding methods disclosed herein. When the first, second, and third sub-layers are bonded to one another, their thread lines (for example, thread lines 2112, 2122, and/or 2132) can be bonded at intersection points. In some embodiments, the bonding of the first, second, and third sub-layers at step 2250 can be part of bonding together thread layers of a thread pattern (for example, thread pattern 1520) that includes the thread layer.

Step 2260 comprises cutting the one or more continuous threads along the perimeter edge to form the thread layer. In some embodiments, the thread layer can be part of the thread pattern, which is cut at step 2260.

Step 2270 comprises coupling at least a portion of the perimeter edge to the article of apparel. In some embodiments, step 2270 can comprise coupling at least the portion of the perimeter edge to a sole (for example, sole 180) via stitching and/or board lasting. In some embodiments, the perimeter edge can be coupled directly or via another component. In some embodiments, the perimeter edge can form part of a perimeter edge of a thread pattern (for example, thread pattern 1520) that is coupled to an article of apparel (for example, article of footwear 100). In some embodiments, method 2200 can omit step 2270. In such embodiments, the thread pattern comprising the thread layer (or the thread layer itself) can define the article of apparel.

In some embodiments, method 2200 can comprise winding additional sub-layers that progressively decrease or increase in thread line count.

In some embodiments, method 2200 can be performed for any one or more of the thread layers identified in method 2000 (for example, for thread layer 500, 600, 700, 720, 740, 800, 900, 1000, 1100, 1200, 1220, 1300, and/or 1400). In some embodiments, method 2200 can comprise winding adjacent layers 2110a, 2120a, 2130a, etc. instead of sub-layers of the same thread layer.

In some embodiments, a gradient transition from a first property of a thread pattern to a second property of the thread pattern can be created by a thread pattern comprising edge-adjacent thread layers, with each layer comprising a different thread type, and the thread type of each of the edge-adjacent thread layers comprising a thread type characteristic value that decreases with respect to same thread type characteristic value of an immediately adjacent edge-adjacent thread layer.

In such embodiments, the “edge-adjacent thread layers” refers to a group of thread layers that occupy any number of levels in the stack of a thread pattern and comprise edge thread lines that are immediately adjacent to each other in the stack. In some embodiments, two edge-adjacent thread layers can be separated by a thread layer occupying a level between a first edge-adjacent thread layer and a second edge-adjacent thread layer. In some embodiments, the edge-adjacent thread layers can be level-adjacent thread layers. “Level-adjacent thread layers” refers to a group of thread layers that occupy a common level in the stack of a thread pattern and comprise edge thread lines that are immediately adjacent to each other in the level.

FIGS. 24A and 24B illustrate a thread pattern 2400 comprising edge-adjacent thread layers 2410, 2420, and 2430 comprising different thread types with a characteristic that progressively changes from layer to layer. In such embodiments, the thread type of each of the edge-adjacent thread layers 2410, 2420, and 2430 comprises a thread type characteristic value that increases or decreases with respect to same thread type characteristic value of an immediately adjacent edge-adjacent thread layer 2410, 2420, and 2430. For example, in some embodiments, the thread layers 2410, 2420, and 2430 can comprise different thread types with a tensile stiffness that progressively changes from layer to layer. In such embodiments, the tensile stiffness can progressively increase or decrease by at least 10% for each of thread layers 2410, 2420, and 2430. In some embodiments, thread layers 2410, 2420, and 2430 can comprise thread lines of different materials that comprise such tensile stiffness differences even in an unwound state. In some embodiments, thread layers 2410, 2420, and 2430 can comprise the same material, but tensile stiffness can progressively increase or decrease by varying the tension at which thread lines of thread layers 2410, 2420, and 2430 are wound.

Edge-adjacent thread layers 2410, 2420, and 2430 comprise thread lines 2412, 2422, and 2432, respectively. Further, each of thread layers 2410, 2420, and 2430 comprise a leading edge thread line and a trailing edge thread line. Thread layer 2410 comprises a leading edge thread line 2414 and a trailing edge thread line 2416. Thread layer 2420 comprises a leading edge thread line 2424 and a trailing edge thread line 2426. Thread layer 2430 comprises a leading edge thread line 2434 and a trailing edge thread line 2436.

Leading edge thread lines can mark a first edge of a thread pattern on a shoe upper and trailing edge thread lines can mark a second edge of the thread pattern on the shoe upper opposite the leading edge. In a series of edge-adjacent thread layers, a leading edge thread line of the second edge-adjacent thread layer will be immediately adjacent a trailing edge thread line of a first edge-adjacent thread layer, and so on. For example, as shown in FIGS. 24A and 24B, leading edge thread line 2424 of edge-adjacent thread layer 2420 is immediately adjacent trailing edge thread line 2416 of edge-adjacent thread layer 2410, and so on.

In some embodiments, each of the edge-adjacent thread layers 2410, 2420, and 2430 do not comprise a thread line that overlays a thread line of an immediately adjacent edge-adjacent thread layer along entire lengths of the thread lines. For example, leading edge thread line 2424 of edge-adjacent thread layer 2420 may not overlay trailing edge thread line 2416 of edge-adjacent thread layer 2410 along entire lengths of the thread lines, and so on.

In some embodiments, each edge-adjacent thread layer 2410, 2420, and 2430 can comprise thread lines 2412, 2422, 2432 that extend substantially parallel to thread lines 2412, 2422, 2432 of an immediately adjacent edge-adjacent thread layer 2410, 2420, and 2430. For example, thread layer 2410 can comprise thread lines 2412 that extend substantially parallel to thread lines 2422 of thread layer 2420. In some embodiments, each edge-adjacent thread layer 2410, 2420, and 2430 can comprise thread lines 2412, 2422, 2432 that extend substantially parallel to thread lines 2412, 2422, 2432 of each other edge-adjacent thread layer 2410, 2420, and 2430. For example, thread layer 2410 can comprise thread lines 2412 that extend substantially parallel to thread lines 2422 of thread layer 2420 and substantially parallel to thread lines 2432 of thread layer 2430.

In some embodiments, the thread type characteristic value of each of the edge-adjacent thread layers 2410, 2420, and 2430 decreases or increases with respect to the thread type characteristic value the immediately adjacent edge-adjacent layer 2410, 2420, and 2430 by the same increment. For example, the thread type characteristic value of adjacent edge-adjacent layers 2410, 2420, and 2430 can progressively decrease or increase by a 10% increment.

FIG. 23 shows an exemplary computer system 2300 by which embodiments, or portions thereof, can be implemented as computer-readable code, according to some embodiments. For example, aspects of the methods discussed herein can be implemented by computer system 2300 using hardware, software, firmware, tangible computer readable media having instructions stored thereon, or a combination thereof and can be implemented by one or more computer systems or other processing systems.

If programmable logic is used, such logic can execute on a commercially available processing platform or a special purpose device. One of ordinary skill in the art can appreciate that embodiments of the disclosed subject matter can be practiced with various computer system configurations, including multi-core multiprocessor systems, minicomputers, and mainframe computers, computer linked or clustered with distributed functions, as well as pervasive or miniature computers that can be embedded into virtually any device.

For instance, at least one processor device and a memory can be used to implement the above-described embodiments. A processor device can be a single processor, a plurality of processors, or combinations thereof. Processor devices can have one or more processor “cores.”

Various embodiments described herein can be implemented in terms of this example computer system 2300. After reading this description, it will become apparent to a person skilled in the relevant art how to implement one or more of the embodiments using other computer systems and/or computer architectures. Although operations can be described as a sequential process, some of the operations can in fact be performed in parallel, concurrently, and/or in a distributed environment, and with program code stored locally or remotely for access by single or multi-processor machines. In addition, in some embodiments the order of operations can be rearranged without departing from the spirit of the disclosed subject matter.

Processor device 2304 can be a special purpose or a general-purpose processor device. As will be appreciated by persons skilled in the relevant art, processor device 2304 can also be a single processor in a multi-core/multiprocessor system, such system operating alone, or in a cluster of computing devices operating in a cluster or server farm. Processor device 2304 is connected to a communication infrastructure 2306, for example, a bus, message queue, network, or multi-core message-passing scheme.

Computer system 2300 also comprises a main memory 2308, for example, random access memory (RAM), and can also comprise a secondary memory 2310. Secondary memory 2310 can comprise, for example, a hard disk drive 2312, or removable storage drive 2314. Removable storage drive 2314 can comprise a floppy disk drive, a magnetic tape drive, an optical disk drive, a flash memory, a Universal Serial Bus (USB) drive, or the like. The removable storage drive 2314 reads from and/or writes to a removable storage unit 2318 in a well-known manner. Removable storage unit 2318 can comprise a floppy disk, magnetic tape, optical disk, etc. which is read by and written to by removable storage drive 2314. As will be appreciated by persons skilled in the relevant art, removable storage unit 2318 comprises a computer usable storage medium having stored therein computer software and/or data.

Computer system 2300 (optionally) comprises a display interface 2302 (which can comprise input and output devices such as keyboards, mice, etc.) that forwards graphics, text, and other data from communication infrastructure 2306 (or from a frame buffer not shown) for display on display unit 2330.

In additional and/or alternative implementations, secondary memory 2310 can comprise other similar means for allowing computer programs or other instructions to be loaded into computer system 2300. Such means can comprise, for example, a removable storage unit 2322 and an interface 2320. Examples of such means can comprise a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units 2322 and interfaces 2320 which allow software and data to be transferred from the removable storage unit 2322 to computer system 2300.

Computer system 2300 can also comprise a communication interface 2324. Communication interface 2324 allows software and data to be transferred between computer system 2300 and external devices. Communication interface 2324 can comprise a modem, a network interface (such as an Ethernet card), a communication port, a PCMCIA slot and card, or the like. Software and data transferred via communication interface 2324 can be in the form of signals, which can be electronic, electromagnetic, optical, or other signals capable of being received by communication interface 2324. These signals can be provided to communication interface 2324 via a communication path 2326. Communication path 2326 carries signals and can be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, an RF link or other communication channels.

In this document, the terms “computer program medium” and “computer usable medium” are used to generally refer to media such as removable storage unit 2318, removable storage unit 2322, and a hard disk installed in hard disk drive 2312. Computer program medium and computer usable medium can also refer to memories, such as main memory 2308 and secondary memory 2310, which can be memory semiconductors (for example, DRAMs, etc.).

Computer programs (also called computer control logic) are stored in main memory 2308 and/or secondary memory 2310. Computer programs can also be received via communication interface 2324. Such computer programs, when executed, enable computer system 2300 to implement the embodiments as discussed herein. In particular, the computer programs, when executed, enable processor device 2304 to implement the processes of the embodiments discussed here. Accordingly, such computer programs represent controllers of the computer system 2300. Where the embodiments are implemented using software, the software can be stored in a computer program product and loaded into computer system 2300 using removable storage drive 2314, interface 2320, and hard disk drive 2312, or communication interface 2324.

Embodiments described herein also can be directed to computer program products comprising software stored on any computer useable medium. Such software, when executed in one or more data processing device, causes a data processing device(s) to operate as described herein. Embodiments described herein can employ any computer useable or readable medium. Examples of computer useable mediums comprise, but are not limited to, primary storage devices (for example, any type of random access memory), secondary storage devices (for example, hard drives, floppy disks, CD ROMS, ZIP disks, tapes, magnetic storage devices, and optical storage devices, MEMS, nanotechnological storage device, etc.).

While various embodiments have been described herein, they have been presented by way of example, and not limitation. It should be apparent that adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It therefore will be apparent to one skilled in the art that various changes in form and detail can be made to the embodiments disclosed herein without departing from the spirit and scope of the present disclosure. The elements of the embodiments presented herein are not necessarily mutually exclusive, but can be interchanged to meet various situations as would be appreciated by one of skill in the art.

Where a range of numerical values comprising upper and lower values is recited herein, unless otherwise stated in specific circumstances, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the disclosure or claims be limited to the specific values recited when defining a range. Further, when an amount, concentration, or other value or parameter is given as a range, one or more ranges, or as list of upper values and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper range limit or value and any lower range limit or value, regardless of whether such pairs are separately disclosed.

The foregoing description of the specific embodiments will so fully reveal the general nature of the invention(s) that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention(s). Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.

The breadth and scope of the present invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.