HK1110751B - Article of footwear having an upper with thread structural elements - Google Patents

Abstract

An article of footwear includes an upper that is at least partially formed from a base layer and thread sections that lie adjacent a surface of the base layer. The thread sections are positioned to provide structural elements that, for example, restrain stretch in directions corresponding with longitudinal axes of the thread sections. In some configurations of the footwear, a first portion of the thread sections may extend between forefoot and heel regions of the footwear, and a second portion of the thread sections may extend vertically. An embroidering process may be utilized to position the thread sections on the base layer.

Description

Footwear having upper with thread structural elements

Background

Conventional footwear products generally include two primary elements, an upper and a sole structure. The upper is secured to the sole structure and forms a void within the interior of the footwear for comfortably and securely receiving a foot. The sole structure is secured to a lower surface of the upper so as to be positioned between the upper and the ground. For example, in some athletic footwear products, the sole structure may include a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces to relieve pressure on the foot and leg during running, walking, and other ambulatory activities. The outsole is secured to a lower surface of the midsole and forms a ground-contacting portion of a sole structure that is formed from a durable and wear-resistant material. The sole structure may also include a sockliner (sockliner) positioned within the void and proximate a bottom surface of the foot to enhance footwear comfort.

The upper generally extends over the instep and toe areas of the foot, along the medial and lateral sides of the foot, and around the heel area of the foot. In some articles of footwear, such as basketball shoes and boots, the upper may extend upward and around the ankle to provide support for the ankle. Access to the void on the interior of the upper is generally provided by an ankle opening in the heel region of the footwear. A lacing system is often incorporated into the upper to adjust the comfort of the upper and thereby permit entry and removal of the foot from the void within the upper. The lacing system also allows the wearer to modify certain dimensions of the upper, particularly the circumference, to accommodate feet with varying dimensions. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability of the footwear, and the upper may incorporate a heel counter (heel counter) to limit movement of the heel.

Different materials are commonly used in the manufacture of shoe uppers. For example, the upper of an athletic shoe may be formed from multiple material layers that include an exterior layer, a middle layer, and an interior layer. The materials forming the exterior layer of the upper may be selected based upon the properties of stretch-resistance, wear-resistance, flexibility, and air-permeability, for example. With respect to the outer layer, the toe region and the heel region may be made of leather, synthetic leather, or a rubber material to impart a relatively high degree of wear-resistance. Leather, synthetic leather, and rubber materials may not exhibit the desired degree of flexibility and air-permeability for the various other areas of the exterior layer of the upper. Thus, other areas of the outer layer may be made of, for example, synthetic fabric. Accordingly, the exterior layer of the upper may be formed from numerous material elements that each impart different properties to the upper. The middle layer of the upper is typically formed from a lightweight polymer foam material that provides cushioning and enhances comfort. Similarly, an interior layer of the upper may be formed of a comfortable and moisture-wicking textile that removes perspiration from the area immediately surrounding the foot. In some articles of athletic footwear, the various layers may be joined with adhesives, and stitching may be used to join elements within the individual layers or to reinforce specific areas of the upper. Accordingly, the conventional upper has a layered structure, and each individual layer imparts different properties to different areas of the footwear.

SUMMARY

One aspect of the invention is an article of footwear having an upper and a sole structure secured to the upper. The upper includes a base layer, threads, and a securing component. The base layer defines a first surface and an opposing second surface. The line has segments, for example, located close to the first surface and substantially parallel to the first surface at a spacing greater than twelve millimeters. Furthermore, the fixing part is connected to the base layer.

Another aspect of the invention is an article of footwear having an upper with a base layer and a plurality of thread segments. The base layer has a first surface and an opposing second surface. The thread segments are spaced apart from the base layer and are located adjacent to at least a portion of the first surface. At least some of the line segments are substantially aligned. The upper defines a first direction corresponding to a strand segment longitudinal axis, and the upper defines a second direction orthogonal to the first direction. The upper is substantially inextensible in a first direction and the upper is extensible by at least ten percent in a second direction.

Yet another aspect of the invention is a method of manufacturing an article of footwear having an upper and a sole structure. The method includes embroidering a base layer with at least one thread to position a plurality of segments of the thread proximate a surface of the base layer for more than twelve millimeters. The base layer and the at least one thread are incorporated into the upper, which is secured to the sole structure.

The advantages and features of novelty characterizing the present invention are pointed out with particularity in the appended claims. To gain an improved understanding of the advantages and features of novelty, however, reference may be made to the following descriptive matter and accompanying drawings that describe and illustrate various embodiments and concepts related to the invention.

Drawings

The foregoing summary, as well as the following detailed description of the invention, will be better understood when read in conjunction with the appended drawings.

FIG. 1 is a lateral side elevational view of an article of footwear having an upper in accordance with aspects of the invention;

FIG. 2 is a medial side elevational view of the article of footwear;

FIG. 3 is a top plan view of the article of footwear;

FIG. 4 is a bottom plan view of the article of footwear;

FIG. 5 is a rear elevational view of the article of footwear;

FIG. 6 is a top plan view of a first embroidered element forming at least a portion of a lateral side of the upper;

FIG. 7 is a top plan view of a second embroidered element forming at least a portion of a medial side of the upper;

8A-8O are top plan views illustrating steps for forming a first embroidered element and a second embroidered element;

FIGS. 9A-9D are front views of steps for assembling a shoe;

FIGS. 10A-10D are perspective views of a first step for securing a wire to a base portion;

11A-11D are perspective views of a second step for securing a wire to a base portion;

fig. 12A-12C are perspective views of a third step for securing the thread to the base portion.

Detailed Description

Introduction to

The following discussion and accompanying figures disclose an article of footwear having an upper with an embroidered configuration. In addition, different methods of manufacturing the upper are disclosed. The disclosed upper and method relate to footwear having a structure that is suitable for running, particularly sprinting. However, the concepts related to the upper are not limited to footwear designed for running, but may be utilized in a wide variety of athletic footwear styles, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, soccer shoes, tennis shoes, football shoes, walking shoes, and hiking shoes, for example. The concepts may be applied to footwear styles that are generally considered to be non-athletic, including dress shoes, loafers (loafers), sandals, and work boots. Accordingly, the concepts disclosed herein apply to a wide variety of footwear styles.

General structure of shoes

Article of footwear 10 is depicted in figures 1-5 as having the general structure of a running shoe and includes a sole structure 20 and an upper 30. For reference purposes, footwear 10 may be divided into three general regions: forefoot region 11, midfoot region 12, and heel region 13, as shown in fig. 1 and 2. Footwear 10 also includes a lateral side 14 and a medial side 15. Forefoot region 11 generally includes portions of footwear 10 corresponding with the toes and the joints connecting the metatarsals with the phalanges. Midfoot region 12 generally includes portions of footwear 10 corresponding with the arch area of the foot, and heel region 13 corresponds with rear portions of the foot including the calcaneus bone. Lateral side 14 and medial side 15 extend through each of regions 11-13 and correspond with opposite sides of footwear 10. Regions 11-13 and sides 14-15 are not intended to demarcate precise areas of footwear 10. Rather, regions 11-13 and sides 14-15 are intended to represent general areas of footwear 10 to aid in the following discussion. In addition to footwear 10, regions 11-13, and sides 14-15 may also be utilized for sole structure 20, and upper 30 and the individual components thereof.

Sole structure 20 is secured to upper 30 and extends between the foot and the ground when footwear 10 is worn. In addition to providing traction, sole structure 20 may attenuate ground reaction forces as sole structure 20 is compressed between the foot and the ground during walking, running, and other foot motions. The configuration of sole structure 20 may vary significantly to include a variety of conventional and non-conventional configurations. However, as an example, a suitable structure for sole structure 20 is depicted in figures 1 and 2 as including a first sole element 21 and a second sole element 22.

First sole element 21 extends through the longitudinal length of footwear 10 (i.e., through each of regions 11-13) and may be formed from a polymer foam material, such as polyurethane and ethylvinylacetate. Partial upper 30 wraps around the sides of first sole element 21 and is secured to a lower area of first sole element 21. In each of regions 11-13, a lower region of first sole element 21 is exposed to form a portion of the ground-contacting surface of footwear 10. A portion of upper 30 secured to a lower region of first sole element 21 may also be exposed in regions 12 and 13 and may contact the ground in use. An upper region of first sole element 21 is positioned to contact a bottom surface of the foot (i.e., the sole) and thereby form a foot-supporting surface within upper 30. In some configurations, however, a footbed may be located within upper 30 and adjacent an upper region of first sole element 21 to form a foot-supporting surface for footwear 10.

Second sole element 22 is positioned in each of regions 11 and 12 and is secured to either or both of first sole element 21 and upper 30. However, portions of first sole element 21 extend into upper 30, and second sole element 22 is located on an exterior surface of footwear 10 to form a portion of the ground-contacting surface in regions 11 and 12. To impart traction, second sole element 22 includes a plurality of projections 23, which may have removable cleat structures. Suitable materials for second sole element 22 include various rubbers or other polymeric materials that are both durable and wear resistant.

Upper 30 defines a void within footwear 10 for receiving and securing a foot with respect to sole structure 20. More specifically, the void is shaped to receive and extend along a lateral side of the foot, a medial side of the foot, over the foot, and under the foot. Access to the space is provided through an ankle opening 31 located in at least heel region 13. A lace 32 extends through various lace apertures 33 in upper 30 and allows the wearer to modify dimensions of upper 30 to accommodate feet of different sizes. Lace 32 also allows the wearer to relax upper 30 and facilitate removal of the foot from the void. Even if not depicted, upper 30 may include a tongue that extends under lace 32 to enhance the comfort and adjustability of footwear 10.

With the exception of lace 32, the primary elements of upper 30 are first embroidered element 40 and second embroidered element 50. First embroidered element 40 forms portions of upper 30 corresponding with lateral side 14 and second embroidered element 50 forms portions of upper 30 corresponding with medial side 15. Accordingly, each embroidered element 40 and 50 extends through each area 11-13. In general, and as described in greater detail below, upper 30 is basically assembled by joining the edges of embroidered elements 40 and 50 in forefoot region 11 and heel region 13 to impart the general shape to the void. In addition, assembled upper 30 includes a covered portion that incorporates lace 32 and embroidered elements 40 and 50 around the sides of first sole element 21, as well as securing the portions to a lower area of first sole element 21.

First embroidery unit

First embroidered element 40 is depicted individually in fig. 6 as including a base layer 41 and a plurality of threads 42. An embroidery process, which will be described in greater detail below, is used to secure or position thread 42 relative to base layer 41. In general, base layer 41 is a substrate to which threads 42 are secured during an embroidering process, and threads 42 are positioned to form structural elements within upper 30. As a structural element, for example, strands 42 may limit stretch in a particular direction of upper 30 or strands 42 may reinforce various areas of upper 30.

Although base layer 41 is depicted as a single piece of material, base layer 41 may be formed from a plurality of connected pieces. Similarly, base layer 41 may be a single layer of material, or base layer may be formed from multiple coextensive layers. As one example, base layer 41 may include a connecting layer or other securing component that bonds, secures, or otherwise connects portions of threads 42 to base layer 41.

Base layer 41 defines various edges 43a-43d, which are used as a reference in the following materials. Edge 43a extends through each of regions 11-13 and defines a portion of ankle opening 31. Edge 43b is primarily located in forefoot region 11 and forms an endpoint for different threads 42. Edge 43c, which is disposed opposite edge 43b, is located primarily in heel region 13 and forms the opposite endpoint for different threads 42. During the manufacturing process of footwear 10, edges 43a and 43c are joined with second embroidered element 50 in forefoot region 11 and heel region 13, respectively. Edge 43d, which is disposed opposite edge 43a, extends through each of regions 11-13 and wraps around first sole element 21 and is secured to a lower region of first sole element 21. The particular configuration of matrix layer 41, and the corresponding locations and shapes of edges 43a-43d, may vary significantly depending on the configuration of footwear 10.

Base layer 41 may be made of any generally two-dimensional material. As used in accordance with the present invention, the term "two-dimensional material" or variants thereof is meant to include generally flat materials exhibiting both a length and a width substantially greater than a thickness. Thus, suitable materials for base layer 41 include, for example, different fabrics, polymer sheets, or a combination of fabrics and polymer sheets. Fabrics are typically made of fibers, filaments, or yarns, either of which may be formed (a) directly from a web of fibers, by bonding, fusing, or interlocking to form nonwoven fabrics and felts, or (b) by mechanically manipulating yarns to produce a woven fabric, for example. The fabric may incorporate fibers that may be aligned to impart extensibility in one direction or extensibility in multiple directions, and may include a coating that forms a breathable and waterproof barrier, for example. The polymer sheet may be extruded, rolled, or otherwise formed from a polymer material to exhibit a generally flat appearance. Two-dimensional materials may also include laminated or otherwise layered materials comprising two or more layers of fabric, polymer sheet, or a combination of fabric and polymer sheet. In addition to textiles and polymer sheets, other two-dimensional materials may be used for base layer 41. While two-dimensional materials may have smooth or generally non-textured surfaces, some two-dimensional materials may exhibit texture or other surface features, such as, for example, indentations, protrusions, ribs (rib), or various patterns. Two-dimensional materials generally remain flat and exhibit a length and width that are substantially greater than the thickness despite the presence of surface features.

Portions of threads 42 extend through base layer 41 or are located adjacent to base layer 41. In areas where threads 42 extend through base layer 41, threads 42 are directly connected or otherwise secured to base layer 41.

Threads 42 are located in areas proximate to base layer 41 and threads 42 may not be secured to base layer 41 or may be attached with an attachment layer or other securing component that bonds, secures, or otherwise attaches portions of threads 42 to base layer 41. To form the structural elements in upper 30, multiple strands 42 or segments of a single strand 42 may be grouped together in one of different strand groups 44a-44 e. Thread group 44a includes threads 42 that extend between edges 43b and 43c, thereby extending through various regions 11-13 of footwear 10. Thread group 44b includes threads 42 that are positioned proximate lace apertures 33 and extend radially outward from lace apertures 33. Thread group 44c includes thread 42 extending from thread group 44b (i.e., the area proximate lace apertures 33) to the area proximate edge 43 d. Thread group 44d includes threads 42 that extend from edge 43c to edge 43d and are primarily located in heel region 13.

Article of footwear 10 is depicted as having the general configuration of a running shoe. During walking, running, or other foot motions, the forces generated within footwear 10 may tend to stretch upper 30 in different directions, and the forces may be concentrated in different locations. Each strand 42 is positioned to form a structural element in upper 30. More specifically, thread groups 44a-44d are collections of segments of multiple threads 42 or individual threads 42 that form structural members to resist stretching in different directions or locations where reinforcing forces are collected. Thread group 44a extends through portions of first embroidered element 40 corresponding with areas 11-13 to resist longitudinal stretching (i.e., in a direction that extends through each of areas 11-13 and between edges 43b and 43 c). Thread group 44b is positioned adjacent lace apertures 33 to resist the buildup of forces due to tension in lace 32. Thread group 44c generally extends in a direction orthogonal to thread group 44a to resist stretch in the medial-lateral direction (i.e., in a direction extending around upper 30). In addition, thread group 44d is positioned in heel region 13 to form a heel counter that limits movement of the heel. Thread group 44e extends around the periphery of base layer 41 and corresponds with the location of edges 43a-43 d. Accordingly, strands 42 are positioned to form structural elements in upper 30.

The wire 42 may be made of any generally one-dimensional material. As used with respect to the present invention, the term "one-dimensional material" or variants thereof is meant to include generally elongated materials that exhibit a length that is substantially greater than a width and a thickness. Thus, suitable materials for the thread 42 include, for example, different filaments (filaments) and yarns. In addition to the primary, naturally occurring silk, the silk may be made from a variety of synthetic materials, such as rayon, nylon, polyester, and acrylic. In addition, various engineered fibers, such as aramid fibers, para-aramid fibers, carbon fibers, and the like, may be used. The yarn may be made of at least one filament or a plurality of fibers. Filaments have an indefinite length, while fibers have a relatively short length and are usually produced via a spinning or twisting process to produce a yarn of suitable length. As regards the yarns formed by filaments, these yarns may be formed by a single filament or by a plurality of single filaments grouped together. The yarn may also comprise separate filaments made of different materials, or the yarn may comprise a plurality of filaments, each filament being made of two or more different materials. Similar concepts also apply to yarns made of fibers. Accordingly, filaments and yarns may have a variety of configurations that exhibit a length that is substantially greater than a width and a thickness. In addition to filaments and yarns, other one-dimensional materials may be used for threads 42. While one-dimensional materials will typically have a cross-section that is substantially equal in width and thickness (e.g., a circular or square cross-section), some one-dimensional materials may have a width that is greater than the thickness (e.g., a rectangular cross-section). Although the width is larger, a material may be considered a one-dimensional structure if its length is substantially greater than the width and thickness of the material.

Second embroidery unit

Second embroidered element 50 is depicted individually in fig. 7 as including a base layer 51 and a plurality of threads 52. An embroidery process similar to the embroidery process used to form first embroidered element 50 is used to secure or position thread 52 relative to base layer 51. In general, base layer 51 is a substrate to which threads 52 are secured during an embroidering process, and threads 52 are positioned to form structural elements in upper 30. As a structural element, strands 52 may, for example, limit stretch in a particular direction of upper 30 or strands 52 may reinforce various areas of upper 30.

Base layer 51 may be made of any generally two-dimensional material, including any of the two-dimensional materials described above for base layer 41. Although the base layer 51 is described as a single piece of material, the base layer 51 may be formed from a plurality of connected pieces. Similarly, the base layer 51 may be a single layer of material, or the base layer may be formed from multiple coextensive layers. As one example, base layer 51 may include a connecting layer or other securing component that bonds, secures, or otherwise connects portions of threads 52 to base layer 51. Further, the thread 52 may be made of any generally one-dimensional material, including any one-dimensional material used for the thread 42 described above.

The base layer 51 defines various edges 53a-53d, which are referenced in the following materials. Edge 53a extends through each of regions 11-13 and defines a portion of ankle opening 31. Edge 53b is primarily located in forefoot region 11 and forms an endpoint for different threads 52. Edge 53c, which is disposed opposite edge 53b, is primarily located in heel region 13 and forms the opposite endpoint for different threads 52. During the manufacturing process of footwear 10, edges 53a and 53c connect with second embroidered element 40 in forefoot region 11 and heel region 13, respectively. Edge 53d, which is disposed opposite edge 53a, extends through each of regions 11-13 and wraps around first sole element 21 and is secured to a lower region of first sole element 21. The particular configuration of matrix layer 51, and the corresponding locations and shapes of edges 53a-53d, may vary significantly depending on the configuration of footwear 10.

The partial threads 52 may extend through the base layer 51 or be located adjacent to the base layer 51. In areas where threads 52 extend through base layer 51, threads 52 are directly connected or otherwise secured to base layer 51. Threads 52 are located in areas proximate to base layer 51, and threads 52 may not be secured to base layer 51 or may be attached with an attachment layer or other securing means that bonds, secures, or otherwise attaches portions of threads 52 to base layer 51. To form the structural elements in upper 30, multiple strands 52 or segments of a single strand 52 may be grouped together in one of different strand groups 54a-54 e. Thread group 54a includes threads 52 located in forefoot region 11 and in an anterior portion of midfoot region 12, and a different one of thread groups 54a extends posteriorly from edge 53b and longitudinally. Thread group 54b includes threads 52 that are positioned proximate lace apertures 33 and extend radially outward from lace apertures 33. Thread group 54c includes thread 52 extending from thread group 54b (i.e., the area proximate lace apertures 33) to the area proximate edge 53 d. Thread group 54d includes threads 52 that extend from edge 53c to edge 53d and are primarily located in heel region 13. Thread group 54e includes threads 52 located in heel region 13 and in a posterior portion of midfoot region 12, and a different thread 52 in thread group 54e extends forward from edge 53c and in the longitudinal direction. Thread group 54f extends around the periphery of base layer 51 and corresponds in position to edges 53a-53 d.

As discussed with respect to first embroidered element 40, the forces generated in footwear 10 may tend to stretch upper 30 in different directions and the forces may be concentrated in different locations. Each strand 52 is positioned to form a structural element in upper 30. More specifically, thread groups 54a-54e are collections of multiple threads 52 or segments of a single thread 52 that form locations where structural members are collected to resist stretching or strengthening forces in different directions. Thread group 54a extends through a portion of second embroidered element 50 corresponding with at least forefoot region 11 to resist longitudinal stretching. Thread group 54b is positioned adjacent lace apertures 33 to resist the buildup of forces due to tension in lace 32. Thread group 54c generally extends in a direction orthogonal to thread groups 54a and 54e to resist stretch in the medial-lateral direction (i.e., in a direction extending around upper 30). Thread group 54d is positioned in heel region 13 to form the opposite side of the heel counter that limits heel movement. In addition, thread group 54e is positioned in at least heel region 13 to resist longitudinal expansion. Accordingly, strands 52 are positioned to form structural elements in upper 30.

Structural member

As discussed in the background section above, a conventional upper may be formed from multiple material layers, each layer imparting different properties to different areas of the upper. In use, the upper may be subjected to considerable tensile forces, with one or more layers of material located in various areas of the upper to resist the tensile forces. That is, a single layer may be incorporated into specific portions of the upper to resist tensile forces that may occur during use of the footwear. As one example, a knitted fabric may be incorporated into the upper to impart stretch-resistance in the longitudinal direction. Woven fabrics are made from yarns that are interwoven at right angles to one another. If the woven fabric is incorporated into an upper to achieve machine direction stretch resistance, only yarns oriented in the machine direction will contribute to machine direction stretch resistance, and yarns oriented orthogonal to the machine direction will generally not contribute to machine direction stretch resistance. Thus, about half of the yarns in the woven fabric are redundant for machine direction stretch resistance. As another example, the degree of stretch-resistance desired in various areas of the upper may vary. Some areas of the upper may require a relatively high degree of stretch-resistance, while other areas of the upper may require a relatively low degree of stretch-resistance. Because the woven fabric may be used in areas where both a high degree of stretch resistance and a low degree of stretch resistance are desired, some of the yarns in the woven fabric are redundant in areas where a low degree of stretch resistance is desired. In each of these examples, the excess yarn adds to the overall mass of the shoe, but does not add beneficial properties to the shoe. Similar concepts apply to other materials such as leather and polymer sheets that are utilized for one or more of abrasion resistance, flexibility, breathability, cushioning, and water absorbency, for example.

In light of the above discussion, the materials used in conventional uppers made from multiple layers of materials may have superfluous portions that are significantly less beneficial to the desired properties of the upper. For example, with respect to stretch resistance, one layer may have a material that imparts (a) more directional stretch resistance or (b) a greater degree of stretch resistance than is necessary or desired. Thus, the excess of these materials may increase the overall mass of the shoe without contributing beneficial properties.

Upper 30 is manufactured to present a minimum of excess material as compared to conventional layered structures. Base layers 41 and 51 provide coverage for the foot, but exhibit a relatively low mass. Some of the threads 42 and 52 (i.e., thread groups 44a, 54a, 44c, 54c, 44d, 54d, and 54e) are positioned to provide a particular, desired direction of stretch-resistance, and the number of threads 42 and 52 is selected to impart only a desired degree of stretch-resistance. Other strands 42 and 52 (i.e., strands 44b, 44e, 54b, and 54f) are positioned to reinforce specific areas of upper 20. Thus, the orientation, location, and number of wires 42 and 52 are selected to provide a structural component that is tailored for a particular purpose.

Each of the thread groups 44a-44d and 54a-54e is a group of threads 42 and 52 providing a structural component as described above. More specifically, however, thread group 44a is positioned to provide longitudinal stretch-resistance on lateral side 14, and the number of threads 42 in thread group 44a is selected to provide a particular degree of stretch-resistance. Similarly, thread groups 54a and 54e are positioned to provide longitudinal stretch-resistance in regions 11 and 13 of medial side 15, and the number of threads 52 in thread groups 54a and 54e is selected to provide a particular degree of stretch-resistance in regions 11 and 13. Each of thread groups 44b and 54b reinforces lace apertures 33, and the number of threads surrounding each lace aperture is selected to provide a particular degree of reinforcement. Each of thread groups 44c and 54c extend from lace apertures 33 and are selected to provide a particular degree of stretch-resistance in a direction extending around upper 30, and the number of threads 42 in thread groups 44c and 54c is selected to provide a particular degree of stretch-resistance. In addition, thread groups 44d and 54d are positioned to form a heel counter, with the number of threads in the thread groups 44d and 54d imparting a particular degree of stability to the heel counter. Thread groups 44e and 54f reinforce the edges of embroidered elements 40 and 50, including the portions of embroidered elements 40 and 50 that form ankle opening 31 and the portions of embroidered elements 40 and 50 that are connected to one another or to other portions of footwear 10. Thus, this characteristic is provided by the lines 42 and 52 based at least in part on the orientation, location and number of the lines 42 and 52.

Matrix layers 41 and 51 may be, for example, inextensible materials, materials with unidirectional stretch, or materials with bidirectional stretch, depending on the particular structure of footwear 10 and the intended use of footwear 10. In general, materials having bi-directional stretch provide upper 30 with a greater ability to conform with the contours of the foot, thereby enhancing the comfort of footwear 10. In configurations where base layers 41 and 51 have bi-directional stretch, the combination of base layers 41 and 51 and threads 42 and 52 effectively modify the stretch properties of upper 30 at specific locations. For first embroidered element 40, the combination of base layer 41 and threads 42 having bi-directional extensibility form areas of upper 30 having different stretch characteristics that include (a) first areas where threads 42 are not present and upper 30 exhibits bi-directional extensibility, (b) second areas where threads 42 are present and do not cross each other, upper 30 exhibits uni-directional extensibility with the direction orthogonal to threads 42, and (c) third areas where threads 42 are present and do not cross each other, upper 30 exhibits substantially no extensibility. A similar concept applies to second embroidered element 50.

The first region includes a region where no line is present. Referring to fig. 6, an example of the first area is marked by reference mark 54a, and is where no line 42 appears. Because threads 42 are not present in first areas, base layer 41 is not bounded by threads 42 and upper 30 is free to stretch in both directions. The second region includes regions where lines 42 appear but do not intersect each other at a generally right angle. Referring to fig. 6, an example of the second area is marked by reference numeral 45 b. Because threads 42 are substantially aligned in the second region, threads 42 resist stretching in a direction parallel to the direction in which threads 42 lie. However, threads 42 do not resist stretching in a direction orthogonal to threads 42. Accordingly, base layer 41 is free to stretch in a direction orthogonal to threads 42, thereby providing a unidirectional stretch to upper 30. In some configurations, base layer 41 may stretch at least ten percent in a direction orthogonal to threads 42, while base layer 41 does not substantially stretch in a direction parallel to threads 42. The third region includes a region where the lines 42 appear and intersect each other at a substantially right angle (i.e., an angle greater than 60 degrees). Referring to fig. 6, an example of the third area is marked by reference numeral 45 c. Because the threads 42 cross each other at generally right angles, the threads 42 resist stretching in substantially all directions. Accordingly, base layer 41 is not free to stretch in any direction, thereby providing a relatively non-stretch structure to upper 30 in the third area. A similar concept applies to second embroidered element 50 and examples of areas corresponding to the first area are identified by reference numeral 55a in fig. 7, areas corresponding to the second area are identified by reference numeral 55b in fig. 7 and areas corresponding to the third area are identified by reference numeral 55c in fig. 7.

Transitions between regions occur at the intersections between regions where the relative number and orientation of lines 42 and 52 change. At the junctions between the zones, upper 30 may vary from having bi-directional stretch, to having uni-directional stretch, from having bi-directional stretch to having no stretch, or from having uni-directional stretch to having no stretch, for example. Assuming that the difference between the regions is the relative number and orientation of lines 42 and 52, then the transition between the regions may occur abruptly. That is, upper 30 may transition from one area to another area within the thickness space of one of strands 42 and 52. Different configurations may be employed to reduce the abruptness of transitions between regions. For example, lines 42 and 52 near the regional transition may have stretch properties. For example, the stretch properties of lines 42 and 52 at the intersection will reduce the abruptness of the transition when transitioning from the first region to the second region. Structurally, lines 42 and 52 near the transition (i.e., near the boundary of the line set) may have greater stretchability than lines 42 and 52 further from the transition (i.e., near the center of the line set). In addition to extensibility, threads 42 and 52, which are made of a non-extensible material, may have a gathered (i.e., zig-zag) shape to allow for an extension at the transition.

Threads 42 and 52 may be used to modify properties of footwear 10 other than stretch resistance. For example, strands 42 and 52 may be utilized to provide additional wear-resistance in specific areas of upper 30. For example, strands 42 and 52 may be concentrated in areas of upper 30 that are subject to wear, such as in forefoot region 11 and near sole structure 20. If used for wear resistance, the threads 42 and 52 may be selected from materials that also exhibit relatively high wear resistance. Strands 42 and 52 may also be utilized to modify the bending characteristics of upper 30. That is, regions of relatively high concentration of lines 42 and 52 may be less curved than regions of relatively low concentration of lines 42 and 52. Similarly, regions of relatively high concentration of lines 42 and 52 may be less breathable than regions of relatively low concentration of lines 42 and 52.

The orientation, location, and number of lines 42 and 52 in FIGS. 1-7 are intended to provide examples of suitable structures for footwear 10 in various aspects of the present invention. In other constructions for footwear 10, different thread groups 44a-44d and 54a-54e may not be present, or additional thread groups may be present to provide additional structural elements in footwear 10. If further longitudinal stretch resistance is desired, thread groups similar to thread group 44a may be included on lateral side 14, or thread groups 54a and 54e may be altered to extend through midfoot region 12. If further stretch-resistance is desired around upper 30, additional threads 42 and 52 may be added to thread groups 44c and 54 c. Similarly, further stretch-resistance around upper 30 may be provided by adding a thread group that extends around forefoot region 11 or a thread group that extends around heel region 13.

The manner of running and the individual's preferences also determine the orientation, location and number of lines 42 and 52. For example, some individuals may have a relatively high degree of pronation (i.e., a pronation of the foot), then having a greater number of threads 42 in the thread group 44c may reduce the degree of pronation. Some also desire greater longitudinal stretch resistance, and footwear 10 may be modified to include more strands 42 in strand set 44 a. Some individuals may also prefer upper 30 to fit more feet, which may require the addition of more strands 42 and 52 to strand sets 44b, 44c, 54b, and 54 c. Accordingly, by varying the orientation, location, and number of strands 42 and 52, footwear 10 may be tailored to suit the manner of running or the preferences of the individual.

Matrix layers 41 and 51 are depicted as having a configuration that collectively covers substantially all of the medial and lateral sides of the foot. As described above, base layers 41 and 51 are substrates to which threads 42 and 52 are secured during embroidery. However, in some configurations, portions of base layers 41 and 51 may not be present such that threads 42 and 52 are positioned against the foot or a sock worn over the foot. That is, base layers 41 and 51 may be formed with holes or incisions (cuts) that expose the foot. In other constructions, base layers 42 and 52, or portions thereof, may be formed from water-soluble materials that are removed after the embroidering step. That is, upper 30 may be dissolved after threads 42 and 52 are secured to base layers 41 and 51. Accordingly, matrix layers 41 and 51 may be partially or completely absent in some configurations of footwear 10.

A substantial portion of the total length of threads 42 and 52 is located adjacent to base layers 41 and 51, but is not directly secured to base layers 41 and 51. For example, to ensure that threads 42 remain in place, a connecting layer or other connecting component that bonds, secures, or otherwise connects portions of threads 42 to base layer 41 may be applied. For example, the connecting or other securing component may be a thermoplastic polymer sheet that is positioned between threads 42 and base layer 41 and heated to bond threads 42 and base layer 41 together. The connecting or other securing component may also be, for example, a thermoplastic polymer sheet or fabric that extends over threads 42 and base layer 41 to bond threads 42 and base layer 41 together. In addition, the connecting or other securing component may be an adhesive that bonds threads 42 and base layer 41 together. In some configurations, additional threads may be stitched over threads 42 to secure threads 42 to base layer 41. In addition, various structures or methods may be used to secure threads 42 to base layer 41. Similar concepts may be applied to connect base layer 51 and threads 52.

Portions of the lines 42 in the different line groups 44a, 44c, and 44d may be substantially parallel to each other. For example, as depicted in fig. 6, the distance between the partial lines 42 actually changes. That is, the lines 42 radiate outwardly. As for thread group 44a, different threads 42 are relatively close to one another in midfoot region 12. However, as threads 42 extend toward forefoot region 11 and heel region 13, the distance between each of threads 42 increases. Accordingly, threads 42 radiate outward in forefoot region 11 and heel region 13. Similarly, different strands 42 in thread group 44c also radiate outward and away from lace apertures 33. Strands 42 are relatively close to one another in portions of upper 30 that are near lace apertures 33, but tend to separate or radiate outward in portions of upper 30 that are further from lace apertures 33. The radial nature discussed above may, for example, serve to distribute forces from relatively small areas (e.g., lace apertures 33) to larger areas. That is, the radial characteristic may be used to distribute forces throughout various areas of upper 30.

In accordance with the above discussion, upper 30 is at least partially formed through an embroidery process that forms structural elements from threads 42 and 52. Depending on the orientation, location, and number of strands 42 and 52, different structural elements may be formed in upper 30. As examples, the structural member may impart stretch resistance, strengthen the zone, strengthen the wear resistance, change the flexibility, or provide a breathable zone to a particular area. Accordingly, by controlling the orientation, location, and number of threads 42 and 52, the properties of upper 30 and footwear 10 may be controlled.

Embroidering step

FIGS. 8A-8O depict an example of a method of producing each embroidered element 40 and 50. In general, the steps for forming first embroidered element 40 are similar to the steps for forming second embroidered element 50. Accordingly, the following discussion focuses on the method of producing the first embroidered element, and it is understood that second embroidered element 50 may be produced in a similar manner.

First embroidered element 40 may be at least partially formed through an embroidery process that may be performed by either mechanical or manual methods. With respect to mechanical embroidery, a variety of conventional embroidery machines may be used to form first embroidered element 40, and the embroidery machines may be programmed to embroider a particular pattern or design from one or more threads. Generally, embroidery machines form patterns and designs by repeatedly securing threads to different locations such that portions of the threads extend between the locations and are visible. More specifically, the embroidery machine forms a series of lock-stitches by (a) piercing a first location of base layer 41 with a needle to thread a first loop of thread 42 through base layer 41, (b) securing the first loop of thread 42 with another thread threaded through the first loop, (c) moving the needle to a second location to extend thread 42 from the first location to the second location and visible on a surface of base layer 41, (d) piercing the second location of base layer 41 with the needle to thread a second loop of thread 42 through base layer 41, and (e) securing the second loop of thread 42 with another thread threaded through the second loop. Thus, the embroidery machine operates to secure the thread 42 to two defined positions and also extends the thread 42 between the two positions. By repeating these steps, an embroidery is formed from threads 42 on base layer 41.

Conventional embroidery machines may form patterns and designs on base layer 41 by forming satin-stitches, plain-stitches, or fill-stitches, each of which may use lock-stitches to secure thread 42 to base layer 41. The forge grain stitch is a series of zigzag stitches formed close together. Flat stitches extend between two locations and are often used for fine details, contours, and backings. A closed stitch is a series of plain stitches formed close together to form different patterns and stitch directions, and is typically used to cover a relatively large area. With respect to satin stitches, conventional embroidery machines typically limit satin stitches to twelve millimeters. That is, when the embroidery machine forms a satin stitch, the distance between the first position and the second position at which the thread is fixed to the base layer is typically limited to twelve millimeters. Thus, conventional satin stitch embroidery includes threads that extend between locations that are spaced apart by twelve millimeters or less. However, forming embroidery component 40 may require that the embroidery machine be modified to form satin stitches extending between locations spaced greater than twelve millimeters apart. In some aspects of the invention, for example, stitches may be separated by greater than five centimeters. That is, for example, threads may be continuously exposed on the surface of base layer 41 at a distance greater than twelve millimeters or greater than five centimeters.

With respect to fig. 8A, base layer 41 is depicted in combination with loops 60, loops 60 having the configuration of a conventional rectangular loop for use in embroidery operations. The main components of the ring 60 are an outer ring 61, an inner ring 62, and a tensioner 63. Outer ring 61 extends around inner ring 62, and an outer peripheral portion of substrate layer 41 extends between outer ring 61 and inner ring 62, as is known in the art. Tensioning devices 63 adjust the tension in outer ring 61 so that inner ring 62 is positioned within outer ring 61 and base layer 41 is held securely in place. In this configuration, the central area of base layer 41 lies in a single plane and may be under slight tension to ensure that base layer 41 is securely positioned in the next step of the manufacturing process. Thus, in general, loops 60 are utilized as a frame to securely position base layer 41 during the embroidery operation that forms first embroidered element 40.

Once base layer 41 is secured within loops 60, the embroidery machine begins to position and secure thread 42 to base layer 41. Initially, the embroidery machine forms the outline of first embroidered element 40 as depicted in FIG. 8B. The contour includes thread group 44e that extends around the periphery of first embroidered element 40 and corresponds with edges 43a-43 d. Portions of edge 43a forming ankle opening 31 are depicted as having a thicker structure than other areas of thread group 44e, which imparts reinforcement to ankle opening 31. In other configurations of first embroidered element 40, all of thread group 44e may exhibit a thicker configuration or a portion of edge 43a forming ankle opening 31 may have a relatively thin configuration. In addition, in some configurations of first embroidered element 40, thread group 44e may be partially or completely absent. Different types of stitches may be used to form the thread group 44e, including darts, plain stitches, closed stitches, or combinations thereof.

After formation of wire set 44e, wire set 44a may be formed. Referring to FIG. 8C, a portion 42a of thread 42 extends between two points, the endpoints being positioned at locations outside of first embroidered element 40. The end points of section 42a are secured with a lock stitch and the central area of section 42a (i.e., the area of the non-end points of section 42 a) lies adjacent to base layer 41 and is not secured to base layer 41. That is, the central area of portion 42a is continuously exposed on the surface of base layer 41. The embroidery machine then forms a relatively short portion 42b of the thread 42 and also forms another portion 42c across the portion 42a, as depicted in FIG. 8D. Then this general step is repeated until the lineset 44a is completed, as depicted in fig. 8E.

Thread group 44c is formed in a manner similar to thread group 44 a. Referring to fig. 8F, portion 42d of line 42 extends between two endpoints that are located within the outline formed by line group 44 e. The end points of section 42d are secured with a lock stitch and the central area of section 42d (i.e., the area of the non-end points of section 42 d) lies adjacent to base layer 41 and is not secured to base layer 41. In addition, the central region traverses line group 44 a. The embroidery machine then forms a relatively short portion 42e of thread 42 and also forms another portion 42f that also traverses the thread group 44a, as depicted in FIG. 8G. Then this general procedure is repeated until one of the various portions of the line set 44c is completed, as depicted in fig. 8H. The embroidery machine then forms one of the various portions of thread group 44b using, for example, a plurality of tambour needles, as depicted in FIG. 8I. The steps discussed above for forming one of the respective portions of thread group 44c and one of the respective portions of thread group 44b are repeated an additional four times to form the respective thread groups 44c and 44b, as depicted in fig. 8J.

In some configurations, the ends of the thread group 44c may abut the periphery of the thread group 44 b. However, as depicted in the figure, the thread group 44c extends beyond the periphery of the thread group 44 b. That is, thread group 44c may extend on threads 42 forming thread group 44b, or thread group 44b may extend on threads 42 forming thread group 44 c. More specifically, the thread 42 from each thread group 44b and 44c may be twisted (intertwine). When lace 32 extends through lace apertures 33 and is tightened, thread group 44b reinforces lace apertures 33 and thread group 44c distributes tension along the sides of upper 30. By winding thread groups 44b and 44c, the force on lace apertures 33 is more efficiently transferred to thread group 44 c.

Wire set 44d is formed in a manner similar to wire sets 44a and 44 c. Referring to fig. 8K, a portion 42g of thread 42 extends between two endpoints that are located proximate to the outline formed by thread group 44e in heel region 13. The end points of section 42d are secured with a lock stitch and the central area of section 42d (i.e., the area of the non-end points of section 42 d) lies adjacent to base layer 41 and is not secured to base layer 41. That is, the central area of portion 42d is continuously exposed on the surface of base layer 41. Further, the central region traverses the line group 44 a. Then this general procedure is repeated until the wire set 44d is completed, as depicted in fig. 8L.

Once thread group 44d is completed, apertures 33 may be formed through base layer 41 in areas that correspond with the centers of thread groups 44 b. In addition, first embroidered element 40 may be cut from portions of base layer 41 that are outboard of thread group 44e to form edges 43a-43d, as depicted in FIG. 8M. At the time first embroidered element 40 is cut from the outer portion of base layer 41, the portion of thread 42 forming thread group 44a is severed. As discussed above, base layer 41 may include a connecting layer or other securing component that bonds, secures, or otherwise secures portions of threads 42 to base layer 41. The connecting layer or other securing element, which will be described in greater detail below, may be added or used prior to cutting first embroidered element 40 from the outer portion of base layer 41.

The general steps described above and in fig. 8A-8M for forming first embroidered element 40 discuss the specific order in which the various thread groups 44a-44e are formed. In the order discussed, thread groups 44c and 44d cross thread group 44a, which places thread group 44a between base layer 41 and thread groups 44c and 44 d. The discussed sequence also forms the line groups 44b and 44c in a generally uniform manner. That is, partial line group 44c is formed, then partial line group 44b is formed, and this step is repeated until each of line groups 44b and 44c is completed. However, the order discussed above is one example of various orders that may be used to form first embroidered element 40 and various other orders for forming each of thread groups 44a-44e may also be used. Accordingly, the general steps discussed above and depicted in FIGS. 8A-8M provide an example of one manner in which first embroidered element 40 may be manufactured, and various other steps may be used instead.

Second embroidered element 50 is formed through an embroidering step that may be similar to the steps used to form first embroidered element 40. Referring to FIG. 8N, second embroidered element 50 is depicted subsequent to the embroidering step in which thread groups 54a-54f are formed. Lace apertures 33 may then be formed through base layer 51 in areas that correspond with the centers of thread groups 54 b. In addition, second embroidered element 50 may be cut from portions of base layer 51 that are outboard of thread group 54f to form edges 53a-53d, as depicted in FIG. 8O. A connecting layer or other securing means to join, secure, or otherwise connect portions of thread 52 to base layer 51 may be added prior to cutting second embroidered element 50 from an outer portion of base layer 51, as described in detail below. As with first embroidered element 40, various orders for forming the various thread groups 54a-54f may be used.

Assembly of shoes

Once embroidered elements 40 and 50 are formed in the manner described above, footwear 10 is assembled. An example of one manner in which footwear 10 may be assembled is depicted in figures 9A-9D. Initially, by securing embroidered elements 40 and 50 together in forefoot region 11 and heel region 13, the manufacture of upper 30 is substantially complete, as depicted in FIG. 9A. More specifically, the front portions of edges 43a and 53a are connected, and respective edges 43c and 53c are also connected. For example, different types of stitching or adhesives may be used to join embroidered elements 40 and 50.

After upper 30 is completed, sole elements 21 and 22 are placed, as depicted in figure 9B. First sole element 21 is positioned between embroidered elements 40 and 50 such that a lower portion of embroidered elements 40 and 50 wrap around the sides of first sole element 21. For example, adhesive may be used to secure the lower portions of embroidered elements 40 and 50 to the lower area of first sole element 21, as depicted in figure 9C. When combined in this manner, then an upper area of first sole element 21 is positioned to provide a foot-supporting surface within upper 30. In some configurations, however, a footbed may be located within upper 30 and adjacent an upper region of first sole element 21 to form a foot-supporting surface for footwear 10.

The second sole element is then secured (e.g., using adhesive) to first sole element 21 and embroidered elements 40 and 50, as depicted in figure 9D. In this case, each embroidered element 40 and 50, first sole element 21, and second sole element 22 form part of the ground-contacting surface of footwear 10. To impart additional traction, a projection 23 in the form of a removable spike may be incorporated into second sole element 22. Finally, lace 32 is threaded through lace apertures 33 in a conventional manner to substantially complete the assembly of footwear 10.

Fixing member

Each segment (e.g., portions 42a-42g) of line 42 has two end points and a central portion extending between the end points. The end points are secured with a lock stitch and the central area (i.e., the area of the segment that is not the end point) is located adjacent to base layer 41 and is not secured to base layer 41. To secure the central region to base layer 41, a connection layer that bonds, secures, or otherwise connects portions of threads 42 to base layer 41 may be used. The following discussion presents different methods by which a tie layer or other securing agent may be added to first embroidered element 40. Similar concepts may be applied to second embroidered element 50.

One step for securing partial threads 42 to base layer 41 is depicted in fig. 10A-10D. Referring to fig. 10A, first embroidered element 40 is depicted as being formed through an embroidering step, but is not cut from an outer portion of base layer 41 (i.e., as in fig. 8L). In addition, connecting layer 70 is depicted as being overlaid on a surface of first embroidered element 40 that includes thread 42.

The tie layer 70 is a thin sheet of thermoplastic polymer material, for example between one thousandth of a millimeter and three millimeters thick. Suitable polymeric materials for tie layer 70 include, for example, polyurethane and ethylene vinyl acetate. To heat connecting layer 70 and bond connecting layer 70 to first embroidered element 40, connecting layer 70 and first embroidered element 40 are placed between a pair of platens (platens) 71 and 72 of a heated press (heatedpress), as depicted in FIG. 10B. As the temperature of connecting layer 70 increases, the polymer material forming connecting layer 70 increases such that the polymer material penetrates the structure of base layer 41 and threads 42. Once removed from the heated press, connecting layer 70 cools and effectively bonds threads 42 to substrate layer 41, as depicted in fig. 10C. First embroidered element 40 may then be cut from an outer portion of base layer 41.

Connecting layer 70 ensures that thread group 44a remains intact after first embroidered element 40 is removed from the outer portion of base layer 41. In addition, connecting layer 70 ensures that portions of thread groups 44c and 44d, for example, remain properly positioned with respect to base layer 41. Although the ends of the different sections of thread 42 forming thread groups 44c and 44d are secured to base layer 41 with a lock stitch, the central portion is not secured to base layer 41 and no connecting layer 70 is present. Accordingly, connecting layer 70 effectively bonds each thread 42 to base layer 41.

Base layer 41 may exhibit a breathable structure that allows perspiration and hot air to escape upper 20. However, the addition of connecting layer 70 may decrease the degree of ventilation of upper 20. Whereas connecting layer 70 is depicted in fig. 10A as having a non-continuous structure, connecting layer 70 may also be shaped with different apertures corresponding to areas of first embroidered element 40 where connecting layer 70 is not desired. Accordingly, the apertures in connecting layer 40 may serve to enhance the air-permeable characteristics of upper 30. In addition, reducing the amount of material used for connecting layer 70 has the advantage of minimizing the mass of footwear 10.

Another step for securing portions of threads 42 to base layer 41 is depicted in fig. 11A-11D. Referring to fig. 11A, base layer 41 is depicted as being connected to connection layer 70 prior to the addition of threads 42. An embroidering step is then used to form thread groups 44a-44e such that a connecting layer is between base layer 41 and thread 42, as depicted in figure 11B. To heat connecting layer 70 and bond threads 42 to base layer 41, connecting layer 70 and first embroidered element 40 are placed between platens 71 and 72 of a heated press, as depicted in figure 11C. Upon removal from the heated press, connecting layer 70 cools and effectively bonds threads 42 to substrate layer 41. First embroidered element 40 may then be cut from an outer portion of base layer 41 as depicted in figure 11D. During the embroidering step, threads 42 are placed in tension, which tends to pull inward on base layer 41. One advantage of applying connecting layer 70 to base layer 41 prior to the embroidering step is that connecting layer 70 helps to resist inward pulling of threads 42.

Another step for securing portion 42 to base layer 41 is depicted in fig. 12A-12C. Referring to fig. 12A, first embroidered element 40 is depicted as being formed through an embroidering step, but is not cut from an outer portion of base layer 41 (i.e., as in fig. 8L). An adhesive securing component is then sprayed or otherwise applied to first embroidered element 40 as depicted in fig. 12B, thereby securing threads 42 to base layer 41. First embroidered element 40 may then be cut from an outer portion of base layer 41 as depicted in figure 12C.

Conclusion

In accordance with the above discussion, upper 30 is at least partially formed through an embroidering step that forms structural elements from threads 42 and 52. Depending on the orientation, location, and number of strands 42 and 52, different structural elements may be formed in upper 30. By way of example, the structural component may impart stretch resistance to particular areas, reinforce areas, enhance wear resistance, improve bendability, or provide breathable zones. Accordingly, by controlling the orientation, location, and number of threads 42 and 52, the properties of upper 30 and footwear 10 may be controlled.

The invention is disclosed above and in the accompanying drawings with reference to a variety of embodiments. The purpose served by the disclosure, however, is to provide an example of the various features and concepts related to aspects of the invention, not to limit the scope of aspects of the invention. One skilled in the relevant art will recognize that numerous variations and modifications may be made to the embodiments described above without departing from the scope of the present invention, as defined by the appended claims.

Claims (30)

1. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a fabric layer formed at least in part from a plurality of yarns, the fabric layer having a first surface and an opposing second surface, the fabric layer defining a first region and a second region that are separated by a distance of at least five centimeters, and the fabric layer defining a third region and a fourth region that are also separated by a distance of at least five centimeters;

a first thread group having a first thread segment extending between the first area and the second area, the first thread segment being located proximate to the first surface and being substantially parallel to the first surface in the distance between the first area and the second area, and the first thread segment being separated from the yarns of the fabric layer; and

a second thread group having a second thread segment extending between the third area and the fourth area, the second thread segment being located proximate to the first surface and being substantially parallel to the first surface in the distance between the third area and the fourth area, and the second thread segment being separated from the yarns of the fabric layer,

wherein at least some of the first line segments are oriented to extend in a first direction and at least some of the second line segments intersect the first line segments and are oriented to extend in a second direction.

2. The article of footwear recited in claim 1, wherein the first area is in a forefoot region of the upper and the second area is in a heel region of the upper.

3. The article of footwear of claim 2, wherein the third area is adjacent to a receiving lace portion of the upper and the fourth area is adjacent to the sole structure.

4. The article of footwear of claim 3, wherein the upper includes a third thread group having a third thread segment extending around the shoe-receiving lace portion.

5. The article of footwear of claim 4, wherein the receiving lace portion is an aperture extending through the fabric layer.

6. The article of footwear recited in claim 1, wherein the first strand segment does not extend through the fabric layer in an area located between the first area and the second area, and the second strand segment does not extend through the fabric layer in an area located between the third area and the fourth area.

7. The article of footwear recited in claim 1, wherein the fabric layer stretches at least ten percent prior to tensile failure, and the first strand segment and the second strand segment limit stretch of the fabric layer in a direction that is coincident with a longitudinal axis of the first strand segment and the second strand segment.

8. The article of footwear of claim 1, wherein the first strand segment is formed from a single strand.

9. The article of footwear of claim 8, wherein the second strand segment is formed from the single strand.

10. The article of footwear of claim 1, wherein the first direction is offset from the second direction by at least 60 degrees.

11. An article of footwear having an upper and a sole structure secured to the upper, the upper comprising:

a fabric layer formed at least in part from a plurality of yarns, the fabric layer having a first surface and an opposing second surface;

a plurality of first thread segments extending from a forefoot region of the upper to a heel region of the upper, the first thread segments located proximate to the first surface and not extending through the first surface in a region between the forefoot region and the heel region, and the first thread segments being separate from the yarns of the fabric layer; and

a plurality of second thread segments extending from an upper region of the upper to a lower region of the upper, the second thread segments being located proximate to the first surface and not extending through the first surface in a region between the upper region and the lower region, and the second thread segments being separate from the yarns of the fabric layer,

the first and second line segments have a crossed arrangement.

12. The article of footwear of claim 11, wherein the upper includes a plurality of third thread segments extending around a receiving lace portion of the upper.

13. The article of footwear of claim 12, wherein the receiving lace portion is an aperture extending through the fabric layer.

14. The article of footwear of claim 11, wherein the upper includes a plurality of third thread segments positioned in the heel region and extending from the upper region to the lower region.

15. The article of footwear recited in claim 11, wherein the upper includes a plurality of third thread segments located proximate to an edge of the fabric layer.

16. The article of footwear recited in claim 11, wherein the fabric layer is a material having at least two-way stretch, and the upper includes:

a first area, wherein the upper has a bi-directional stretch characteristic, the first strand segment and the second strand segment not being present in the first area;

a second area, wherein the upper has a unidirectional extensibility characteristic, only one of the first thread segment and the second thread segment being present in the second area; and

a third area, wherein the upper has substantially inextensible properties, each of the first strand segment and the second strand segment being present in the third area.

17. The article of footwear recited in claim 11, wherein (a) the first strand segment extends between the second strand segment and the fabric layer, or (b) the second strand segment extends between the first strand segment and the fabric layer.

18. The article of footwear recited in claim 11, wherein the upper includes a securing component that connects the first strand segment and the second strand segment to the fabric layer, and the securing component is a polymer material layer that bonds the first strand segment and the second strand segment to the fabric layer.

19. The article of footwear recited in claim 11, wherein the upper includes a securing component that connects the first strand segment and the second strand segment to the fabric layer, and the securing component is an adhesive applied to at least the fabric layer.

20. The article of footwear recited in claim 11, wherein the fabric layer forms at least a portion of a lateral side of the upper, and the upper includes another fabric layer having thread segments that extend (a) in a direction that is coincident with a direction between the forefoot region and the heel region, or (b) from the upper area of the upper to the lower area of the upper.

21. An article of footwear having an upper and a sole structure secured to the upper, at least a portion of the upper comprising:

a base layer having a first surface and an opposing second surface;

a plurality of thread segments separated from the base layer and located proximate to and parallel to at least a portion of the first surface for a distance of at least five centimeters, at least a portion of the thread segments being substantially aligned,

the upper defines a first direction that is coincident with a longitudinal axis of the strand segments, and the upper defines a second direction that is orthogonal to the first direction, the upper being substantially non-stretchable in the first direction, and the upper being stretchable by at least ten percent in the second direction.

22. The article of footwear recited in claim 21, wherein the base layer is a textile material that is capable of stretching at least ten percent before tensile failure.

23. The article of footwear of claim 22, wherein the strand segments are substantially inextensible.

24. The article of footwear of claim 21, wherein the strand segments extend in a longitudinal length direction of the footwear.

25. The article of footwear of claim 21, wherein the line segments cross each other.

26. The article of footwear recited in claim 21, wherein the strand segments extend from an upper area of the upper to a lower area of the upper.

27. The article of footwear recited in claim 21, wherein a securing component connects the strand segments to the base layer, and the securing component is a layer of polymer material.

28. The article of footwear recited in claim 21, wherein a securing component connects the strand segments to the base layer, and the securing component is an adhesive applied to at least the base layer.

29. The article of footwear of claim 21, wherein a portion of the strand segments are non-parallel.

30. The article of footwear of claim 21, wherein the strand segments are formed from different strands having different properties.