CN106551466B

CN106551466B - Article of footwear including an upper with mesh material

Info

Publication number: CN106551466B
Application number: CN201611102200.3A
Authority: CN
Inventors: 杰夫·莫克斯
Original assignee: All Star LP
Current assignee: All Star LP
Priority date: 2012-01-02
Filing date: 2012-03-05
Publication date: 2020-08-07
Anticipated expiration: 2032-03-05
Also published as: EP2800493B1; CN104185431B; DE202012013698U1; DE202012013699U1; EP3560368A1; WO2013103363A1; CN106551466A; EP2800493A4; EP2800493A1; CN104185431A

Abstract

The present application relates to an article of footwear including an upper having a mesh material. An article of footwear includes an upper and a mesh material. The mesh material may be incorporated into the upper. The mesh material may include high tensile strength strands and non-high tensile strength strands. The high tensile strength strands and the non-high tensile strength strands may interlock such that the high tensile strength strands are substantially held in place. The mesh material may be provided as a woven or knitted material. The mesh material may have a fashion design, which may be a lattice pattern, herringbone pattern, seersucker pattern, or other pattern.

Description

Article of footwear including an upper with mesh material

The present application is a divisional application of application No. 201280065727.7, filing date 2012, 3-5, entitled "article of footwear including an upper having a mesh material".

This application is a continuation-in-part application of U.S. patent application No. 29/401,070, filed 2011 on 6/9 to the united states patent office, and claims priority to that application, according to U.S. code 35, clause 120, which prior U.S. patent application is hereby incorporated by reference in its entirety.

Technical Field

The present invention relates to an article of footwear including an upper having a mesh material.

Background

An article of footwear generally includes two primary elements: an upper and a sole structure. The upper is generally formed from a plurality of material elements (e.g., textiles, polymer sheet layers, foam layers, leather, synthetic leather) that are stitched or adhesively bonded together to form a void in the interior of the footwear for comfortably and securely receiving a foot. More specifically, the upper forms a structure that extends over instep and toe areas of the foot, along medial and lateral sides of the foot, and around a heel area of the foot. The upper may also incorporate a lacing system to adjust the fit of the footwear, as well as to allow the foot to enter and exit the void within the upper. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability and comfort of the footwear, and the upper may incorporate a heel counter.

The different materials forming the upper impart different properties to different areas of the upper. For example, the textile elements may provide breathability and may absorb moisture from the foot, the foam layer may compress to impart comfort, and the leather may impart durability and wear-resistance. As the number of material elements increases, the overall mass of the footwear may increase proportionally. While many materials may be incorporated and used to provide a desired design, such a design may result in a heavier upper that may reduce mobility, performance, and comfort for the wearer.

The time and expense associated with transporting, storing, cutting, and joining the material elements may also increase as the number of material elements of the upper increases. In addition, waste material from the cutting and stitching processes may accumulate to a greater degree as the number of material elements incorporated into the upper increases. Also, products with a larger number of material elements may be more difficult to recycle than products formed from fewer material elements.

Disclosure of Invention

One of the challenges in designing athletic footwear is providing designers with design freedom to combine different materials for the upper to achieve a desired appearance while minimizing the weight of the upper.

Thus, by reducing the number of material elements, the mass and waste of the upper may be reduced while increasing manufacturing efficiency and recyclability.

In view of these considerations, there is a need for an article of footwear that advantageously includes a strong, lightweight structure that also provides the designer a great deal of design freedom when creating an article of footwear with a stylish design.

Various aspects of an article of footwear are disclosed below.

According to an embodiment, an article of footwear may include an upper and a mesh material. The mesh material may be incorporated into the upper. The mesh material may include high tensile strength strands and non-high tensile strength strands. The high tensile strength strands and the non-high tensile strength strands may interlock such that the high tensile strength strands are substantially held in place.

In one embodiment, the mesh material provides substantially the entire thickness of the upper.

In one embodiment, the mesh material is a woven material.

In one embodiment, the mesh material is a knitted material.

In one embodiment, the mesh material has a lattice pattern.

In one embodiment, the mesh material has a herringbone pattern.

In one embodiment, the mesh material has a seersucker pattern.

In one embodiment, the upper includes a layer located beneath the mesh material, wherein the mesh material is translucent and the layer is viewed through the mesh material.

According to an embodiment, an article of footwear may include an upper including a mesh. The mesh may include high tensile strength strands and non-high tensile strength strands. The non-high tensile strength strands may substantially hold the high tensile strength strands in place. The mesh may have a lattice pattern.

In one embodiment, the mesh provides substantially the entire thickness of the upper.

In one embodiment, the mesh is a woven material.

In one embodiment, the upper includes a layer located beneath the mesh, wherein the mesh is translucent and the layer is viewed through the mesh.

According to an embodiment, an article of footwear may include an upper including a mesh. The mesh may include high tensile strength strands and non-high tensile strength strands. The non-high tensile strength strands may substantially hold the high tensile strength strands in place. The mesh may have a herringbone pattern.

In one embodiment, the mesh is a knitted material.

According to an embodiment, an article of footwear may include an upper including a mesh. The mesh may include high tensile strength strands and non-high tensile strength strands. The non-high tensile strength strands may substantially hold the high tensile strength strands in place. The mesh may have a seestrucker pattern (seeersucker pattern).

In one embodiment, the mesh is a knitted material.

Drawings

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

Fig. 1 is an isometric view of a mesh including wires according to an embodiment.

Fig. 2 is a front view of an article of footwear according to an embodiment.

Fig. 3 is a lateral side view of the article of footwear of fig. 2.

Fig. 4 is a medial side view of the article of footwear of fig. 2.

Fig. 5 is a top view of a web material, under an embodiment.

Fig. 6 illustrates a step of applying a mesh material in a manufacturing process of an article of footwear according to an embodiment.

Fig. 7 shows an article of footwear being manufactured after application of a mesh material, in accordance with an embodiment.

Fig. 8 is an exploded view of an article of footwear according to an embodiment.

Fig. 9 is a top view of a mesh material, under an embodiment.

Fig. 10 is an isometric view of the mesh material of fig. 9.

Fig. 11 is a cross-sectional view of the mesh material of fig. 10.

Fig. 12A is a view of a mesh material, under an embodiment.

Fig. 12B is an enlarged view of the mesh material of fig. 12A.

Fig. 13 is a cross-sectional view taken along line 13-13 in fig. 12A.

Fig. 14 is a cross-sectional view taken along line 14-14 in fig. 12A.

Fig. 15 is a side view of a high tensile strength wire according to an embodiment.

Fig. 16 is a side view of an article of footwear according to an embodiment.

Fig. 17 is a cross-sectional view of an article of footwear according to an embodiment.

Fig. 18 is a cross-sectional view of an article of footwear according to an embodiment.

Fig. 19 is a side view of an article of footwear according to an embodiment.

Fig. 20A is a side view of an upper of an article of footwear according to an embodiment.

Fig. 20B is a side view of the upper of fig. 20A with the mesh material removed.

Fig. 20C is a lateral elevational view of the upper of fig. 20B with the intermediate layer removed.

Fig. 21 is a side view of an article of footwear according to an embodiment.

Fig. 22 is an exploded view of an article of footwear according to an embodiment.

Fig. 23 is a view of a mesh material, under an embodiment.

Fig. 24 is a side view of a conventional tension strand element (tension strand element) according to an embodiment.

Figure 25 is an isometric view of an enlarged area 25 of the tensile strand element of figure 24.

Figure 26 is an exploded view of the tensile strand element of figure 25.

Fig. 27 is a picture of an article of footwear incorporating a mesh material having a lattice pattern, under an embodiment.

Fig. 28 is a picture of a mesh material having a herringbone pattern, under an embodiment.

Fig. 29 is a picture of an article of footwear incorporating a mesh material with a seersucker pattern, under an embodiment.

Detailed Description

The following discussion and accompanying figures disclose an article of footwear having an upper that includes a mesh material. The mesh material may include tensile strand elements. Articles of footwear are disclosed having a general configuration that is suitable for a variety of pursuits. Concepts associated with the footwear (including the upper) may also be applied to a variety of other athletic footwear types, including baseball shoes, basketball shoes, cross-training shoes, cycling shoes, football shoes, tennis shoes, soccer shoes, and hiking boots, for example. The concepts may also be applied to footwear styles that are generally considered to be non-athletic, including dress shoes, loafers, sandals, and work boots. Accordingly, the concepts disclosed herein apply to a wide variety of footwear types. However, the mesh material may be used in a variety of other products, including backpacks and other bags and garments (e.g., pants, shirts, headwear), for example. Thus, the concepts disclosed herein may be applied to a variety of products.

A conventional upper may be formed from multiple material layers that may each impart different properties to different areas of the upper. During use, the upper may experience significant tensile forces, and one or more material layers are positioned in areas of the upper to resist the tensile forces. That is, various layers may be bonded to specific portions of the upper to resist tensile forces that may occur during use of the footwear. For example, a textile may be incorporated into the upper to impart stretch resistance in the longitudinal direction. Such a fabric may be, for example, a woven fabric formed from yarns interwoven at right angles to one another. If the woven fabric is incorporated into an upper for purposes of longitudinal stretch resistance, only yarns oriented in the longitudinal direction will contribute to the longitudinal stretch resistance, and yarns oriented orthogonal to the longitudinal direction will generally not contribute to the longitudinal stretch resistance. Therefore, about half of the yarns in the woven fabric are not necessary for longitudinal stretch resistance.

As an extension of this example, the degree of stretch resistance required in different areas of the upper may vary. Certain areas of the upper may require a relatively high degree of stretch resistance due to the forces experienced by those areas, 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 may not be necessary in areas where a low degree of stretch resistance is desired. In this example, the unnecessary yarns add to the overall mass of the footwear without adding to the beneficial properties to the footwear. Similar concepts apply to other materials, such as leather and polymer sheets, which may be used for one or more of abrasion resistance, flexibility, breathability, cushioning, and perspiration.

Based on the above discussion, the materials used in conventional uppers formed from multiple material layers may have unnecessary portions that do not significantly contribute to the desired properties of the upper, but increase the overall weight of the article of footwear. With respect to stretch resistance, for example, the layer may have a material that imparts (a) a greater number of directions of stretch resistance, or (b) a greater degree of stretch resistance than is needed or desired. Thus, unnecessary portions of these materials may increase the overall mass of the footwear without contributing beneficial properties.

One approach to addressing these problems is to incorporate tensile strand elements into the upper to provide strength and tensile resistance to the upper. The use of such tensile thread elements is discussed in, for example, U.S. application No. 12/362,371 filed on 1-29 th 2009, U.S. application No. 12/419,985 filed on 4-7 th 2009, U.S. application No. 12/419,987 filed on 4-7 th 2009, U.S. application No. 12/546,017 filed on 8-24 th 2009, U.S. application No. 12/546,019 filed on 8-24 th 2009, U.S. application No. 12/546,022 filed on 8-24 th 2009, U.S. application No. 12/847,836 filed on 7-30 th 2010 and U.S. application No. 13/196,365 filed on 8-2 nd 2011, each of which is hereby incorporated by reference in its entirety.

Conventional tensile strand elements include strands having a relatively high tensile strength. Returning to the example of fig. 24, a conventional tensile strand element 40 may include strands 34 having a relatively high tensile strength, the strands 34 enhancing the tensile resistance of the strand element 40. The tensile strand elements 40 may be incorporated into layers of the upper to increase strength and impart tensile resistance to the upper, while utilizing less material due to the elongated and relatively narrow shape of the tensile strand elements.

To maintain the position of the strands, conventional tensile strand elements may position the strands between two materials, coverings, or layers that are used to hold the strands in place. Examples of such materials, coverings, or layers are discussed in, for example, U.S. application No. 12/362,371 filed on 1-29 th 2009, U.S. application No. 12/419,985 filed on 4-7 th 2009, U.S. application No. 12/419,987 filed on 4-7 th 2009, U.S. application No. 12/546,017 filed on 8-24 th 2009, U.S. application No. 12/546,019 filed on 8-24 th 2009, U.S. application No. 12/546,022 filed on 8-24 th 2009, U.S. application No. 12/847,836 filed on 7-30 th 2010, and U.S. application No. 13/196,365 filed on 8-2 nd 2011, each of which is hereby incorporated by reference in its entirety. Returning to fig. 25, which is an enlarged view of an area 25 of the tensile strand element 40 of fig. 24, the tensile strand element 40 may include a base layer 41 and a cover layer 42, with the strands 34 positioned between the base layer 41 and the cover layer 42. Fig. 26 shows an exploded view of the embodiment of fig. 25 and also illustrates how the thread 34 is positioned between the base layer 41 and the cover layer 42. The lines 34 may extend parallel to the surface of the base layer 41 and the cover layer 42. Being substantially parallel to the surfaces of base layer 41 and cover layer 42, threads 34 resist stretching in a direction corresponding to the surfaces of base layer 41 and cover layer 42.

The lines 34 may be formed of any generally one-dimensional material. As used with respect to the present invention, the term "one-dimensional material" or variations thereof is intended to include generally elongated materials exhibiting a length substantially greater than a width and a thickness. Accordingly, suitable materials for thread 34 include various filaments, fibers, yarns, threads, cables, or ropes formed from rayon, nylon, polyester, polyacrylic, silk, cotton, carbon, glass, aramid (e.g., para-aramid fiber and meta-aramid fiber), ultra-high molecular weight polyethylene, liquid crystal polymer, copper, aluminum, and steel. Such materials may provide a relatively high tensile strength that enhances the tensile resistance of the material in which the strands 34 are incorporated. Filaments have an indefinite length and may be used individually as the thread 34, while fibers have a relatively short length and are typically subjected to a spinning process or twisting process to produce a thread of suitable length.

The individual filaments used in the thread 34 may be formed from a single material (i.e., a single component filament) or from multiple materials (i.e., a bi-component filament). Similarly, different filaments may be formed of different materials. For example, yarns used as threads 34 may include filaments that are each formed of a common material, may include filaments that are each formed of two or more different materials, or may include filaments that are each formed of two or more different materials. Similar concepts also apply to wires, cables or ropes. The thickness of the wire 34 may also vary significantly, for example, in a range from 0.03 millimeters to over 5 millimeters. While one-dimensional materials may 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, oval, or other elongated cross-section).

The strands may be used to alter properties of the article of footwear other than tensile resistance. For example, strands may be utilized to provide additional wear-resistance in specific areas of the upper. For example, the strands may be concentrated in areas of the upper that experience wear, such as in a forefoot region of the upper and adjacent the sole structure. If used for wear resistance, the thread may be selected from materials exhibiting relatively high wear resistance properties. The strands may also be utilized to modify the bending characteristics of the upper. For example, a region with a relatively high concentration of lines may bend to a lesser extent than a region with a relatively low concentration of lines. Similarly, areas with relatively high concentrations of lines may be less breathable than areas with relatively low concentrations of lines. In addition, the strands may be used to join or attach the upper to the sole structure while utilizing a lighter weight than conventional uppers that use, for example, leather or other fabric panels joined to the sole structure. The strands may also strengthen this connection between the upper and the sole structure.

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

In conventional designs, the tensile strand elements may be provided as separate elements, such as separate filaments, yarns, or strands, that are placed on top of a foundation layer of the upper. To ensure that the tensile strand elements remain in place, a connecting layer or other securing element may bond, secure, or otherwise connect the tensile strand elements to the base layer. According to one example, a sheet of thermoplastic polymer may be positioned between the strands and the base layer and heated to bond the strands and the base layer together. According to another example, the connecting or securing element may be a sheet or fabric of thermoplastic polymer, for example, which extends over the thread and the base layer to bond the thread and the base layer together. Such a sheet, in turn, may serve as a covering layer that forms a portion of the exterior or exposed surface of the upper, with the combination of the foundation layer, strands, and covering sheet providing substantially all of the thickness of the upper in certain areas. In another example, the connecting element or other securing element may be an adhesive that bonds the thread and the base layer together. In other examples, additional separate threads are stitched over the thread to secure the tensile thread element to the base layer. Thus, a variety of structures and methods may be used to secure the wires to the underlying foundation layer.

While conventional tensile strand elements provide a high degree of performance, such as by enhancing the tensile resistance of the upper, methods used to incorporate tensile strand elements into an upper may provide a fashionable and pleasing article of footwear for certain uses. For example, by bonding lines 34 between base layer 41 and cover layer 42, an article of footwear is produced that has a style that is high performance and that is used for athletic purposes but not necessarily for recreational purposes. It would be desirable to provide an article of footwear that provides a high level of performance, but is also fashionable and pleasing for a variety of uses, such as both athletic and casual uses.

According to embodiments, the thread may be incorporated into the mesh material. The mesh material may include a combination of high tensile strength strands and non-high tensile strength strands that do not have high tensile strength. For example, strands that do not have high tensile strength may be crossed by high tensile strength strands. A mesh comprising a pattern of intersecting strands may advantageously provide a structure that holds the high tensile strength strands generally in place while also providing enhanced performance. Thus, the mesh material may include high tensile strength strands that enhance the strength and tensile resistance of the mesh, but do not require a base layer and cover layer to maintain the position of the high tensile strength strands. Such a web may advantageously be breathable and flexible, but also have relatively high strength and limited stretch. In addition to advantageously providing enhanced performance and material savings, the mesh material may also provide a stylish design.

Fig. 1 shows a web 10 comprising a first set 25 of high tensile strength strands. According to embodiments, the first set 25 of high tensile strength strands may include a different number of tensile strength strands. The number of tensile strength strands selected for a given set of high tensile strength strands may be selected, for example, according to the desired strength and/or tensile resistance of web 10. For example, the first set 25 of high tensile strength strands may include a first high tensile strength strand 21, a second high tensile strength strand 22, a third high tensile strength strand 23, and a fourth high tensile strength strand 24, although the first set 25 of high tensile strength strands may include other numbers of high tensile strength strands. The high tensile strength strands may be in the same form and made of the same materials as the strands 34 used in the conventional tensile strand elements 40 discussed above. For example, the first set 25 of high tensile strength strands may be high tensile strength nylon. Because of the tensile properties of the high tensile strength strands, the first set 25 of high tensile strength strands may be used to increase the strength of the web 10 and enhance the tensile resistance of the web 10.

The mesh 10 may include a second set 34 of strands that intersect the first set 25 of high tensile strength strands. According to an embodiment, the second group 34 of lines may comprise a different number of lines. For example, the number of strands selected for the second group 34 of strands may be selected to provide a sufficient number of strands to cross and generally hold in place the high tensile strength strands. For example, the second set 34 may include the first line 31, the second line 32, and the third line 33, although the second set 34 may include other numbers of lines.

The strands in the second group 34 of strands may be non-high tensile strength strands. For example, the strands in the second set 34 may be in a different form and/or made of a different material than the high tensile strength strands in the first set 25. For example, non-high tensile strength strands, such as the strands in the second set 34, may be made of polyester. In another example, the non-high tensile strength strands may be made from a blend of 60% polyester & 40% polyester 150D. In another example, when the web 10 includes high tensile strength strands and non-high tensile strength strands, the web 10 may be made of different materials, which may be selected according to the strength and tensile resistance desired for the web 10.

The strands in the second set 34 do not necessarily reinforce the strength and tensile resistance of the web 10 to the extent that the high tensile strength strands reinforce. However, the strands in the second set 34 may intersect the high tensile strength strands in the first set 25 and provide a mesh structure that substantially holds the high tensile strength strands in the first set 25 in place. For example, the strands in the second set 34 may form a mesh structure that interlocks with the high tensile strength strands in the first set 25, the interlocking mesh structure restricting movement of the high tensile strength strands in the first set 25.

According to embodiments, the mesh 10 may include multiple sets of wires. For example, the web 10 may include a first set 25 of high tensile strength strands and at least a second set 34 of strands that intersect the high tensile strength strands in the first set 25. In another example, the mesh 10 may include multiple sets of strands, such as the second set 34 of strands and the third set 38 of strands, that intersect the high tensile strength strands in the first set 25. The third set 38 of lines may be substantially the same as or similar to those in the second set 34. For example, the third set 38 may include the first line 35, the second line 36, and the third line 37, although the third set 38 may include any number of lines. According to one example, the second set 34 of strands and the third set of strands may be repeated in any number along a direction that extends along the length of the high tensile strength strands in the first set 25. This may result in multiple sets of strands intersecting the high tensile strength strands in the first set 25, such that the multiple sets of strands serve to substantially hold the high tensile strength strands in the first set 25 in place.

According to an embodiment, the net 10 may comprise additional sets of threads extending in substantially the same direction as the first set 25 of threads. For example, mesh 10 may include a fourth set of threads 44 and a fifth set of threads 49. Fourth set of lines 44 and fifth set of lines 49 may include any number of lines. For example, the fourth set of lines 44 may include a first line 40, a second line 41, a third line 42, and a fourth line 43, and the fifth set of lines 49 may include a first line 45, a second line 46, a third line 47, and a fourth line 48, although the fourth set of lines 44 and the fifth set of lines 49 may include any number of lines. According to an embodiment, the lines in the fourth group 44 and the lines in the fifth group 49 may be lines like those in the second group 34. In such an embodiment, the wires in fourth set 44, the wires in fifth set 49, and the wires in second set 34 may be made of the same material and have the same structure, with the wires in fourth set 44 and the wires in fifth set 49 intersecting the wires in second set 34 to form the mesh structure of mesh 10.

According to an embodiment, a repeating pattern may be provided in which sets of high tensile strength strands alternate with sets of non-high tensile strength strands. For example, the strands in fourth group 44 and the strands in fifth group 49 may be non-high tensile strength strands on either side of first group 25 of high tensile strength strands, with the sets of high tensile strength strands alternating with the sets of non-high tensile strength strands in a direction substantially perpendicular to the longitudinal axes of the strands. According to another embodiment, the strands in either or both of fourth set 44 and fifth set 49 may be substantially the same or similar high tensile strength strands as those in first set 25. The sets of strands may be selected to include high tensile strength strands or non-high tensile strength strands depending on the desired strength and tensile resistance of the web 10.

According to an embodiment, any one of the sets of strands may comprise a mixture of high tensile strength strands and non-high tensile strength strands. Such a mixture may be selected according to the desired strength and tensile resistance of the web 10.

According to embodiments, the web 10 may be formed from monofilament strands. For example, the non-high tensile strength strands may be formed from monofilament strands, such as strands in the second group 34 and other groups that include non-high tensile strength strands.

The web 10 may be a woven material (woven material) or a knit material (knit material). For example, the web 10 may be produced as a woven or knitted material to provide not only a high performance material having strength and stretch resistance, but also a web material having a desired pattern or style.

According to an embodiment, the mesh 10 may be a woven material, wherein the threads pass over and under each other alternately in the warp and weft directions. For example, the high tensile strength wires in the first set 25 may extend in the warp direction, while the wires in the second set 34 may extend in the weft direction. For example, when the strands in the second group 34 cross the high tensile strength strands in the first group 25, the strands in the second group 34 may alternately pass above and below the high tensile strength strands in the first group 25. Such a pattern of braided strands may provide both high tensile strength strands for enhancing the strength and tensile resistance of the mesh material and non-high tensile strength strands for interlocking with and holding the high tensile strength strands generally in place.

According to another embodiment, the mesh 10 may be a knitted material, wherein the threads are knitted together. For example, the high tensile strength strands in the first set 25 may extend along their respective lengths in a first direction and the non-high tensile strength strands in the second set 34 may cross the high tensile strength strands and knit adjacent high tensile strength strands in the first set 25 to each other. For example, the non-high tensile strength strands in the second set 34 may form loops between the first and

second strands

21, 22 in the first set 25 that will knit the first and

second strands

21, 22 together. The non-high tensile strength strands may similarly knit other high tensile strength strands to one another and may connect adjacent sets of strands to one another.

The mesh materials described above may be included in an article of footwear to advantageously provide the article of footwear with increased strength and tensile resistance, but also with freedom to design various pleasing styles. For example, the mesh material itself may be used to incorporate different fashion designs into an article of footwear. Returning to the example of fig. 2, article of footwear 100 may include an upper 110 and a sole structure 120. Fig. 3 shows a view of lateral side 111 of footwear 100 of fig. 2 and fig. 4 shows a view of medial side 112 of footwear 100. For reference purposes, footwear 100 may be divided into three general areas: forefoot region 101, midfoot region 102, and heel region 103, as shown in fig. 3 and 4. Forefoot region 101 generally includes portions of footwear 100 corresponding with toe portions 136 where the toes and joints connecting the metatarsals with the phalanges will be present. Midfoot region 102 generally includes portions of footwear 100 corresponding with an arch area of the foot, while heel region 103 corresponds with heel portion 138 and rear portions of the foot (including the calcaneus bone). Region 101, medial side 112, and lateral side 111 may be applied to sole structure 20, upper 30, and individual elements thereof. Regions 101-103, medial side 112, and lateral side 111 are not intended to demarcate precise areas of footwear 100. Rather, regions 101-103, medial side 112, and lateral side 111 are intended to represent general areas of footwear 100 to aid in the following discussion.

Sole structure 120 is secured to upper 110 and sole structure 120 extends between the foot and the ground when footwear 100 is worn. Sole structure 120 may include a midsole, an outsole, and a sockliner (not shown). The midsole is secured to a lower surface of upper 110 and may be formed from a compressible polymer foam element (e.g., polyurethane or ethylvinylacetate foam) that attenuates ground reaction forces (i.e., provides cushioning) as compression is created between the foot and the ground during walking, running, or other ambulatory activities. In further configurations, the midsole may incorporate fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot, or the midsole may be primarily formed from a fluid-filled chamber. The outsole is secured to a lower surface of the midsole and may be formed of a wear-resistant rubber material that is textured to impart traction. The sockliner is located within upper 110 and is oriented to extend under a lower surface of the foot. While this configuration for sole structure 120 provides an example of a sole structure that may be used in conjunction with upper 110, a variety of other conventional or nonconventional configurations for sole structure 120 may also be used. Accordingly, the structure and features of sole structure 120, or any sole structure used with upper 110, may vary significantly.

Upper 110 defines a void 134 in footwear 100 for receiving the foot and securing the foot relative to sole structure 120. Void 134 may be shaped to receive the foot and extend along lateral side 111 of the foot, along medial side 112 of the foot, over the foot, around the heel, and under the foot. A lace 132 extends through plurality of lace apertures 130 and allows the wearer to modify dimensions of upper 110 to accommodate the size of the foot. More specifically, lace 132 allows the wearer to tighten upper 110 around the foot, and lace 132 allows the wearer to loosen upper 110 to facilitate entry and exit of the foot from void 134. In addition, upper 110 may include a tongue (not depicted) that extends under lace 132.

According to an embodiment, upper 110 may include stitching 140. Stitching 140 may be utilized to join the materials of upper 110 and/or provide a stylish design to upper 110. For example, threads may be utilized for stitching 140 that contrast with the surrounding material of upper 110 such that stitching 140 is more visible to provide a stylish design.

Different portions of upper 110 may be formed from one or more of a variety of material elements (e.g., textiles, polymer sheets, foam layers, leather, synthetic leather) that are stitched or bonded together to form a void within footwear 100. Upper 110 may also incorporate a heel counter that limits movement of the heel in heel region 101, or may also incorporate a wear-resistant toe guard located in forefoot region 103. Although various material elements or other elements may be incorporated into upper 110, different strands 34 are incorporated into areas of one or both of lateral side 111 and medial side 112.

The mesh materials discussed above may be incorporated into upper 100. According to one embodiment, mesh material 150 may be incorporated into upper 110. As shown in the examples of fig. 2-4, mesh material 150 may form, for example, a majority of lateral side 111 of upper 110 and a majority of medial side 112 of upper 110. Accordingly, web material 150 may have the following configuration: (a) extend from a higher area of upper 110 to a lower area of upper 110 and extend through each of regions 101-103, (b) define different lace apertures 130, and (c) may form an exterior surface (i.e., an exterior, exposed surface of footwear 100).

Mesh material 150 may include a first set 113 of high tensile strength strands, as shown in the example of fig. 3. The high tensile strength strands enhance the strength and tensile resistance of mesh material 150 and upper 110 in which mesh material 150 is incorporated.

During walking, running, or other ambulatory activities, the forces generated in footwear 100 may tend to stretch upper 110 in different directions, and the forces may be concentrated in different locations. That is, many of the material elements forming upper 110 may stretch when placed in tension by movement of the foot. Although the high tensile strength strands may also stretch, the high tensile strength strands generally stretch to a lesser degree than the other material elements forming upper 110. Accordingly, mesh material 150 may be positioned to provide a structural component in upper 110 that reinforces the upper and resists stretching in a particular direction or locations where increased forces are concentrated. Such a mesh material 150 may also provide weight savings by providing a lightweight structure that is relatively strong. The high tensile strength strands may be positioned to provide stretch resistance in a particular direction and orientation, and the number of high tensile strength strands may be selected to impart a desired degree of stretch resistance. Thus, the orientation, positioning, and number of high tensile strength strands may be selected to provide a structural component tailored for a particular purpose.

For example, the various high tensile strength strands extending between lace apertures 130 and sole structure 120 resist stretching in the medial-lateral direction (i.e., in a direction extending around upper 110). These high tensile strength strands may also be positioned adjacent lace apertures 130 and extend from lace apertures 130 to resist stretching due to tension in lace 132. Given that the high tensile strength strands cross other strands, whether the other strands are other high tensile strength strands or non-high tensile strength strands, the forces from the tensioning of lace 132 or the forces from the movement of the foot may be distributed over different areas of upper 110. Accordingly, the high tensile strength strands are positioned to form a tensile-resistant structural element in upper 110.

According to an embodiment, web structure 150 may include high tensile strength strands that extend longitudinally along footwear 100 between forefoot region 103 and heel region 101. Such high tensile strength strands resist stretching in the longitudinal direction (i.e., in the direction extending through each of the regions 101-103). In this embodiment, the high tensile strength strands may cross each other and allow the forces from lace 132 at different lace apertures 130 to be more widely distributed throughout upper 110.

According to an embodiment, mesh material 150 may be oriented such that the high tensile strength strands in mesh material 150 are angled with respect to sole structure 120. For example, mesh material 150 may be oriented such that high tensile strength strands of mesh material 150, such as the high tensile strength strands in first set 113, are diagonally angled between sole structure 120 and lace apertures 130. The running style or preferences of an individual may determine, for example, the orientation, location, and number of high tensile strength strands. For example, some individuals may have a relatively high degree of pronation (i.e., inward rolling of the foot), and thus providing a greater number of high tensile strength strands on lateral side 111 may reduce the degree of pronation. Some individuals may also prefer that upper 110 fit more comfortably, which may require the addition of more high tensile strength strands throughout upper 110. Accordingly, footwear 100 may be customized to a running style or personal preference by varying the orientation, positioning, and number of high tensile strength strands. In addition, mesh material 150 may impart stretch resistance to particular areas, reinforce areas, enhance wear-resistance, improve flexibility, or provide areas of breathability to upper 110. Accordingly, by controlling the orientation, positioning, and number of the wires, the properties of upper 110 and footwear 100 may be controlled.

Upper 110 may include multiple sets of high tensile strength strands, such as a second set 114 of high tensile strength strands, as shown in fig. 3. Upper 110 may also include one or more sets of non-high tensile strength strands. For example, the upper may include at least a third set of non-high tensile strength strands, as shown in fig. 3. According to an embodiment, the first group of high tensile strength strands 113 and the second group of high tensile strength strands 114 may be arranged in an alternating pattern, wherein the third group of non-high tensile strength strands 115 is located between the first group of high tensile strength strands 113 and the second group of high tensile strength strands 114, as shown in fig. 3. Upper 110 may also include a fourth set 116 of non-high tensile strength strands that intersect first set 113 of high tensile strength strands and second set 114 of high tensile strength strands, as shown in fig. 3. Thus, the non-high tensile strength strands in the fourth group 116 may interlock with the high tensile strength strands in the first group 113 and the high tensile strength strands in the second group 114 to substantially hold the high tensile strength strands in the first group 113 and the high tensile strength strands in the second group 114 in place.

Based on the above discussion, mesh material 150 including high tensile strength strands may be utilized to form structural components in upper 110. In general, the high tensile strength strands resist stretching to limit the overall stretch of upper 110. High tensile strength strands may also be utilized to distribute forces (e.g., forces from lace 132 and lace apertures 130) across different areas of upper 110. Thus, the orientation, positioning, and number of high tensile strength strands may be selected to provide structural components that are tailored to a particular purpose. The high tensile strength strands of web material 150 may be arranged to impart one-dimensional stretch or multi-dimensional stretch. The mesh material also includes a coating that forms, for example, a breathable and waterproof barrier.

The threads forming mesh material 150 may be arranged such that mesh material 150 exhibits a stylish design. The design incorporating mesh material 150 including high tensile strength strands advantageously provides footwear 100 with high performance due to the enhanced strength and tensile resistance of mesh material 150, and with the weight savings provided by mesh material 150 due to its high strength and tensile resistance without the use of a base layer or cover layer, and footwear 100 also has a stylish design that is desirable for both athletic and recreational uses. For example, footwear 100 that incorporates mesh material 150 when worn while playing tennis may provide high performance, but also provide a design that is desirable not only during tennis matches but also during casual wear away from tennis courts.

For example, the threads of mesh material 150 may be arranged in a grid design, as shown in fig. 2-4. Such a lattice design may be created, for example, by intersecting sets of high tensile strength strands and sets of non-high tensile strength strands in the mesh structure. In such a mesh structure, the high tensile strength strands and the non-high tensile strength strands may interlock with each other such that the high tensile strength strands are generally held in place. The lattice design may include, for example, multiple sets of high tensile strength strands alternating with non-high tensile strength strands. As shown in fig. 3, the first group 113 of high tensile strength strands and the second group 114 of high tensile strength strands may alternate with the third group 115 of non-high tensile strength strands.

According to an embodiment, the high tensile strength wires may be compared to the non-high tensile strength wires such that the high tensile strength wires are prominent and more visible than the non-high tensile strength wires. As shown in the example of fig. 3, the high tensile strength strands 117 in the first set 113 of high tensile strength strands may be compared to and protrude from surrounding non-high tensile strength strands that intersect the high tensile strength strands 117 or extend proximate to the high tensile strength strands 117. Such an effect may be accomplished, for example, by making the high tensile strength strands 117 thicker than the surrounding non-high tensile strength strands and/or making the high tensile strength strands 117 appear a different color than the surrounding non-high tensile strength strands.

The mesh material may be incorporated into the article of footwear using different methods. According to embodiments, the mesh material may be provided in sheet form, which is then incorporated into the article of footwear. As shown in the example of fig. 5, the mesh material may be provided as a sheet 200, the sheet 200 being cut to correspond to a desired shape of the article of footwear. For example, sheet 200 may be cut to correspond to the shape of an upper of an article of footwear. As shown in the example of fig. 5, sheet 200 may be cut to include both a medial side 210 and a lateral side 212 that correspond to the medial and lateral sides of the upper, respectively. Such a sheet 200 of mesh material may be applied to an upper 121 of an article of footwear by wrapping the sheet 200 around the upper 121, as shown in the example of fig. 6. For example, sheet 200 of mesh material may be first applied to toe portion 214 of upper 121 and then lowered in the direction indicated by arrow Y in fig. 6 such that medial side 210 and lateral side 212 of sheet 200 are each wrapped around a side of upper 121. The ends of medial side 210 and lateral side 212 of sheet 200 may then be wrapped around heel portion 216 of upper 121 to provide an article of footwear including sheet 200 of mesh material, as shown in the example of fig. 7. Such articles of footwear incorporating mesh materials advantageously provide high performance due to the strength and tensile resistance of the mesh materials and also provide a fashion design desirable for both athletic and recreational uses.

Other methods may be used to incorporate the mesh material into the article of footwear. According to embodiments, discrete portions of mesh material separated from one another may be applied to an upper of an article of footwear to incorporate the mesh material into the article of footwear. The method of incorporating the mesh material into the article of footwear may be selected according to the desired amount of mesh material incorporated into the article of footwear and according to the desired style or pattern of the article of footwear.

The mesh material incorporated into the article of footwear may have a breathable structure due to the woven or knitted structure of the mesh material. Such woven or knitted structures are somewhat open and allow some air to pass through the mesh material. Thus, the mesh material may advantageously make the upper into which the mesh material is incorporated more breathable. Additionally, the structure of the mesh material may also be translucent or transparent and allow a degree of light to pass through the mesh material. Thus, the mesh material may allow a viewer to see the material or layer underneath the mesh material. Such effects may be used to increase the fashion or design of an article of footwear, for example, by incorporating a layer beneath the mesh material that is viewable through the mesh material to some extent.

Turning to fig. 8, an exploded view of an article of footwear incorporating mesh material 152 is shown. The mesh material 152 may be translucent or transparent, allowing a viewer to see the material or layer underlying the mesh material 152. For example, layer 154 may be disposed beneath mesh material 152. Layer 154 may include a rear portion 155 and a strap portion 157, as shown in the example of fig. 8. Rear portion 155 and/or strap portion 157 of layer 154 may be provided to add fashion design to the article of footwear, as layer 154 may be viewable through mesh material 152. For example, the back portion 155 may have a different color, design, or pattern than the mesh material 152 and other surrounding materials such that the back portion 155 of layer 154 is different and may be more easily viewed through mesh material 152. Band portion 157 may also be different from mesh material 152 and the surrounding material such that band portion 157 may be more easily viewed through mesh material 152. According to these embodiments, layer 154 may contribute to the fashion design of an article of footwear by providing a design and/or color that is observable through mesh material 152. According to another embodiment, layer 154 need not be distinct from mesh material 152, which may also contribute to the fashion design of the article of footwear. For example, a design may be selected for an article of footwear that minimizes distinctive design and/or color for a simplified but stylish design. Fig. 27 is also included to provide a picture of an article of footwear incorporating a mesh material having a grid pattern, in accordance with an embodiment.

The article of footwear may also include a cushion 156, which may serve as a foundation layer. Similar to layer 154, liner 156 may also be different from mesh material 152 and the surrounding material, such that liner 156 may be more easily viewed through mesh material 152. As such, the liner 156 may contribute to the fashion design of the article of footwear by providing a design and/or color that is observable through the mesh material 152. According to another embodiment, the liner 156 need not be distinct from the mesh material 152, which may also contribute to the fashion design of the article of footwear.

The liner 156 may be formed of any generally two-dimensional material. As used with respect to the present invention, the term "two-dimensional material" or variations thereof is intended to include generally planar materials exhibiting a length and width that are substantially greater than a thickness. Suitable materials for the pad 156 include, for example, a variety of fabrics, polymer sheets, or a combination of fabrics and polymer sheets. Fabrics are generally made of fibers, filaments, or yarns that are, for example, (a) produced directly from a web of fibers by bonding, fusing, or interlocking to construct non-woven fabrics and felts, or (b) formed by mechanical manipulation of yarns to produce woven fabrics. The polymeric sheet may be extruded, rolled, or otherwise formed from a polymeric material to exhibit a generally planar 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 the liner 156. While two-dimensional materials may have smooth or substantially non-textured surfaces, some two-dimensional materials will exhibit texture or other surface features, such as, for example, dimples, protrusions, ribs, or various patterns. Despite the presence of surface features, two-dimensional materials remain generally planar and exhibit a length and width that are significantly greater than the thickness.

As shown in the example of fig. 8, the article of footwear may also include a strap 158 and a heel counter 150. The strap 158 may help secure the upper of the article of footwear to the foot 160 and thus improve the feel of the article of footwear. The strap 158 may be disposed, for example, on either or both of the medial and lateral sides of the article of footwear. The strap 158 may be positioned underneath the mesh material 152. Depending on the embodiment, strap 158 may be different from mesh material 152 such that strap 158 is more easily viewed through mesh material 152 or relative to mesh material 152. Thus, the band 158 may contribute to the overall fashion design of the article of footwear due to its distinctive color and/or pattern. According to another embodiment, strap 158 need not be distinct from mesh material 152, but may also contribute to the fashion design of the article of footwear.

Mesh material 152 may be attached to an upper of an article of footwear to secure mesh material 152 in place. According to an embodiment, the mesh material 152 may be attached to the strap portion 153. For example, a top portion of mesh material 152 may be welded to band portion 153 and a bottom portion of mesh material may be connected to a sole structure of an article of footwear. The belt portion 153 may be made of a material suitable to provide a desired design or color. For example, the belt portion 153 may be made of Thermoplastic Polyurethane (TPU).

According to embodiments, the mesh material 152 itself may be colored. Providing color to mesh material 152 may increase the fashion design of mesh material 152 and the article of footwear in which it is incorporated. For example, the threads of mesh material 152 may be colored. Such lines may be colored the same color or different lines may be colored different colors. In an example of a lattice design of mesh material 152, the lines of mesh material 152 may have different colors to highlight the lattice pattern. According to an embodiment, the strands of mesh material 152 may include high tensile strength strands made of, for example, nylon and non-high tensile strength strands made of, for example, polyester. The mesh material 152 may then be dyed such that the non-high tensile strength strands become colored, while the high tensile strength strands are not colored. In such an example, the non-colored high tensile strength strands would be apparent and significant relative to the colored non-high tensile strength strands. For example, the mesh material 152 may be exhaust dyed to color non-high tensile strength strands made of polyester.

As discussed above, the mesh material incorporated into the upper of the article of footwear may be a woven material. Returning to fig. 9, the mesh material 160 may include a first set 226 of high tensile strength strands that are interleaved with a second set 162 of non-high tensile strength strands and woven to provide strength and tensile resistance to the mesh material 160 while substantially holding the first set 226 of high tensile strength strands in place. Mesh material 160 may include additional sets of high tensile strength strands and additional sets of non-high tensile strength strands. The set of high tensile strength strands and the set of non-high tensile strength strands may be arranged in an alternating pattern to provide a design.

As shown in the example of fig. 10, which is an isometric view of the mesh material 160 of fig. 9, sets of threads of the mesh material 160 may be woven in a fashion pattern, such as, for example, a lattice design. According to an embodiment, the first group 226 of high tensile strength strands may be woven with the second group 228 of non-high tensile strength strands and the third group 230 of non-high tensile strength strands. For example, the first group 226 of high tensile strength strands may extend in the warp direction 234 of the mesh material 160, while the second group 228 of non-high tensile strength strands and the third group 230 of non-high tensile strength strands extend in the weft direction 236. Such a weave pattern would provide, for example, a mesh material 160 that is substantially resistant to stretching in the warp and

weft directions

234, 236, but may allow some stretching in a direction 238 (the offset direction), which direction 238 is diagonal to the warp and

weft directions

234, 236. The diagonal direction 238 may extend between the warp direction 234 and the weft direction 236, for example, at a substantially 45 degree angle.

Thus, the mesh material 160 may have, for example, increased strength and stretch resistance in the warp and weft directions 234, 236 (e.g., along the direction in which the first and

second sets

226, 228 of threads extend), but may allow for some stretching in the diagonal direction 238.

According to an embodiment, the second group 228 of non-high tensile strength strands and the third group 230 of non-high tensile strength strands may intersect the high tensile strength strands in the first group 226 to provide an interlocking pattern between the high tensile strength strands and the non-high tensile strength strands. Such interlocking patterns may hold the high tensile strength strands generally in place while providing strength and tensile resistance to the lattice design.

For example, as shown in fig. 11, which is a cross-sectional view along line 11-11 in fig. 10, a single high tensile strength line 164 may cross and interlock with non-high tensile strength lines 163 and non-high tensile strength lines 165 extending in the weft direction 236. As shown in the example of fig. 11, the non-high tensile strength strands 163 may pass over each high tensile strength strand 164, while the non-high tensile strength strands 165 pass under each high tensile strength strand 164. In the regions 167 between the high tensile strength strands 164, the non-high tensile strength strands 163 and the non-high tensile strength strands 165 may pass each other and may be woven or connected to each other. For example, another non-high tensile strength strand (not shown) may be threaded between the non-high tensile strength strands 163 and the non-high tensile strength strands 165 in the region 167, such as through loops formed by the non-high tensile strength strands 163 and the non-high tensile strength strands 165 to weave the non-high tensile strength strands 163 and the non-high tensile strength strands 165 in the region 167.

According to an embodiment, the mesh material 160 may also include a fourth set 232 of non-high tensile strength strands extending along a warp direction 234. A fourth set 232 of non-high tensile strength strands may be crossed and woven with the non-high tensile strength strands in the second set 228 and the non-high tensile strength strands in the third set 230. According to an embodiment, the weave pattern formed between the strands in first set 226 and second and

third sets

228, 230, and the weave pattern formed between fourth set 232 and second and

third sets

228, 230 may be selected to provide different regions of mesh material 160 having different patterns. For example, first area 218, second area 220, third area 222, and fourth area 224 of mesh material 160 may have different patterns to provide a lattice design. The lattice design provided by the weave pattern of first, second, third and

fourth areas

218, 220, 222, 224 may repeat, for example, alternately in the warp and

weft directions

234, 236 to provide mesh material 160 with a lattice design.

Fig. 12A shows an example of a weave pattern of a mesh material 170 according to an embodiment. Mesh material 170 may include high tensile strength strands 172 that cross and interlock with non-high tensile strength strands 176 and non-high tensile strength strands 178. Fig. 12B is an enlarged view of the mesh material 170 of fig. 12A to aid in viewing the weave pattern of the mesh material 170. For example, the non-high tensile strength strands 176 and the non-high tensile strength strands 178 may be alternately woven over and under the high tensile strength strands 172 to provide a weave pattern that substantially holds the high tensile strength strands 172 in place.

Additionally, mesh material 170 may include non-high tensile strength strands 174 that extend in substantially the same direction as high tensile strength strands 172 and interlock with non-high tensile strength strands 176 and non-high tensile strength strands 178, as shown in fig. 13 and 14. Such a weave pattern formed between the high tensile strength strands 172, the non-high tensile strength strands 176, the non-high tensile strength strands 178, and the non-high tensile strength strands 174 may be repeated through the web material to provide a desired pattern. Figure 15 shows a side view of an exemplary high tensile strength wire.

As discussed above, the mesh material may be oriented such that the high tensile strength strands of the mesh material are angled diagonally between the sole structure and the lace apertures of the shoelace. According to another embodiment, the high tensile strength strands of mesh material may be oriented in a generally vertical direction between the sole structure and the lace apertures.

Returning to fig. 16, article of footwear 180 may include mesh material 187. Mesh material 187, in turn, may include a first set 12 of high tensile strength strands and a second set 10 of non-high tensile strength strands. As shown in the enlarged portion of fig. 16, the first group 12 may include a first high tensile strength strand 181, a second high tensile strength strand 182, and a third high tensile strength strand 183, although any number of high tensile strength strands may be included in the first group 12. For example, the number of high tensile strength strands in first group 12 may vary depending on the desired strength or stretch resistance of mesh material 187.

Further, as shown in the enlarged portion of fig. 16, the second group 10 may include first non-high tensile strength strands 184, second non-high tensile strength strands 185, and second non-high tensile strength strands 186, although the second group 10 may include any number of non-high tensile strength strands. Mesh material 187 may include other sets of strands, such as a third set 14 of high tensile strength strands and a fourth set 16 of strands, where fourth set 16 is a set of high tensile strength strands or a set of non-high tensile strength strands that intersect the strands in first set 12, second set 10, and third set 14. According to an embodiment, the alternating pattern of the first group 12 of high tensile strength strands, the second group 10 of non-high tensile strength strands, and the third group 14 of high tensile strength strands may be repeated in the horizontal direction and the vertical direction to provide the mesh material 187 with a desired pattern, such as, for example, a lattice pattern.

As shown in the example of fig. 16, the high tensile strength strands in first set 12 and the non-high tensile strength strands in second set 10 may extend in a substantially vertical direction between sole structure 189 and lace apertures 188 of footwear 180.

The plurality of sets of high tensile strength strands and the plurality of sets of non-high tensile strength strands may include different numbers of strands and the respective sets may have different widths. The number and width of the strands for a given set of strands may be selected, for example, based on the desired strength and stretch resistance of mesh material 187. For example, first set 12 of high tensile strength strands may have a width in a horizontal direction (which is substantially perpendicular to a vertical direction extending between sole structure 189 and lace apertures 188) of approximately 0.5cm to 4.0 cm. The second group 10 of non-high tensile strength strands may have a width corresponding to the first group 12 or may have a different width falling within a range of approximately 0.5cm to 4.0 cm. The third set 14 of high tensile strength strands may have the same width as the first set 12 or may have a different width to provide mesh material 187 with varying designs. The fourth set 16 of threads may have a height in the vertical direction that is the same as the width of the first set 12, such as when a repeating square pattern is desired for the mesh material 187, or the fourth set 16 of threads may have a height that is different and falls within a range of about 0.5cm to 4.0 cm.

As discussed above, due to the structure of the mesh material, the mesh may be at least translucent. Accordingly, the mesh material may be layered over other materials to provide additional patterns or designs to the article of footwear. As shown in the example of fig. 17, which shows a cross-section of an article of footwear, mesh material 194 may be layered over another layer 192 (such as a cushion) and attached to sole structure 190. As discussed above, the layer 192 may have a color, design, or pattern that enhances the design provided by the mesh material 194.

According to embodiments, because the mesh material itself may provide strength, stretch resistance, and a fashion design, as well as being breathable, an article of footwear may be provided in which the mesh material provides a primary layer of the upper. As shown in the example of fig. 18, mesh material 252 may be attached to sole structure 250 and serve as a primary layer of the upper. Such mesh material 252 may be the only layer provided to the upper, for example, in portions of the upper, and may provide substantially the entire thickness of the upper in those portions where only mesh material 252 is present, as shown in fig. 18. This embodiment advantageously provides an article of footwear that requires less material for the upper and its padding, provides a lightweight structure, provides weight savings, and allows more air to flow freely around the foot within the article of footwear.

The web material may be formed into a pattern using principles other than those described above, such as a pattern other than the grid pattern described above. According to embodiments, the mesh material may be formed in a herringbone pattern. Such a herringbone pattern may be formed, for example, from a knitted mesh material.

Fig. 19 shows a side view of article of footwear 300, which article of footwear 300 incorporates mesh material 350 formed in a herringbone pattern. Mesh material 350 may include a plurality of high tensile strength strands, such as first high tensile strength strands 351 and second high tensile strength strands 352. A set of non-high tensile strength strands 353 may be located between high tensile strength strands 351 and second high tensile strength strands 352. According to an embodiment, groups of non-high tensile strength strands 353 may intersect high tensile strength strands 351 and second high tensile strength strands 352 to form an interlocking mesh structure that substantially holds high tensile strength strands 351 and high tensile strength strands 352 in place. For example, the groups of non-high tensile strength strands 353 may form a knit structure in which high tensile strength strands 351 and high tensile strength strands 352 are knit together through loops formed by the groups 353 of non-high tensile strength strands. Fig. 28 is included to provide a picture of a mesh material having a herringbone pattern in accordance with an embodiment.

According to an embodiment, each of the high tensile strength strands 351 and the high tensile strength strands 352 may have a width 18 of approximately 0.5cm to 4.0 cm. According to an embodiment, the group 353 of non-high tensile strength strands may have a width 17 of approximately 0.5cm to 4.0 cm.

As shown in the example of fig. 19, high tensile strength strands 351, high tensile strength strands 352, and groups 353 of non-high tensile strength strands may be oriented at an angle between sole structure 320 and lace apertures 330 for lace 332. According to another embodiment, the high tensile strength strands and the non-high tensile strength strands may be oriented to extend in a generally vertical direction between sole structure 320 and lace apertures 330.

The web material used in the herringbone pattern may have the characteristics of the web material described above. For example, the mesh material used in the herringbone pattern may be translucent and allow layers and materials underlying the mesh material to be viewed by an observer. Returning to fig. 20A, a completed upper 340 of an article of footwear is shown incorporating mesh material 350 in a herringbone pattern. Fig. 20B shows upper 340 of fig. 20A with mesh material 350 removed to more clearly show the layers underlying mesh material 350. According to an embodiment, upper 340 may include one or more strips 360 underlying mesh material 350. Bands 360 may be provided to help secure upper 340 to the foot and improve the feel of the article of footwear. Intermediate layer 362 may also be disposed underneath mesh material 350. Strap 360 and/or intermediate layer 362 may have a color and/or pattern that contributes to the design of mesh material 350. For example, strap 360 and/or intermediate layer 362 may have a different color and/or design than mesh material 350. In another example, strap 360 and/or intermediate layer 362 may have a color and/or design that is indistinguishable from mesh material 350. According to an embodiment, when intermediate layer 362 is present, upper 340 may also include a liner 366 disposed below mesh material 350 and intermediate layer 362. Liner 366 may have a color and/or pattern that contributes to the design of mesh material 350. Additionally, the liner 366 may have different portions with different colors and/or patterns. For example, when different portions of liner 366 desire different designs or colors, liner 366 may include portion 364 having a different color and/or pattern than the remainder of liner 366.

According to embodiments, the mesh material may be formed into a seersucker pattern. Such a seersucker pattern may be formed, for example, from a knitted mesh material. Fig. 21 shows an example of an article of footwear 400 that incorporates a mesh material 410 having a seersucker pattern. Mesh material 410 may include high tensile strength strands 430, which high tensile strength strands 430 provide strength and tensile resistance to mesh material 410. Mesh material 410 may have the characteristics of mesh materials discussed above. For example, mesh material 410 may be breathable and translucent. As shown in the example of fig. 21, mesh material 410 may be bonded such that high tensile strength strands 430 are oriented at an angle between sole structure 412 and lace apertures 420, although other angles may be utilized, such as a substantially perpendicular angle between sole structure 412 and lace apertures 420. Fig. 29 is a picture of an article of footwear incorporating a mesh material with a seersucker pattern, under an embodiment.

Fig. 22 shows an exploded view of the upper of the article of footwear 400 of fig. 21. As shown in the embodiment of fig. 22, the upper may include a strap 424, mesh material 410, and a liner 422. Straps 424 may be provided to help secure the upper to the foot and improve the feel of article of footwear 400. A liner 422 may also be provided. According to an embodiment, the strap 424 and/or the liner 422 may have a color and/or pattern that contributes to the design of the mesh material 410. Although fig. 22 depicts strap 424 as being on top of mesh material 410, strap 424 may be located underneath mesh material 410.

The mesh material in the form of a seersucker pattern may include high tensile strength strands and intersecting non-high tensile strength strands that interlock with the high tensile strength strands to provide a mesh structure that substantially holds the high tensile strength strands in place. Returning to fig. 23, a mesh material 500 may be provided with a seersucker pattern, the mesh material 500 including first 501 and second 502 high tensile strength strands. Mesh material 500 may also include non-high tensile strength strands 510 between first high tensile strength strands 501 and second high tensile strength strands 502, the non-high tensile strength strands 510 connecting first high tensile strength strands 501 and second high tensile strength strands 502 together. For example, non-high tensile strength strands 510 may have a knitting pattern that knits first high tensile strength strands 501 and second high tensile strength strands 502 together, such as, for example, with knitted loops formed by non-high tensile strength strands 510.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Accordingly, the embodiments are not limited except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the appended claims.

Claims

1. An article of footwear having a forefoot region, a midfoot region, and a heel region, the article of footwear comprising:

a sole structure; and

an upper, the upper comprising:

a mesh material comprising high tensile strength strands and non-high tensile strength strands, wherein the high tensile strength strands interlock with the non-high tensile strength strands such that the high tensile strength strands are substantially held in place; and

the shoelace holes;

wherein the mesh material is oriented such that high tensile strength strands in the mesh material are positioned adjacent to the lace apertures and extend diagonally from the lace apertures to the sole structure such that the high tensile strength strands resist stretching between the lace apertures and the sole structure and resist stretching due to tension in the lace,

wherein the high tensile strength strands include first high tensile strength strands that extend diagonally between a first lace aperture in the midfoot region and the sole structure in the heel region such that the first high tensile strength strands resist stretching between the midfoot region and the heel region.

2. The article of footwear of claim 1, wherein the mesh material is a knit material.

3. The article of footwear of claim 1, wherein the mesh material is a woven material.

4. The article of footwear recited in claim 1, wherein the high tensile strength strands include multifilament yarns.

5. The article of footwear recited in claim 1, wherein the high tensile strength strands include second high tensile strength strands that extend diagonally between a second lace aperture and the sole structure at the midfoot region of the upper, such that the second high tensile strength strands resist stretching between the second lace aperture and the sole structure.

6. The article of footwear of claim 1, wherein the mesh material further includes additional high tensile strength strands extending longitudinally along the article of footwear between the forefoot region and the heel region.

7. The article of footwear of claim 1, wherein the high tensile strength strands are compared to the non-high tensile strength strands such that the high tensile strength strands protrude and are more visible than the non-high tensile strength strands.

8. The article of footwear of claim 1, wherein the mesh material is connected to the sole structure.

9. The article of footwear of claim 1, further comprising a cover layer forming an exterior surface of the upper.

10. The article of footwear of claim 1, wherein the mesh material is provided in a sheet to be incorporated into the article of footwear.

11. An article of footwear having a forefoot region, a midfoot region, and a heel region, the article of footwear comprising:

a sole structure; and

a mesh upper coupled to the sole structure, the upper comprising:

a mesh material comprising high tensile strength strands and non-high tensile strength strands forming a plurality of sets of non-high tensile strength strands, wherein the high tensile strength strands interlock with one or more of the non-high tensile strength strands such that the high tensile strength strands generally remain in place; and

lace apertures formed in the web material;

wherein the high tensile strength strands are positioned adjacent to the lace apertures and extend from the lace apertures to the sole structure to resist stretching due to tension in the lace.

12. The article of footwear according to claim 11, wherein the mesh material is substantially an entire thickness of the upper.

13. The article of footwear recited in claim 11, wherein the high tensile strength strands are oriented in a substantially vertical direction between the sole structure and the lace apertures.

14. The article of footwear of claim 13, the mesh material including a first set of high tensile strength strands and a second set of non-high tensile strength strands, the second set of non-high tensile strength strands being positioned adjacent to the first set of high tensile strength strands.

15. The article of footwear of claim 11, wherein the high tensile strength strands are compared to the non-high tensile strength strands such that the high tensile strength strands protrude and are more visible than the non-high tensile strength strands.

16. The article of footwear of claim 14, the mesh material further comprising a third set of high tensile strength strands and a fourth set of high tensile strength strands, the fourth set of high tensile strength strands intersecting the first set of high tensile strength strands, the second set of non-high tensile strength strands, and the third set of high tensile strength strands.

17. The article of footwear of claim 14, the mesh material further comprising a third set of high tensile strength strands and a fourth set of non-high tensile strength strands, the fourth set of non-high tensile strength strands intersecting the first set of high tensile strength strands, the second set of non-high tensile strength strands, and the third set of high tensile strength strands.

18. The article of footwear recited in claim 11, wherein the high tensile strength strands of mesh material are angled diagonally between the sole structure and the lace apertures.

19. The article of footwear recited in claim 18, wherein the high tensile strength strands include first high tensile strength strands that extend diagonally between a first lace aperture at the midfoot region and the sole structure at the heel region, such that the first high tensile strength strands resist stretching between the midfoot region and the heel region.

20. The article of footwear recited in claim 11, wherein the high tensile strength strands are attached to the sole structure.