ARTICLE OF FOOTWEAR WITH IMPROVED PERFORMANCE CHARACTERISTICS

Abstract

An upper for an article of footwear includes a mesh textile portion including pillars including one or more first yarns aligned in a first direction and defining a major axis of the mesh textile portion and links including one or more second yarns and aligned in a second direction defining a minor axis of the mesh textile portion. The minor axis is transverse the major axis, the pillars have a greater thickness and/or greater denier than the links, and the major axis is offset from a lengthwise dimension of the upper by a bias angle ranging from about 30 to about 60.

Claims

1. An upper for an article of footwear, the upper comprising a mesh textile portion including pillars comprising one or more first yarns and aligned in a first direction defining a major axis of the mesh textile portion and connecting links comprising one or more second yarns and aligned in a second direction defining a minor axis of the mesh textile portion, wherein the minor axis is transverse the major axis, the pillars have a greater thickness than the links, and the major axis is offset from a lengthwise dimension of the upper by a bias angle ranging from about 30 to about 60.

2. The upper of claim 1, wherein the bias angle is about 45.

3. The upper of claim 1, wherein a first thickness of the pillars is at least 2 times greater than a second thickness of the links.

4. The upper of claim 1, further comprising voids defined between intersecting pillars and links of the mesh textile portion, wherein each void has an elongated shape with a greatest dimension of each void oriented in a direction of the major axis for the mesh textile portion.

5. The upper of claim 1, wherein the mesh textile portion comprises a first panel that extends along at least a portion of a lateral side of the upper and a second panel that extends along at least a portion of a medial side of the upper.

6. The upper of claim 5, wherein the major axis of the first panel is offset from and transverse the major axis of the second panel.

7. The upper of claim 6, wherein the pillars along the major axis of the first panel at the lateral side converges at a convergence location of the upper with the pillars along the major axis of the second panel at the medial side.

8. The upper of claim 7, wherein the convergence location of the upper comprises a toe cage portion of the upper.

9. The upper of claim 5, wherein the major axis of the first panel is about parallel with the major axis of the second panel.

10. The upper of claim 5, wherein at least some of the pillars of the first panel and the second panel extend between the medial side and the lateral side of the upper.

11. The upper of claim 1, wherein the mesh textile portion comprises a knit structure.

12. The upper of claim 1, wherein the upper further comprises a plurality of layers, the plurality of layers comprising a first layer including the mesh textile portion and a second layer coupled with the first layer.

13. The upper of claim 12, wherein the second layer comprises a polyurethane laminate material.

14. The upper of claim 12, wherein the first layer defines an exterior surface portion of the upper, and the second layer is disposed beneath the first layer.

15. An article of footwear comprising a sole structure and the upper of claim 1 coupled with the sole structure.

16. An article of footwear comprising: a sole; and an upper coupled to the sole, the upper comprising an open textile structure including a plurality of strands, wherein the textile further comprises: pillar members including a first pillar member spaced from a second pillar member by a gap; and a plurality of linking members extending from the first pillar member to the second pillar member, the plurality of linking members permitting relative movement between the first pillar member and the second pillar member.

17. The article of footwear of claim 16, wherein: the open textile structure is a knit textile comprising courses and wales; and the pillar members comprise a interconnected loops formed of one or more strands.

18. The article of footwear of claim 16, wherein: the open textile structure is a woven structure comprising a warp and a weft; the weft incudes a weft strand; and the warp includes a first warp strand twisted around a second warp strand between picks of the weft strand.

19. The article of footwear of claim 16, wherein the linking members define a plurality of openings along the gap between the first pillar member and the second pillar member.

20. The article of footwear of claim 16, wherein the plurality of strands comprises a plurality of hard yarns.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is an example embodiment of an article of footwear or athletic shoe including a mesh textile formed as a portion of the shoe upper as described herein.

[0010] FIG. 2A depicts a portion of a mesh textile for incorporation into the shoe upper of FIG. 1.

[0011] FIG. 2B is an enlarged view of a portion of the mesh textile of FIG. 2A.

[0012] FIG. 2C depicts another embodiment of a mesh textile for incorporation into the shoe upper of FIG. 1.

[0013] FIG. 3 is an enlarged view of a portion of the mesh textile along a side of the upper showing orientation of the major and minor axes of the mesh textile in relation to a lengthwise dimension of the shoe upper.

[0014] FIG. 4 is an example embodiment depicted a flat, two-dimensional material or blank used to form a shoe upper and including the mesh textile of FIGS. 2A and 2B.

[0015] FIG. 5 is an example embodiment of a portion of a shoe including the front end/toe end with a toe cage portion of an upper formed with the blank of FIG. 4.

[0016] FIG. 6 is another example embodiment of a portion of a shoe including the front end/toe end with toe cage portion of an upper formed with a blank that includes a mesh textile as described herein.

[0017] FIG. 7A is a schematic of a textile embodiment, shown in its normal position.

[0018] FIG. 7B and FIG. 7C show the textile of FIG. 7A under selected loads.

[0019] FIG. 8 illustrates a schematic of a knit textile structure in accordance with an embodiment.

[0020] FIGS. 9A and 9B illustrate schematics of a woven textile structure in accordance with an embodiment.

[0021] In the following detailed description, reference is made to the accompanying figures which form a part hereof wherein like numerals designate like parts throughout, and in which is shown, by way of illustration, embodiments that may be practiced. It is to be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of the present disclosure. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.

DETAILED DESCRIPTION

[0022] Aspects of the disclosure are disclosed herein. Alternate embodiments of the present disclosure and their equivalents may be devised without parting from the spirit or scope of the present disclosure. It should be noted that any discussion herein regarding one embodiment, an embodiment, an exemplary embodiment, and the like indicate that the embodiment described may include a particular feature, structure, or characteristic, and that such particular feature, structure, or characteristic may not necessarily be included in every embodiment. In addition, references to the foregoing do not necessarily comprise a reference to the same embodiment. Finally, irrespective of whether it is explicitly described, one of ordinary skill in the art would readily appreciate that each of the particular features, structures, or characteristics of the given embodiments may be utilized in connection or combination with those of any other embodiment discussed herein.

[0023] For the purposes of the present disclosure, the phrase A and/or B means (A), (B), or (A and B). For the purposes of the present disclosure, the phrase A, B, and/or C means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

[0024] Further, the terms comprising, including, having, and the like, as used with respect to embodiments of the present disclosure, are synonymous. The term about, as used herein with regard to a numerical value or range of numerical values (e.g., describing a physical property or a particular dimensional value or angular alignment), means that the particular numerical value to which this term refers can vary by 5%.

[0025] The term longitudinal or lengthwise as used throughout this detailed description and in the claims, refers to a direction extending along the length of a component. For example, a longitudinal direction of an article of footwear extends from forefoot region to heel region of the article of footwear. The term forward or front is used to refer to the general direction in which the toes of a foot point, and the term rearward or back is used to refer to the opposite direction, i.e., the direction in which the heel of the foot is facing. The term lateral direction, as used throughout this detailed description and in the claims, refers to a side-to-side direction extending along the width of a component. In other words, the lateral direction may extend between medial side and lateral side of the article of footwear. Finally, the term vertical, as used throughout this detailed description and in the claims, refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where an article of footwear is planted flat on a ground surface, the vertical direction may extend from the ground surface upward.

[0026] Initially, it is noted that the figures depict an embodiment of an article of footwear including an upper and sole structure for a single foot (e.g., an article of footwear for a right foot of a user). However, it is noted that the same or similar features can also be provided for an article of footwear for the opposing foot (e.g., for the opposing left foot of a user), where such features of the upper for the other foot can be a reflection or can be mirror image symmetrical in relation to the upper depicted in the figures.

[0027] An article of footwear including an upper with a textile formed of a plurality of ribs or pillars coupled (e.g., connected, interconnected, etc.) by transverse links spaced along the length of the pillars such that the pillars move relative to each other. As described herein with reference to the example embodiment of FIG. 1, an article of footwear or athletic shoe 100 includes an upper 110 and a sole structure 190 secured to the upper 110.

[0028] The sole structure can include an outsole 192 and a midsole 194, where the midsole is disposed between the outsole and the upper. The midsole and outsole can be formed of any conventional or other suitable types of polymers and/or other materials. The sole structure 190 may be formed of a single material or may be formed of a plurality of materials. In example embodiments in which the sole structure includes a midsole and an outsole, the midsole may be formed of one or more materials including, without limitation, ethylene vinyl acetate (EVA), an EVA blended with one or more of an EVA modifier, a polyolefin block copolymer, and a triblock copolymer, and a polyether block amide (e.g., a PEBAX material). The outsole may be formed of one or more materials including, without limitation, elastomers (e.g., thermoplastic polyurethane), siloxanes, natural rubber, and synthetic rubber. In still further embodiments, the sole structure can comprise a single or unitary member that connects with the upper.

[0029] The shoe 100 and upper 110 include a front or forefoot region 120 that generally aligns with the ball and toes of a user's foot (i.e., when a user is wearing the upper), a midfoot region 130 that generally aligns with the arch and instep areas of the user's foot, and a hind foot region 140 that generally aligns with the heel and ankle areas of the user's foot. The upper 110 further includes a medial side 150 that is oriented along the medial or big toe side of the user's foot, a lateral side 160 that is oriented along the lateral or little toe side of the user's foot, a toe (i.e., front) end 125 or toe cage that corresponds with the toe end of the user's foot and a heel (i.e., rear) end 145 that corresponds with the heel of the user's foot. The heel end 145 has a curved shape defining a heel cup that generally conforms to the user's heel and extends between the medial and lateral sides 150, 160 of the upper 110. A main opening at a top or neck portion of the upper 110, which is defined between the toe end 125, heel end 145, medial and lateral sides 150, 160 provides access to a cavity of the upper that is configured to receive the user's foot. The midfoot region 130 further includes a vamp section extending from the toe cage toward the neck portion of the upper, where the vamp section of the upper 110 includes an open section defined between the upper edges of the medial and lateral sides 150, 160 and that extends to the main opening of the upper. The medial/lateral side upper edges can include cut-out holes or eyelets that are suitably aligned and dimensioned to receive a shoe lace or other fastener that firmly secures the user's foot within the upper (i.e., by pulling or cinching the lateral and medial sides toward each other using the shoe lace or other fastener). In certain embodiments, a tongue member can be secured at the open vamp section of the upper 110. The tongue portion can be a separate portion or component that is secured to other portions of the upper or, alternatively, the tongue portion can be integrally formed with other portions of the upper. In other embodiments, the upper can be formed from one or more textile panels or portions and/or any other materials (e.g., molded polymer sections) that are coupled or secured together to form the upper as described herein.

[0030] At least one portion or panel of the upper including a textile or fabric selectively positioned within the upper that is configured to mechanically fold, buckle, or lock out in response to applied load. In an embodiment, the textile includes a plurality of ribs or pillars oriented along a major axis. Adjacent pillars are coupled (e.g., connected) by a plurality of spacers or links spaced along the length of the pillars. With this configuration, the links selectively bend and straighten, permitting the localized movement of the pillars under load (discussed in greater detail below).

[0031] The fabric comprises strands. The term strand includes a single fiber, filament, or monofilament, as well as an ordered assemblage of textile fibers having a high ratio of length to diameter and normally used as a unit (e.g., slivers, roving, single yarns, plies yarns, cords, braids, ropes, etc.). In a preferred embodiment a strand is a yarn (a continuous length of textile fibers, filaments, or material in a form suitable for knitting, weaving, or otherwise intertwining to form a textile fabric). A yarn may include several fibers twisted together (spun yarn); several filaments laid together without twist (a zero-twist yarn); several filaments combined with a degree of twist; and/or a single filament with or without twist (a monofilament).

[0032] The strands forming the textile can be natural strands (e.g., cotton strands, wool strands, silk strands, etc.) and/or synthetic strands formed of one or more types of polymers, including fibers or filaments having one or more polymer components formed within the fibers or filaments.

[0033] In an embodiment, strands include clastic strands and/or inelastic strands. Elastic strands are strands formed with elastomeric material (e.g., 100% clastic material). An elastic strand, by virtue of its composition alone, can stretch under tension and then recovering to its original size once the tension is released. Accordingly, elastic strands are utilized to provide a textile with stretch properties. Generally, an elastic strand is formed of an elastomeric material. By way of example, the strand may be formed of elastane, an elastomeric polyester-polyurethane copolymer. By way of further example, the strand may be formed of an elastoester polymer such as a thermoplastic polyester elastomer (TPEE). TPEE is a type of thermoplastic elastomer (TPE), a block copolymer with both hard polyester and soft polyether segments.

[0034] In contrast, an inelastic strand is formed of a non-elastomeric material. Accordingly, inelastic strands (also called hard strands or yarns) possess no inherent stretch and/or recovery properties by virtue of composition. Natural, inelastic strands are formed of cellulose (e.g., cotton, bamboo) and protein (e.g., wool, silk, and soybean). Synthetic inelastic stands are formed of polyester (poly(ethylene terephthalate) and poly(trimethylene terephthalate)), polycaprolactam fibers, poly(hexamethylene adipamide), acrylic, acetate, rayon, nylon and combinations thereof. Inelastic strands take various forms, including spun staple yarns and/or continuous filament yarns. In a specific embodiment, the strand is a polyester yarn.

[0035] In an embodiment, the textile is formed primarily of (e.g., 80%-100%) inelastic strands (hard yarns), resulting in a textile structure with little or no elastomeric stretch (only mechanical stretch).

[0036] The filaments, fibers and/or yarns used to form the textile can also have any suitable cross-sectional geometries and include a single component (e.g., single or homo polymer component) or a plurality of components (e.g., bicomponent or multicomponent). Some non-limiting examples of cross-sectional geometries for fibers or filaments (both single component and multicomponent) include round, polygonal, irregular shaped, hollow, side-by-side (uniform or eccentric), multilobal, sheath-core, etc.

[0037] By varying amounts and types of polymer or other materials (as well as filament cross-sections of such polymer materials) within the filaments, fibers and/or yarns used to form the mesh textile, various physical characteristics of the mesh textile can be controlled or fine-tuned for a particular application (e.g., breathability or air/moisture permeability, elasticity, moisture absorption, etc.).

[0038] As noted above, the textile structure includes a plurality of spaced, interconnected pillars. Referring to FIGS. 2A and 2B, textile 200 used to form one or more portions (e.g., some or all) of the upper 110 of the shoe 100 includes a series of ribs or pillars 210 (also called columns) made of strands, the pillars being oriented along a major or vertical axis of the textile 200 (e.g., the machine direction). Adjacent pillars are spaced from each other by length L, thereby forming a channel or gap between the pillars. In the fabric normal position, the channel spacing is generally consistent along the length of the pillars. The textile 200 further includes a series of spacing strands or links 220 that span the channel, being oriented along a minor or transverse axis 226 of the textile 200 (in the illustrated embodiment, the pillars run vertically while the links run horizontally). The links 220 are spaced along the pillar length, interconnecting the pillars 210 at points of intersection (e.g., forming stitches at such points of intersection). The length of the links 220 (and thus the channel width) is selected to provide a distance or spacing between the points of intersection between pillars 210.

[0039] The gap spacing between pillars along with the link spacing between links is selected to create a plurality of openings 230 (also called windows, apertures or voids) within the textile structure, thereby creating an open or mesh textile 200. Specifically, each opening 230 is defined or located between adjacent pillars 210 and between adjacent links 220. The openings 230 may possess any dimensions (e.g., size and shape) suitable for the described purpose. By way of example, the textile 200 is formed such that the openings (spaces, apertures or voids) 230 are generally elongated and/or generally polygonal (e.g., rectangular) in shape with a lengthwise or greatest dimension of each opening 230 being oriented along the major axis of the textile 200. In another embodiment, the openings 230 can also be elongated oval with a lengthwise or greatest dimension of each void being oriented along the major axis of the textile.

[0040] The number of openings 230 within the textile 200 may be any suitable for its desired purpose (provide a textile upper for footwear). In an embodiment, one or more windows 230 between the pillars 210 may be filled with webbing or fill. As depicted in FIG. 2C, a mesh textile 200 can be formed such that some of the pillars 210 are connected between openings 230 with fill yarns 215. In such embodiments, some of the voids 230 remain the same while some are partially filled with one or more yarns 215 that connect between neighboring first pillars 210 that define boundaries of a particular opening 230. Such a structure, with yarns 215 extending within the voids 230 to connect with major axis pillars 210, can include yarns 215 provided in a variety of different colors (e.g., to achieve a desired visual or other aesthetic effect for the upper) and/or types (e.g., to provide different properties for the mesh textile between areas in which yarns 215 are provided vs. areas in which yarns 215 are absent).

[0041] The strands forming the textile 200 may possess any dimensions (size and/or shape) suitable for their described purpose. In an embodiment, the denier of the yarns forming the pillars 210 may be greater than the denier the yarns forming the links. In an embodiment, the pillars 210 are disposed along the major axis are formed with one or more first yarns (e.g., monofilament polyester yarns) so as to have a much greater denier or thickness in comparison to the links 220 formed from one or more second yarns (e.g., monofilament polyester yarns) along the minor axis. Stated another way, the pillar yarns may have a first thickness and the link yarns may have a second thickness, where the first thickness is at least about 1.5 times greater than the second thickness. In certain embodiments, the first thickness can be at least about 2 times greater, or at least about 2.5 times greater, or at least about 3 times greater, or at least about 3.5 times greater, or at least about 4 times greater or even at least about 5 times greater than the second thickness. In an embodiment, the pillar yarns along the major axis can be at least about 50% greater in denier than the link yarns along the minor axis.

[0042] The above textile structure may be formed by mechanically manipulating strands in processes including knitting, weaving, and/or embroidery. Knitting is a method of constructing fabric by interlocking series of loops of one or more yarns. Yarns are organized into a series of interlocking loops to form courses and wales. The two major knitting classes are warp knitting and weft knitting. In warp knitting, the yarns are vertically connected, generally running lengthwise in the fabric. The yarns are prepared as warps on beams with one or more yarns for each needle (i.e., each course stitch is formed by different types of yarn). Courses are joined together by the adjacent course or row. Accordingly, wales run in the machine direction (e.g., vertically) and courses run orthogonal to the machine direction (e.g., horizontally or across the width of the fabric). In contrast, in weft knitting, one continuous yarn runs crosswise in the fabric (the loops are horizontally connected), making all the loops in one course.

[0043] In an embodiment, the mesh textile 200 is a warp knit fabric formed utilizing raschel knitting (e.g., jacquard raschel). The fabric is made up of pillar stitches, underlapped and overlapped with inserted yarn. Referring to FIG. 8, columns of loops are connected by inlaid yarns traversing from column to column up the fabric. As shown, the pillars 210 are unconnected wales 805 formed of chain or pillar of stitches. The wales are then coupled by an inlaid yarn 810, forming the links 220. By way of example the textile 200 may be a knit fabric formed via a pillar stitch with a horizontal underlapping. With this configuration, the pillars and the links possess a common yarn across textile structure (e.g., the yarn forming the link is present within a pillar regardless of whether the yarn forming the link forms a loop of the wale). In this configuration, the wales are oriented parallel with the major axis 224, while the courses oriented along the minor axis 226.

[0044] In weaving, two or more yarns are interlaced together so that the yarns cross each other at substantially right angles to produce a woven fabric. Warp yarns (ends) run lengthwise (longitudinally) in the fabric, while weft yarns (filling threads or picks) run from side to side (transversely) in the fabric. Specifically, a set of warp or lengthwise yarns are interlaced with a set of crossing or weft yarns. Referring to FIGS. 9A and 9B, in an embodiment, the textile is formed utilizing a weaving process in which a first warp yarn 905 is paired with a second warp yarn 910 (e.g., a doup yarn) that interlock at selected locations along their length about a weft yarn 915. By way of example, this first warp 905 may be twisted around the second warp yarn 910 between picks of the weft 915 (filling) yarn. The first warp yarn 905 may be the same or may differ from the second warp yarn 910 (e.g., the second warp yarn may be a different material, or may possess a lower weight or denier than the first warp yarn). In this manner, the warp yarns are twisted around each other to create an open, mesh structure held together by weft threads. In this configuration, the major axis 224 is oriented in the warp direction and the minor axis 226 is oriented in the weft direction.

[0045] In an embodiment, the mesh textile 200 is a self-supporting, embroidered structure including a plurality of interlocking yarn rows oriented in orthogonal relation. The embroidered structure includes a plurality of crossing yarns (also called binding yarns), each crossing yarn being formed of a pair of component strands that interlock at selected locations along the length of the yarn. The component strands of the are coupled via a stitch (an interlocking structure that locks the strands together) such as a lockstitch, where the one strand of the pair wraps the other strand of the pair. A lockstitch effectively secures the strands to each other, preventing unraveling of crossing yarn. Other exemplary stitches include a tatami stitch, a triaxial fill stitch, satin stitch, running stitch, chain stitch, etc. may be utilized. The stitches may be disposed at any predetermined location along the length of the crossing yarn.

[0046] With this configuration, the textile 200 permits localized mechanical movement between adjacent pillars 210 as limited by the links 220. The links 220, while not elastomeric, are flexible and act as tethers between adjacent pillars. That is, the links are free to buckle and/or pivot, enabling the relative movement of the pillars with respect to each other. In operation, depending on the forces applied to the textile, adjacent pillars 210 translate horizontally (towards or away from each other), move out of plane with each other, and/or translate vertically to the extent permitted by the length of the links 220. In addition, the pillars 210, while flexible, do not permit elastomeric stretch. As such, the pillars are permitted to buckle and twist, but will not appreciably elongate along the major axis 224.

[0047] This is generally shown in the schematic provided in FIGS. 7A, 7B and 7C. Beginning from its normal position (FIG. 7A), the links 220 of the textile 200 are permitted to buckle, fold or otherwise flex to permit relative movement of the pillars 210 in plane (pillars may translate) and out of plane (adjacent pillars can pivot/rotate) to the extent permitted by the length (FIG. 7B). In addition, the pillars 210 are also able to flex/buckle, but will not stretch elastically (FIG. 7C).

[0048] Accordingly, an upper including the mesh textile can provide directional and/or dynamic tensioning to the upper. Under tension, the pillars 210 and links 220 become taut. However, as compressive forces are applied, the links 220 will bend or buckle to allow adjacent pillars 210 to move closer together. This results in a textile structure that provides strength along directions where tension is applied, while also allowing the pillars and/or links to bend, fold, or contract in directions where tension is not applied, avoiding friction points. As explained in greater detail below, an upper including the textile is capable of securing the foot in place (locking the heel in the heel cup and preventing the foot from sliding along the insole), while providing comfort to the wearer, preventing friction points that could occur during the gait cycle.

[0049] The mesh textile 200 is incorporated within the upper 110 such that the major axis 224 (including pillars 210 aligned along the major axis 224) of the mesh textile is at a bias in relation to the longitudinal or lengthwise axis of the upper. In particular, the mesh textile can comprise a portion or panel of the upper that is oriented along the upper so that the major axis of the mesh textile is offset from the lengthwise axis at a bias angle from about 30 to about 60. For example, referring again to FIG. 1 and also to FIG. 3, which depicts an enlarged view of a portion 300 of the upper 110 located along the lateral side 160, the mesh textile 200 at portion 300 is provided as part of the upper 110 such that the major axis of the upper (and arrangement/orientation of the pillars 210) is oriented at a bias angle ranging from about 30 to about 60 (e.g., about 45) in relation to the lengthwise dimension (i.e., heel-to-toe direction) of the upper. The angle of orientation or offset/bias angle of the major axis 224 (i.e., warp or wale direction and lengthwise axes of the pillars 210) for the mesh textile 200 from the lengthwise dimension of the upper is shown as double arrow 305 in FIG. 3. The elongated voids 230 of the mesh textile also include the same bias along the upper, i.e., the elongated voids are oriented such that the length or greatest dimension of each of the voids is also oriented at a bias angle from about 30 to about 60 in relation to the lengthwise dimension of the upper.

[0050] This orientation of the mesh textile major axis along the upper, combined with the different sizes of the pillars and links, can impart beneficial features in supporting the foot during athletic or other movements, such as lateral and medial cutting movements of the foot (e.g., during jumping movements, sprinting movements, running movements, etc.). Alignment of one or more mesh textile portions or panels along the upper in which they are incorporated can also function to maintain the heel of the foot in alignment within the heel cup, e.g., by enhancing forces by the upper imparted on the foot so as to push and maintain the heel into the heel cup portion of the shoe during use. In addition, the mesh textile alignment along the upper in this manner also orients the lengthwise or greatest dimension of the voids of the mesh textile along the same or similar bias as the major axis. This allows for minimal elongation or stretching along the bias of the upper (i.e., along the major axis of the textile incorporated within the upper) while some stretching or elongation of the textile can occur in a direction transverse the bias (i.e., along or in the direction of the minor axis of the textile incorporated within the upper). This can impart enhanced fit properties of the upper with the foot when the shoe is worn and used.

[0051] In addition, incorporation of a mesh textile 200 with major axis 224 and minor axis 226 formed with pillars 210 and links 220 as described herein allows for some degree of movement of the mesh textile section incorporated within an upper in a direction that is transverse the major axis without any (or with minimal or less) moving along the bias or direction of the major axis. In particular, the orientation of the major axis of the mesh textile along the lengthwise dimension of the upper provides a certain rigidity or lockout effect by the mesh textile along its major axis which provides beneficial effects to holding the foot in place within the shoe (e.g., toward the heel end, preventing splaying outward of the foot during a cutting movements, etc.) during certain movements.

[0052] The pillars and links can be formed with the same or different yarns depending upon desired properties for the upper for a particular application. Selection of specific types of polymers used to form the first and second yarns also facilitates fine tuning of desired properties for the upper when combined with the other noted features of the mesh web and its incorporation within the upper at a selected bias of its major axis to the lengthwise dimension of the upper and the shoe.

[0053] As noted herein, the mesh textile can be incorporated in one of more portions or panels and at one or more selected locations of the upper. In the embodiment depicted in FIG. 1, the mesh textile is incorporated along a portion of at least one side, e.g., the medial side and/or the lateral side, of the upper. The mesh textile structure can form the entire medial side and/or the entire lateral side of the upper or just selected portions of one or both the medial and lateral sides. The mesh textile can also be incorporated into the upper at any other locations, such as the vamp section, the toe cage section, and the heel section. In addition, a mesh textile portion or panel can extend between two or more sides or sections of the upper. For example, a mesh textile panel can extend along a portion or the entirety of the medial side or the lateral side of the upper and continue around a portion or the entirety of the heel side (heel cup portion) and/or the toe cage portion. Further, two or more mesh textile portions or panels can be incorporated at different locations (e.g., at the medial side and the lateral side) of the upper, where the mesh textile portions are oriented with a bias of their major axes in relation to the lengthwise direction of the upper and shoe but also offset in their orientations with regard to each other.

[0054] In an example embodiment depicted in FIG. 4, a two-dimensional structure or blank 400 comprises two side sections 402, 404 which are shaped to form at least the lengthwise (medial and lateral) sides of the upper when forming the shoe (e.g., placing the blank 400 over a shoe last to form the contoured features of the upper). The blank 400 can be formed as a cut-out from a textile (e.g., knit, woven or embroidered textile) so as to have the shape that forms a portion of the upper. The blank 400 can further comprise a single, unitary structure or, alternatively, two separate pieces (one piece comprising side section 402, and the other piece comprising side section 404). In the embodiment of FIG. 4, each side section 402, 404 can also define a portion of the front or toe cage section and/or the rear or heel cup section when combined to form the upper.

[0055] A mesh textile 200 panel can form a portion or the entirety of each side section 402, 404. For simplification, only the pillars 210 along the major axis are shown for each mesh textile 200 along each side section 402, 404. As shown in FIG. 4, the major axis for the mesh textile 200 of each side section 402, 404 is at a bias angle between about 30 and about 60 (e.g., about 45) from the lengthwise dimension of the upper that is to be formed from the side sections. As further shown in FIG. 4, the major axis of the mesh textile 200A of side section 402 is offset in relation to (i.e., not parallel with) the major axis of the mesh textile 200B of side section 404.

[0056] For example, after forming an upper with the side sections 402, 404 (as shown in the example embodiment of FIG. 5, which shows a portion of a formed upper with side sections 402, 404 defining the medial and lateral sides and also joining each other to form the toe end with toe cage), the major axis of the mesh textile at the medial side of the upper can be offset by about 90 from the major axis of the mesh textile at the lateral side of the upper. Each mesh textile 200A, 200B can extend beyond the medial and lateral sides (defined by side sections 402, 404) to a portion (e.g., half) or convergence location of the toe cage section at the toe end of the upper and/or at the heel cup section of the upper. At the toe cage section, the major axes of the two mesh textile panels forming sections of the upper are offset or converge (i.e., are not parallel) with each other, where they intersect at about a 90 angle. This further results in a lower end of each pillar 210 at each of the lateral and medial sides extending upward from a lower end of the upper adjacent or near the sole structure toward the front or toe end of the upper. In this embodiment, the configuration of the mesh textile at the side sections 402, 404 (in which the pillars 210 along the major axes converge with each other when extending between lateral and medial sides of the upper) provides features for the shoe when worn in which the heel of the wearer is forced or pushed into the heel cup during foot movements (e.g., running, sprinting, jumping, etc.).

[0057] In another embodiment, one of the side sections (e.g., lateral side section or medial side section) can be used to form the upper such that the side section extends entirely over the toe end and toe cage portion (or around the heel cup) to also form a portion (e.g., some or all) of the other side of the upper. In this embodiment, the major axis of the mesh textile wraps around a toe end or heel end of the upper so that at least a portion of each of the lateral and medial sides of the upper include the mesh textile with the major axis aligned (about parallel) on the lateral and medial sides. This can be achieved, e.g., by forming a blank for an upper with a single mesh textile in which the mesh textile extends from at least a portion of the medial side, around an end (e.g., toc end and/or heel end) and to at least a portion of the lateral side of the upper formed using the blank.

[0058] In a further embodiment, a single panel of the mesh textile can be used to form both the lateral and medial sides of the upper along with some or all of the toe cage section and/or heel cup section. The embodiment of FIG. 6 depicts a single panel of mesh textile 600 that comprises a single panel which is used to form the entire contour of the upper (i.e., lateral and medial sides, heel cup section and toe cage section, vamp, etc.). The pillars 210 arranged along the major axis are all aligned in the same manner, at a bias angle of about 45 from the lengthwise dimension of the upper and shoe. As can be seen in FIG. 6, the pillars 210 on both the lateral and medial sides, as well as the toe cage section (and also the heel cup section, not shown) are uniformly aligned so as to be about parallel with each other. In addition, some of the pillars 210 (e.g., at the toe cage section and heel cup section) extend continuously from the medial side to the lateral side of the upper. This further results in a lower end of each pillar 210 at one side (one of the lateral and medial sides) extending upward from a lower end of the upper adjacent or near the sole structure toward the front or toe end of the upper, while each pillar 210 at the other side (the other of the lateral and medial sides) extends upward from a lower end of the upper adjacent or near the sole structure toward the rear or heel end of the upper. This configuration can provide one or more different effects for the wearer of the shoe in comparison to the embodiment of FIG. 5, including a locking or prohibitive effect for the foot to move in an undesired position within the shoe during certain activities (e.g., side stepping movements, cutting movements, etc.).

[0059] Thus, one or more mesh textile sections or panels can be used to form the upper, in which the major axis of each mesh textile panel is biased or offset from (i.e., not parallel with) the lengthwise dimension of the upper and shoe. The specific orientations of each mesh textile panel can be selected to obtain one or more specific enhanced features for the shoe at one or more selected locations (e.g., at the heel cup section, at the toe cage section, along a portion of the lateral and/or medial sides, etc.). Two or more mesh textile panels can be oriented such that their major axes are offset (i.e., transverse or not parallel) with each other based upon the alignments of the textile panels along the formed upper. In addition to the pillars and links being formed of the same or different polymer materials in their yarns, two or more mesh textile panels forming the upper can also include yarns forming pillars and/or links of the same or different polymer materials. One or more mesh textile sections as described herein can also be incorporated into the upper by overlapping partially or entirely other mesh textile sections to achieve desired properties for the upper for a particular application. The mesh textile sections can also overlap or cover (partially or entirely) and/or be covered (partially or entirely) by other layers used to form the upper, such as molded layers, tape layers, polymer laminate layers (e.g., very thin PU skin layers), etc.

[0060] In other embodiments, the upper can include a plurality of layers including one or more layers formed with one or more mesh textile panels with major axis yarns aligned offset (e.g., from about 30 to about 60) from the longitudinal or lengthwise axis of the upper and article of footwear as described herein combined with other layers disposed on either side of the mesh panel layer(s). For example, as depicted in FIG. 1, the upper can include a layer 170 that underlies or is below a portion of a layer formed of the mesh textile 200. The layer 170 can comprise a molded or laminate material formed, e.g., from thermoplastic polyurethane (TPU), a material formed of polyester fibers molded in a polyurethane binder (e.g., synthetic suede), or other suitable material. In the embodiment of FIG. 1, the mesh textile 200 forms the exterior layer of the upper, with a molded layer 170 provided beneath the mesh textile layer but visible through the mesh apertures or voids in the mesh textile. In other embodiments, the mesh textile layer can be disposed beneath one or more layers. For example, a polyurethane skin layer (e.g., a layer having a thickness less than the thickness of the mesh layer) can be provided over the mesh textile layer. Other types of layers, including knit layers, woven layers, embroidered layers, nonwoven layers, etc. can also be provided to form the upper in combination with one or more mesh textile panels. Additional layers such as the type depicted in FIG. 1 can provide different structural support and/or aesthetic features for the upper.

[0061] As previously noted herein, a shoe upper formed including a mesh textile structure (e.g., as one or more panels formed along some or all of the upper) with a major axis in offset alignment or at a bias with the longitudinal or lengthwise dimension of the upper and shoe to which the upper is incorporated can provide a number of enhanced benefits for the user of the shoe. For example, one or more textile mesh panels can be used to form a portion of the upper at the front or toe end and/or at the rear or heel end to maintain alignment of the foot with the heel cup during movements of the shoe (e.g., in certain sporting or other athletic environments). Such mesh textile arrangements with the shoe upper can also enhance lateral and medial cutting movements of the foot (e.g., when jumping, sprinting, quick or sharp turns while running, etc.). The voids in the mesh textile structure can also be aligned with the greatest axes of the voids being aligned with the same or similar bias as the major axis of the mesh textile structure. Arranging the mesh textile structure with major and minor axes formed with (greater thickness/greater denier) pillars and links in the manner as described herein facilitates a certain degree of stretch of the mesh textile structure in a direction transverse the major axis while minimizing stretch along the major axis such that the foot can be held in place within the shoe during certain movements (e.g., preventing splaying outward of the foot during a cutting movements, etc.). Further, two or more mesh textile panels can be arranged to form the upper, with each being arranged with major axes on the bias in relation to the lengthwise dimension of the upper, where the major axes of the separate panels are transverse each other (e.g., orthogonal to each other). The upper can further be formed with a plurality of layers, in which one or more mesh textile panels form an exposed outer surface portion of the upper, an exposed inner (foot facing) surface portion of the upper, or an intermediate portion (i.e., one or more interior and exterior layers on each side of the mesh textile panel) of the upper.

[0062] While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.

[0063] It is to be understood that terms such as top, bottom, front, rear, side, height, length, width, upper, lower, interior, exterior, and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration.