FOLDED OVERLAY SHEET FOR AN ARTICLE OF FOOTWEAR

Abstract

An article of footwear includes a footwear upper that has a base and an overlay sheet disposed on an exterior surface of the base. The footwear upper also includes one or more cables. The overlay sheet has a first side and a second side. The overlay sheet is folded to define tunnels at which portions of the first side of the overlay sheet face one another such that the tunnels are bordered and surrounded by the first side of the overlay sheet. The one or more cables are disposed within the tunnels.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. Provisional Application No. 63/745,370, filed Jan. 15, 2025 which is incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure generally relates to a folded overlay sheet for an article of footwear that defines one or more tunnels that may house a cable for supporting and/or securing the upper around the foot.

BACKGROUND

Footwear typically includes an upper and a sole structure secured to the upper. The upper is configured to secure a foot over the sole structure, and the sole structure is configured to be located under a wearer's foot to space the foot away from the ground.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only, are schematic in nature, and are intended to be exemplary rather than to limit the scope of the disclosure.

FIG. 1 is a medial side view of an article of footwear that includes a folded overlay sheet defining tunnels and a cable in the tunnels as discussed herein.

FIG. 2 is a lateral side view of the article of footwear of FIG. 1 including another overlay sheet defining tunnels and a cable in the tunnel as discussed herein.

FIG. 3 is a plan view of the article of footwear of FIG. 1.

FIG. 4 is a cross-sectional view of the article of footwear of FIG. 1 taken at lines 4-4 in FIG. 1.

FIG. 5 is a plan view of the overlay sheet of FIG. 1 prior to folding and with the cable secured to the overlay sheet.

FIG. 6 is a plan view of the folded overlay sheet of FIG. 1 prior to securement to the base of the footwear upper, with the cable in the tunnels, and with an arrangement of stitching.

FIG. 7 is a fragmentary cross-sectional view of the medial side of the article of footwear taken at lines 7-7 in FIG. 1.

FIG. 8 is a close-up fragmentary cross-sectional view of a portion of the medial side of the article of footwear of FIG. 7 showing one of the tunnels defined by the folded overlay sheet with the cable including two cable segments in the tunnel.

FIG. 9 is a plan view of the folded overlay sheet of FIG. 1, prior to securement to the base of the footwear upper, with the cable in the tunnels and with another arrangement of stitching.

FIG. 10 is a plan view of the folded overlay sheet of FIG. 1, prior to securement to the base of the footwear upper, with the cable in the tunnels and with still another arrangement of stitching.

FIG. 11 is a plan view of an alternative folded overlay sheet for the article of footwear of FIG. 1, prior to securement to the base of the footwear upper, with the cable in the tunnels and with an arrangement of stitching.

FIG. 12 is a plan view of the folded overlay sheet and cable of FIG. 11 with another arrangement of stitching.

FIG. 13 is a plan view of the folded overlay sheet of FIG. 1, prior to securement to the base of the footwear upper, with separate cables in each of the tunnels and with an arrangement of stitching.

FIG. 14 is a plan view of the folded overlay sheet and cables of FIG. 13 with another arrangement of stitching.

FIG. 15 is a plan view of the folded overlay sheet of FIG. 11, prior to securement to the base of the footwear upper, with separate cables in each of the tunnels and with an arrangement of stitching.

FIG. 16 is a cross-sectional view of another article of footwear having an alternative folded overlay sheet secured to a base of a footwear upper, showing a cable extending in a tunnel defined by the folded overlay sheet.

FIG. 17 is a plan view of the folded overlay sheet of FIG. 16 prior to securement to the base of the footwear upper, showing multiple tunnels defined by the folded overlay sheet, a respective cable in each tunnel and with an arrangement of stitching.

FIG. 18 is a plan view of the folded overlay sheet and cables of FIG. 17 with another arrangement of stitching.

FIG. 19 is a plan view of the folded overlay sheet and cables of FIG. 17 with still another arrangement of stitching.

FIG. 20 is a plan view of an alternative folded overlay sheet for the article of footwear of FIG. 16, prior to securement to the base of the footwear upper, with separate cables in each of the tunnels and with an arrangement of stitching.

DESCRIPTION

The present disclosure generally relates to an overlay sheet for a footwear upper that is configured as a single folded sheet that defines multiple tunnels that house and separate one or more cables that can be used for tightening the upper around a foot. More specifically, an article of footwear disclosed herein includes a footwear upper that has a base and an overlay sheet disposed on an exterior surface of the base. The overlay sheet has a first side and a second side. The overlay sheet is folded to define tunnels at which portions of the first side of the overlay sheet face one another such that the tunnels are bordered and surrounded by the first side of the overlay sheet. One or more cables are disposed within the tunnels.

In an example, the one or more cables may be inextensible. As such, pulling on the cables may enable the overlay sheet and the footwear upper to be tightened around a wearer's foot. In the same example or in a different example, the overlay sheet may be a non-woven textile.

In an example, the first side of the overlay sheet may interface with the exterior surface of the base between adjacent ones of the tunnels. The second side of the overlay sheet may define an exposed exterior surface of the overlay sheet both at the tunnels and between adjacent ones of the tunnels.

The configuration of the overlay sheet thus enables the use of different surface characteristics in the tunnels than at the exposed second side of the second overlay sheet, such as different coefficients of friction, textures, colors etc. In an example, the first side of the overlay sheet has a first coefficient of friction and the second side of the overlay sheet has a second coefficient of friction greater than the first coefficient of friction. The relatively low coefficient of friction at the first side may enable easier movement of the one or more cables within the tunnels.

The overlay sheet is folded, also referred to as pleated, to create the multiple tunnels from a single sheet. For example, at each tunnel, the overlay sheet may include a first fold extending along one side of a length of the tunnel and a second fold extending along an opposite side of a length of the tunnel. The portions of the first side facing one another are between the first fold and the second fold. Additionally, at each tunnel, portions of the second side of the overlay sheet may face one another between the tunnel and the base.

Due to the folded configuration, the overlay sheet, which has a first thickness between the first side and the second side, may have a greater thickness at each of the tunnels. For example, at each of the tunnels, a thickness from an exposed exterior surface of the overlay sheet to the first side of the overlay sheet disposed on the base may be at least three times the first thickness. This is due to the folds causing portions of the overlay sheet to “stack up” at the tunnels. Portions between the tunnels remain unstacked and thus portions of the overlay sheet between adjacent ones of the tunnels have the first thickness from the exposed exterior surface of the overlay sheet to the first side of the overlay sheet disposed on the base.

In some implementations, the base at least partially defines a foot-receiving cavity and has an ankle opening configured for foot entry into the foot-receiving cavity. The article of footwear may further include a sole structure secured to the footwear upper and defining a biteline between the footwear upper and the sole structure. The overlay sheet may have a lower extent disposed below the biteline when the article of footwear is positioned with the ankle opening above the sole structure. For example, a lower extent of the base may also be disposed below the biteline, and both may be secured to one another and/or to the sole structure below the biteline. In an example, an upper extent of the overlay sheet may be disposed forward of the ankle opening and the tunnels may angle forward from the lower extent to the upper extent.

In an example, the one or more cables may each define end portions extending out of the tunnels at an outer edge of the overlay sheet or through apertures that extend through the overlay sheet from the first side to the second side at the tunnel. The end portions may each form respective loops. A lace may extend through the loops. Cinching the lace pulls on at least the end portions tightens the base around the foot-receiving cavity.

The one or more cables may have a variety of configurations. In some implementations, the one or more cables are a single cable that is doubled over in each of the tunnels and extends between the tunnels to the next adjacent tunnel. For example, at each of the tunnels, the one or more cables may include a first cable segment and a second cable segment extending alongside one another in the tunnel, and a loop segment extending out of the tunnel and connecting the first cable segment and the second cable segment.

In other implementations, the one or more cables include a plurality of cables, each cable disposed in a different one of the tunnels. The different cable in each respective tunnel may include a first cable segment and a second cable segment extending alongside one another in the tunnel, and a loop segment extending out of the tunnel and connecting the first cable segment and the second cable segment. Alternatively, the different cable in each respective tunnel may include a single cable segment extending through the tunnel and an end portion configured as a loop segment extending from the single cable segment out of the tunnel.

In an example, the end portions are first end portions, the one or more cables includes a plurality of cables, and each cable of the plurality of cables is disposed in a different respective one of the tunnels and has a second end portion nearer to at an opposite end of the tunnel than to the end of the tunnel through which the first end portion of the cable extends. At least some of the cables may not be secured to the overlay sheet at midportions of the respective tunnels between the first end portion and the second end portion such that the cables are not constrained within the respective tunnels at the midportions of the respective tunnels. Stated differently, the cables are not stitched, bonded, or otherwise secured to the overlay sheet within the respective tunnels at the midportions. Instead, the cables may be secured to the overlay sheet near the second end portions and, optionally, also near the first end portions.

In order to secure the folds of the overlay sheet in place, stitches may extend through the overlay sheet at least where the overlay sheet is folded near a first end of the tunnel and near an opposite second end of the tunnel to secure the folds. However, the folds may be unstitched alongside midportions of the tunnels between the stitches at the first end and at the opposite second end. In some implementations, the stitches may further extend through the one or more cables. Stated differently, the stitches may not only secure the folds, but may also secure the one or more cables to the overlay sheet. In other implementations, the stitches may instead define gaps at the tunnels and the one or more cables may extend out of the tunnels at the gaps such that the stitches do not extend through the one or more cables near the end portions extending out of the tunnels. Such stitches thus only secure the folds and the one or more cables are not secured to the overlay sheet at those stitches (although there may be other stitches, such as at an opposite end of the tunnels, that secure opposite ends of the one or more cables to the overlay sheet).

The overlay sheet may be specifically designed to house the one or more cables in a configuration suited for supporting a foot within the foot receiving cavity. For example, in an implementation, the overlay sheet has an upper portion and a lower portion. The tunnels extend from the upper portion to the lower portion without intersecting one another. A first series of stitches extend along the upper portion of the overlay sheet. A second series of stitches extend along the lower portion of the overlay sheet and are configured to further secure the folds.

The tunnels are thus separated from one another and extend alongside one another. The tunnels may be parallel, but need not be For example, the folds may be such that the tunnels splay away from one another, such as by the tunnels being narrower at the lower extent than at the upper extent, enabling the one or more cables to also splay away from one another within the tunnels. For example, the folds may be both nonparallel with one another and nonintersecting with one another such that the tunnels are wider at a first end of the tunnels than at a second end of the tunnels.

The overlay sheet may provide targeted support to a wearer's foot. In an example, the overlay sheet may be sized and dimensioned to extend on one of a lateral side or a medial side of an article of footwear without extending on both of the lateral side and the medial side of the article of footwear. In an implementation, separate first and second overlay sheets may be used at medial and lateral sides of the base. The overlay sheet may be a first overlay sheet at a medial side of the base, the one or more cables may be one or more first cables, and the tunnels may be a first plurality of tunnels. A second overlay sheet may be disposed on the exterior surface of the base at a lateral side of the base. Similar to the first overlay sheet, the second overlay sheet may have a first side and a second side and may be folded to define a second plurality of tunnels at which portions of the first side of the second overlay sheet face one another such that the second plurality of tunnels are bordered and surrounded by the first side of the second overlay sheet. One or more second cables may be disposed within the second plurality of tunnels.

In another example, a single overlay sheet may provide support at both medial and lateral sides of the foot. For example, the overlay sheet may include a medial side portion disposed at a medial side of the base, a lateral side portion disposed at a lateral side of the base, and an underfoot portion extending under the foot-receiving cavity from the medial side portion to the lateral side portion. The tunnels may extend along the medial side portion, the underfoot portion, and the lateral side portion. The one or more cables may define first end portions extending out of the tunnels at the medial side portion and second end portions extending out of the tunnels at the lateral side portion, the one or more cables extending through the tunnels at the underfoot portion from the medial side portion to the lateral side portion. In an implementation, the first end portions and the second end portions may each form loops. Accordingly, a lace extending through the loops of the first and second end portions may tighten the overlay sheet to the foot.

The shape of the overlay sheet prior to folding may enable it to have desired characteristics in its final folded configuration. For example, the overlay sheet may include an upper edge, a lower edge, and side edges extending between and connecting the upper and lower edges. In an unfolded shape of the overlay sheet, the upper and lower edges of the overlay sheet may be nonlinear and include linear segments extending nonorthogonal to the side edges of the overlay sheet. The linear segments correspond with ends of the tunnels when the overlay sheet is folded to define the tunnels. As such, in the folded state, the upper and lower edges may be nonorthogonal to the side edges and/or to one another.

In one or more implementations, the overlay sheet may be at least partially translucent and may have a first color value at the tunnels between the folds and a second color value lighter than the first color value at portions of the overlay sheet between adjacent tunnels.

Within the scope of the disclosure, a footwear upper includes an overlay sheet having a first side and a second side. The overlay sheet is folded to define tunnels at which portions of the first side of the overlay sheet face one another such that the tunnels are bordered and surrounded by the first side of the overlay sheet. One or more cables are disposed within the tunnels. Further aspects of the footwear upper may be as described herein.

Within the scope of the disclosure, a footwear upper includes an overlay sheet having a first side and a second side. The overlay sheet is folded to define tunnels at which portions of the first side of the overlay sheet face one another. The tunnels extend adjacent to one another without intersecting one another. The overlay sheet includes intermediate portions extending between adjacent ones of the tunnels. The folded overlay sheet is at least three times thicker at the tunnels than at the intermediate portions. Further aspects of the footwear upper may be as described herein.

The overlay sheet may be sized and dimensioned to extend on one of a lateral side or a medial side of an article of footwear without extending on both of the lateral side and the medial side of the article of footwear. In another example, the overlay sheet may be sized and dimensioned to extend on both of the lateral side and the medial side of the article of footwear, such as by including the medial side portion, the lateral side portion, and the underfoot portion extending under the foot-receiving cavity from the medial side portion to the lateral side portion as described above. The tunnels may extend along the medial side portion, the underfoot portion, and the lateral side portion with the one or more cables therein.

The above features and advantages and other features and advantages of the present teachings are readily apparent from the following detailed description of the modes for carrying out the present teachings when taken in connection with the accompanying drawings. It should be understood that even though in the following the embodiments may be separately described, single features thereof may be combined in additional embodiments.

Referring to the drawings, wherein like reference numbers refer to like components throughout the views, FIG. 1 is a medial side view of an article of footwear 10 that includes a folded overlay sheet 12 defining tunnels 14 and a cable 16 in the tunnels 14 as discussed herein.

The article of footwear 10 includes a footwear upper 18 that includes a base 20 and the overlay sheet 12. The base 20 may be a layer or layers of material, for example, and may include multiple sections stitched, adhered, knitted, interwoven, or otherwise secured to one another. The base 20 is referred to as such because it is disposed inward of the overlay sheet 12 (e.g., nearer to the wearer's foot) and serves as a base on which the overlay sheet 12 is secured. For example, stitches 31 in FIG. 4 secure the overlay sheet 12 to the base 20 both near an upper edge 70 and a lower edge 72 of the overlay sheet 12 adjacent to the first and second series of stiches 80, 82 discussed herein. Stitches 31 also extend through the overlay sheet 12 and the base 20 along the side edges 73, 74 of the overlay sheet 12 as shown in FIGS. 1 and 2. In embodiments herein having a series of stitches that has gaps at the tunnels, such as in FIGS. 9-12, 14-15, and 18-20, the stitches 31 to secure the overlay to the base in such embodiments would also be modified from those shown in FIGS. 1-4 to have like gaps.

FIG. 1 also illustrates a sole structure 22 of the article of footwear 10 that underlies the footwear upper 18 and is secured thereto. The sole structure 22 includes a midsole 24 which may be, for example, a resilient foam. The sole structure 22 may include additional components, such as one or more other sole layers overlaying the midsole 24 one or more plates, and/or one or more bladders that retain gas.

The footwear upper 18 is secured to a top surface 26 of the midsole 24, as best shown in FIG. 4. For example, the footwear upper 18 may be adhered and/or stitched to the top surface 26. Stitches 28 are shown extending through the overlay sheet 12A and the base 20 into the midsole 24 and therefore securing the footwear upper 18 to the midsole 24. Like stitches extend through overlay sheet 12B and the base 20 and into the midsole 24.

A biteline 30 shown in FIG. 1 denotes the junction or intersection of the midsole 24 and the footwear upper 18, and is coincident with an upper edge 32 or upper extent of the midsole 24 (which is also the upper edge of the sole structure 22). Stated differently, the sole structure 22 secured to the footwear upper 18 defines the biteline 30 between the footwear upper 18 and the sole structure 22, at the upper extent of the sole structure 22 at the medial side 34 of the article of footwear 10 shown in FIG. 1, as well as at the lateral side 36 shown in FIG. 2, and the front 38 and rear 40 of the article of footwear, indicated in FIG. 1. Adhesive maybe disposed between the biteline and the lower edge 72 of the overlay sheet 12 to further secure the footwear upper 18 to the midsole 24. The sole structure 22 is also shown as including an outsole 42 underlying the midsole 24 and defining a ground contact surface 44 of the article of footwear 10.

The article of footwear 10 is shown as including two separate folded overlay sheets 12, one secured to an exterior surface 21 of the base 20 on the medial side 34 of the base 20, also referred to as a first overlay sheet 12A, and one secured to the exterior surface 21 of the base 20 on the lateral side 36 of the base 20, also referred to as a second overlay sheet 12B. Stated differently, different first and second overlay sheets 12A, 12B are used at medial and lateral sides 34, 36 of the base 20. The tunnels 14 defined by the first overlay sheet 12A may be referred to as a first plurality of tunnels 14A or each individually as a tunnel 14A. The tunnels 14 defined by the second overlay sheet 12B may be referred to as a second plurality of tunnels 14B or each individually as a tunnel 14B. References made herein to overlay sheet 12 apply to both the first overlay sheet 12A and the second overlay sheet 12B. Similarly, references made herein to tunnels 14 apply to both the first plurality of tunnels 14A and the second plurality of tunnels 14B.

The overlay sheets 12A and 12B provide targeted support to a wearer's foot. The overlay sheet 12A is sized and dimensioned to extend on the medial side 34 of the article of footwear 10 without extending on the lateral side 36. The overlay sheet 12B is sized and dimensioned to extend on the lateral side 36 of the article of footwear 10 without extending on the medial side 34.

Additionally, as further discussed herein, the cable 16 shown in FIG. 1 is a single cable, referred to herein as a first cable 16A, and the cable 16 shown in FIG. 2 is a single cable that is separate from the first cable 16A, and is referred to herein as a second cable 16B. References made herein to cable 16 apply to both the first cable 16A and to the second cable 16B. Either or both of the overlay sheets 12A, 12B may be a non-woven textile, or may be other materials sufficiently flexible to permit folding and maintain a folded state as discussed herein.

The footwear upper 18, and, more specifically, the base 20, defines a foot-receiving cavity 23 over the sole structure 22 that receives and contains a wearer's foot over the sole structure 22 during wear. The base 20 defines an ankle opening 25 configured to enable foot entry into the foot-receiving cavity 23. In the embodiment shown, the footwear upper 18 includes a tongue 46 disposed to extend across a throat region 47 of the footwear upper 18 between the medial and lateral sides 34, 36 as shown in FIG. 4. A lace 48 extends through apertures 49 in the base 20, as shown in FIG. 1, as well as through loop portions of the cable 16 as further discussed herein. Cinching the lace 48 pulls on end portions of the cable 16 (discussed further herein) and tightens the overlay sheet 12 as well as the base 20 around the foot-receiving cavity 23 as further discussed herein, adjusting the fit of the footwear upper 18 to a wearer's foot and securing the foot within the foot-receiving cavity 23. In an example, the one or more cables 16 may be inextensible. As such, pulling on the cables 16 enables the overlay sheet 12 and the base 20 of the footwear upper 18 to be tightened around a wearer's foot.

The article of footwear 10 may also be referred to simply as footwear 10, and as illustrated herein is depicted as athletic footwear. Although the article of footwear 10, including the sole structure 22, may be athletic footwear, it may instead be worn and used as a leisure shoe, a dress shoe, a work shoe, a sandal, a slipper, a boot, or as footwear in any other category of footwear.

As indicated in FIG. 1, the article of footwear 10 may be divided into a forefoot region 50, a midfoot region 52, and a heel region 54, which are also the forefoot region, the midfoot region, and the heel region, respectively, of the sole structure 22 and the footwear upper 18. The forefoot region 50 generally includes portions of the article of footwear 10 corresponding with the toes and the metatarsophalangeal joints (which may be referred to as MPT or MPJ joints) connecting the metatarsal bones of the foot and the proximal phalanges of the toes. The midfoot region 52 generally includes portions of the article of footwear 10 corresponding with the arch area and instep of the foot, and the heel region 54 generally corresponds with rear portions of the foot, including the calcaneus bone. The forefoot region 50, the midfoot region 52, and the heel region 54 are not intended to demarcate precise areas of the article of footwear 10, but are instead intended to represent general areas of the article of footwear 10 to aid in the following discussion. The medial side 34 and the lateral side 36 extend through each of the forefoot region 50, the midfoot region 52, and the heel region 54, and correspond with opposite sides of the article of footwear 10, each falling on an opposite side of a longitudinal midline LM of the article of footwear 10, indicated in FIG. 3. The medial side 34 is thus considered opposite to the lateral side 36.

The base 20 and/or the overlay sheet 12 may be a variety of materials, such as leather, textiles, polymers, cotton, foam, composites, etc., and may be different materials than one another. For example, the base 20 may be a polymeric material capable of providing elasticity, and may be of a braided construction, a knitted (e.g., warp-knitted) construction, or a woven construction. A lower extent of the footwear upper 18 is secured to a periphery of the sole structure 22 as shown in FIG. 4. The top surface 26 of the midsole 24 (shown in FIG. 4) may be covered by a strobel 59 secured to the lower extent of the footwear upper 18 by the stitches 31 and/or 82. An insole 60 overlays the strobel 59. Alternatively, the upper may be a 360-degree sock-like or bootie-like upper that extends under the foot and over the top surface 26 and an insole 260 may rest in the foot-receiving cavity 23 as discussed with respect to the article of footwear 210 in FIG. 16.

The midsole 24 may be at least partially a polyurethane foam, or a polyurethane ethylene-vinyl acetate (EVA) foam and may include heat-expanded and molded EVA foam pellets. The midsole 24 may generally include phylon (ethylene vinyl acetate or “EVA”) and/or polyurethane (“PU”) base resins. For example, in one embodiment, the midsole 24 may be a compression molded phylon. If EVA is used, it may have a vinyl acetate (VA) level between approximately 9% and approximately 40%. Suitable EVA resins include Elvax®, provided by E. I. du Pont de Nemours and Company, and Engage™, provided by the Dow Chemical Company, for example. In certain embodiments, the EVA may be formed of a combination of high melt index and low melt index material. For example, the EVA may have a melt index of from about 1 to about 50. The EVA resin may be compounded to include various components including a blowing agent and a curing/crosslinking agent. The blowing agent may have a percent weight between approximately 10% and approximately 20%. The blowing agent may be thermally decomposable and may be selected from ordinary organic and inorganic chemical blowing agents. The nature of the blowing agent is not particularly limited as long as it decomposes under the temperature conditions used in incorporating the foam into the virgin resin. Suitable blowing agents include azodicarboamide, for example. In certain embodiments, a peroxide-based curing agent, such as dicumyl peroxide may be used. The amount of curing agent may be between approximately 0.6% and approximately 1.5%. The EVA may also include homogenizing agents, process aids, and waxes. For example, a mixture of light aliphatic hydrocarbons such as Struktol®60NS, available from Schill+Seilacher “Struktol” GmbH, may be included to permit other materials or scrap EVA to be more easily incorporated into the resin. The EVA may also include other constituents such as a release agent (e.g., stearic acid), activators (e.g., zinc oxide), fillers (e.g., magnesium carbonate), pigments, and clays. In embodiments that incorporate multiple materials, each material may be formed from a material that is compatible and readily bonds with the other material. For example, the materials may each be formed from an EVA resin with suitable blowing agents, crosslinking agents, and other ancillary components, pigments, fillers, and the like. Other suitable materials will become readily apparent to those skilled in the art, given the benefit of this disclosure.

The outsole 42 may be formed from materials that may generally include natural or synthetic rubber or other suitably durable materials. The material or materials for the outsole 42 may be selected to provide a desirable combination of durability and flexibility. Synthetic rubbers that may be used include polybutadiene rubber, ethylene propylene rubber (EPR), styrene isoprene styrene (SIS) copolymer rubber, and styrene butadiene rubber.

FIG. 3 shows the cable 16A disposed within tunnels 14A defined by the first overlay sheet 12A, and the cable 16B disposed within tunnels 14B defined by the second overlay sheet 12B. The tunnels 14A and 14B each extend from an upper edge 70 of the respective overlay sheet 12A or 12B to a respective lower edge 72 of the respective overlay sheet 12A or 12B (best shown in FIG. 4 in which one tunnel 14A and one tunnel 14B is visible). The edges 70, 72 are also referred to as outer edges. The upper edge 70 may also be referred to as an upper extent, and the lower edge 72 may also be referred to as a lower extent. Each of the overlay sheets 12A, 12B is folded, also referred to as pleated, to create the multiple tunnels 14A or 14B from a respective single sheet. For example, at each tunnel 14A, the overlay sheet 12A may include a first fold extending along one side of a length of the tunnel 14A. The first fold is referred to herein as an outer fold, and the four outer folds are referred to as a first outer fold OF1, a second outer fold OF2, a third outer fold OF3, and a fourth outer fold OF4. A second fold also extends along an opposite side of a length of each tunnel 14A. The second fold is referred to herein as an inner fold, and the four inner folds are referred to as a first inner fold IF1, a second inner fold IF2, a third inner fold IF3, and a fourth inner fold IF4. Similarly, the overlay sheet 12B may include a first fold (OF1, OF2, OF3, and OF4, respectively) extending along one side of a length of each tunnel 14B and a second fold (IF1, IF2, IF3, and IF4, respectively) extending along an opposite side of a length of each tunnel 14B. In the overlay sheet 12A, the inner fold is forward of the respective outer fold at each tunnel 14A. In the overlay sheet 12B, the inner fold is rearward of the respective outer fold at each tunnel 14B.

The one or more cables 16 may have a variety of configurations. As shown in the example of FIG. 3, the cables 16 define end portions 16C extending out of the tunnels 14 at an outer edge (upper edge 70) of each overlay sheet 12A, 12B. The end portions 16C form respective loops 16D, also referred to as loop segments. It should be appreciated that a “loop” as defined herein need not be an enclosed circular shape, and includes a curved shape made where the cable 16 doubles over as in FIGS. 1-5 and 8, for example. The lace 48 extends through the loops 16D. FIGS. 6 and 7 best illustrate that the cable 16A is a single cable that is doubled over in each tunnel 14 so that a first cable segment 16A1 and a second cable segment 16A2 extend alongside one another in each tunnel 14, and a loop segment 16D extends out of the tunnel 14 and connects the first cable segment 16A1 and the second cable segment 16A2 in each of the tunnels 14.

As shown in FIG. 6, the cable 16 has a first end 16E and a second end 16F and extends between the tunnels 14 to the next adjacent tunnel 14. The first end 16E and the second end 16F are disposed near a lower portion 73A or lower extent (indicated in FIG. 6) of the overlay sheet 12A (e.g., near the lower edge 72) and may be referred to herein as terminal ends. The lower portion 73A is disposed below the biteline 30 when the article of footwear 10 is positioned with the ankle opening 25 above the sole structure 22 (see FIGS. 1 and 4). A lower extent 20A of the base 20 is also disposed below the biteline 30, and both are secured to one another and to the sole structure 22 below the biteline 30 with the stitching 28. The upper extent 70 of each of the respective overlay sheets 12A and 12B is disposed forward of the ankle opening 25 and the tunnels 14 angle forward from the lower extent 72 to the upper extent 70 as is evident in FIGS. 1 and 2 when considered with FIG. 4.

FIG. 5 is a plan view of the first overlay sheet 12A of FIG. 1 prior to folding with the cable 16A secured to the first overlay sheet 12A. The second overlay sheet 12B may have an identical shape prior to folding. The shape of the overlay sheets 12A, 12B prior to folding may enable each to have desired characteristics in its final folded configuration of FIGS. 1-4. The unfolded overlay sheet 12A is relatively flat, having an exterior side shown in FIG. 5, which is also referred to as a second side 13B of the first overlay sheet 12A. The first overlay sheet 12A also has an opposite first side 13A against which the cable 16 is lain in the arrangement shown and secured to the overlay sheet 12A at its two terminal ends (first end 16E and second end 16F) with stitches 79. The first side 13A and the second side 13B may also be referred to as first and second faces, respectively, and are bounded by the upper edge 70, the lower edge 72, and opposing side edges 73 and 74 extending between and connecting the upper and lower edges 70 ,72. In an unfolded shape or state of the overlay sheet 12A, the upper edge 70 is nonlinear and includes a series of linear segments 70A, 70B, 70C, 70D, 70E, 70F, 70G, 70H, and 70I, each extending nonorthogonal to the side edges 73, 74 of the overlay sheet 12A. Similarly, the lower edge 72 is nonlinear in the unfolded shape or state and includes a series of linear segments 72A, 72B, 72C, 72D, 72E, 72F, 72G, 72H, and 72I, each extending nonorthogonal to the side edges 73, 74 of the overlay sheet 12A. The linear segments 70A-70I and 72A-72I correspond with ends of the tunnels 14A when the overlay sheet 12A is folded to define the tunnels 14A, labelled as 14A1, 14A2, 14A3, and 14A4 in FIG. 6. Although four tunnels 14A are shown, there may be fewer or more tunnels as desired, with the number of tunnels dependent upon the number of folds.

To fold the overlay sheet 12A, four folds are made extending along fold lines OF1L, OF2L, OF3L, and OF4L through the peaks of the upper and lower edges 70, 72 so that the resulting folds OF1, OF2, OF3, and OF4 extend outward of the page of FIG. 5 (e.g., at the side 13B as shown in FIG. 6). These folds OF1, OF2, OF3, and OF4 may be referred to as first folds or outer folds. For example, the folds made along the fold lines OF1L, OF2L, OF3L, and OF4L for folds OF1, OF2, OF3, and OF4 are moved to the left in FIG. 5 (as indicated by solid arrows) while the overlay sheet 12A is folded along fold lines IF1L, IF2L, IF3L, and IF4L at the valleys between adjacent linear segments of the upper and lower edges 70, 72 so that the folds IF1, IF2, IF3, and IF4 extend inward into the page of FIG. 5 (e.g., at the side 13A of FIG. 6) and the overlay sheet 12A is moved to the right at the fold lines IF1L, IF2L, IF3L, and IF4L (indicated by dashed arrows). These folds IF1, IF2, IF3, and IF4 may be referred to as second folds or inner folds.

In this manner the portion of the overlay sheet 12A between fold line OF1L and fold line IF1L is placed behind the right-most portion of the cable 16A in FIG. 5, defining the far-right tunnel 14A1 in FIG. 6, with the linear segment 70B and the linear segment 72B substantially aligning with the linear segments 70A and 72A, respectively. The linear segments 70B and 72B are shorter than the linear segments 70A and 72A, respectively, and the inner fold IF1 is thus disposed between the right-most portion of the cable 16 and the side edge 73 in the folded configuration, as shown in FIG. 6.

Similarly, the portion of the overlay sheet 12A between fold line OF2 and fold line IF2 is placed behind the portion of the cable 16A second from right in FIG. 5, defining the second tunnel 14A2 from the right in FIG. 6, with the linear segment 70D and the linear segment 72D substantially aligning with the linear segments 70C and 72C, respectively. The linear segments 70D and 72D are shorter than the linear segments 70C and 72C, respectively, and the inner fold IF2 is thus disposed between the outer fold OF1 and the outer fold OF2 in the folded configuration, as shown in FIG. 6.

The portion of the overlay sheet 12A between fold line OF3 and fold line IF3 is placed behind the portion of the cable 16A second from left in FIG. 5, defining the third tunnel 14A3 from the right in FIG. 6, with the linear segment 70F and the linear segment 72F substantially aligning with the linear segments 70E and 72E, respectively. The linear segments 70F and 72F are shorter than the linear segments 70E and 72E, respectively, and the inner fold IF3 is thus disposed between the outer fold OF2 and the outer fold OF3 in the folded configuration, as shown in FIG. 6.

The portion of the overlay sheet 12A between fold line OF4 and fold line IF4 is placed behind the left-most portion of the cable 16A in FIG. 5, defining the fourth tunnel 14A4 from the right in FIG. 6, with the linear segment 70H and the linear segment 72H substantially aligning with the linear segments 70G and 72G, respectively. The linear segments 70H and 72H are shorter than the linear segments 70G and 72G, respectively, and the inner fold IF4 is thus disposed between the outer fold OF3 and the outer fold OF4 in the folded configuration, as shown in FIG. 6.

In the folded state of FIG. 6, the upper and lower edges 70, 72 may be nonorthogonal to the side edges 73, 74 and to one another. At each tunnel 14A1-14A4, the first fold (respective outer fold OF1, OF2, OF3, and OF4) extends along one side of a length of the tunnel and the second fold (respective inner fold IF1, IF2, IF3, and IF4) extends along an opposite side of a length of the tunnel. The tunnels 14 angle forward from the lower extent 72 to the upper extent 70, are separated from one another by intermediate portions 12A1, 12A2, and 12A3, respectively, and extend alongside one another. As shown, the tunnels 14 are not quite parallel with one another, but, in another example, may be parallel. As shown, the folds OF1-OF4 and IF1-IF4 are such that the tunnels 14 splay away from one another from the lower extent 72 to the upper extent 70 as some or all of the tunnels 14 are narrower at the lower extent 72 than at the upper extent 70, enabling the one or more cables 16 to also splay away from one another within the tunnels 14. For example, as shown, the folds OF1-OF4 and IF1-IF4 are both nonparallel with one another and nonintersecting with one another such that the tunnels 14 are wider at a first end 17A, 17B, 17C, and 17D of the respective tunnels 14 than at a second end 15A, 15B, 15C, and 15D of the tunnels 14. In FIG. 6, the right-most tunnel A1 is shown having a width W1 at the first end 17A that is wider than the width W2 at the second end 15A. The same is true of each of the other three tunnels 14.

The arrangement of stitching in FIG. 6 (prior to securement of the overlay sheet 12A to the base 20 of the footwear upper 18) includes a first series of stitches 80 extending along the upper portion 71A of the overlay sheet 12A. The upper portion 71A is a portion nearer to the upper edge 70 than to the lower edge 72. A second series of stitches 82 extend along the lower portion 73A of the overlay sheet 12A. The lower portion 73A is a portion nearer to the lower edge 72 than to the upper edge 70. The stitches 80 and 82 are configured to secure the folds OF1-OF4 and IF2-IF4. The stitches 80, 82 thus extend through the overlay sheet 12A at least where the overlay sheet 12A is folded near the first ends 17A-17D of the tunnels 14A1-14A4 and near opposite second ends 15A-15D of the tunnels 14A1-14A4 to secure the folds OF1-OF4 and IF2-IF4. In the example shown, the stitches 80 and 82 also extend through the cable 16, effectively locking the cable 16 in place relative to the overlay sheet 12A at the stitches 80, 82. In other examples shown herein, the cable 16 is not stitched in place relative to the tunnels 14 by stitches that secure the folds OF1-OF4 and IF2-IF4 by stitches extending along the upper portion 71A and/or by stitches extending along the lower portion 73A.

The folds OF1-OF4 and IF2-IF4 are unstitched alongside midportions 19 of the tunnels 14A1-14A4 between the stitches 80 and 82. The midportions 19 are the portions between the upper portion 71A and the lower portion 73A. In fact, the midportions 19 are not adhered or otherwise secured in place but remain folded simply by the material of the overlay sheet 12A able to maintain a crease at the respective fold or at least maintain the fold.

In this configuration, the overlay sheet 12A is specifically designed to arrange the cable 16 in a configuration suited for supporting a foot within the foot_-receiving cavity 23. The cable 16 extends forward from the lower portion 73A to the upper portion 71A within each tunnel 14A1-14A4 without the portions of the cable 16 within each tunnel 14A1-14A4 intersecting one another.

FIG. 7 is a fragmentary cross-sectional view of the medial side 34 of the article of footwear 10 taken at lines 7-7 in FIG. 1. Portions of the first side 13A of the overlay sheet 12A face one another in the tunnels 14A1-14A4 such that the tunnels 14A1-14A4 are bordered and surrounded by the first side 13A of the overlay sheet 12A. The portions of the first side 13A facing one another are between the first fold and the second fold of each respective tunnel 14. For example, between the first fold OF1 and the second fold IF1 of tunnel 14A1, between the first fold OF2 and the second fold IF2 of tunnel 14A2, between the first fold OF3 and the second fold IF3 of tunnel 14A3, and between the first fold OF4 and the second fold IF4 of the fourth tunnel 14A4. Furthermore, because the first side 13A surrounding each tunnel 14A1-14A4 is not secured to itself (e.g., is not thermally bonded or adhered to itself at the midportions 19), the portions of the cable 16 within each tunnel 14A1-14A4 have the ability to move within the tunnels 14A1-14A4 at least at the midportions 19 which may enable the cable 16 to better adapt to the specific configuration of a wearer's foot, providing support without undue stress concentrations.

Additionally, at each tunnel 14A1-14A4, portions of the second side 13B of the overlay sheet 12A face one another between the tunnel and the base 20, as indicated at tunnel 14A2 in FIG. 8.

The first side 13A of the overlay sheet 12A interfaces with the exterior surface 21 of the base 20 intermediate portions of the overlay sheet 12A between adjacent ones of the tunnels 14A1-14A4 (e.g., at intermediate portion 12A1 between tunnels 14A1 and 14A2, at intermediate portion 12A2 between tunnels 14A2 and 14A3, and at intermediate portion 12A3 between tunnels 14A3 and 14A4. The second side 13B of the overlay sheet 12A defines an exposed exterior surface 13C of the overlay sheet 12A both at the tunnels 14A1-14A4 and between adjacent ones of the tunnels 14A1-14A4 at the intermediate portions 12A1, 12A2, and 12A3. In fact, in the embodiment shown, the entire exposed exterior surface 13C is the second side 13B.

Because the tunnels 14A1-14A4 are surrounded only by the first side 13A and the exterior surface 13C is mainly or entirely defined by the second side 13B, the configuration of the overlay sheet 12A enables the use of different surface characteristics of the first side 13A (and therefore in the tunnels 14A1-14A4) in comparison the second side 13B, such as different coefficients of friction, textures, colors, etc.

In an example, the first side 13A may have a first coefficient of friction and the second side 13B may have a second coefficient of friction greater than the first coefficient of friction. This may allow grip at the exterior of the overlay sheet 12A while minimizing friction between the cable 16 and the overlay sheet 12A at the tunnels 14A1-14A4.

The overlay sheet 12A includes intermediate portions 12A1, 12A2, and 12A3 extending between adjacent ones of the tunnels 14A1-14A4, as indicated in FIGS. 1 and 7. Due to the folded configuration, the folded overlay sheet 12A is at least three times thicker at the tunnels 14A1, 14A2, 14A3, and 14A4 than at the intermediate portions 12A1, 12A2, and 12A3. As illustrated in FIG. 8, the overlay sheet 12A has a first thickness T1 between the first side 13A and the second side 13B at the intermediate portions 12A1 and has a greater second thickness T2 at each of the tunnels (shown with respect to tunnel 14A2 and apparent with respect to tunnels 14A1, 14A2, and 14A3 in FIG. 7). This is due to the folds OF1-OF4 and IF1-IF4 causing portions of the overlay sheet 12A to “stack up” at the tunnels 14A1-14A4. Portions between the tunnels 14A1-14A4 (e.g., at the intermediate portions 12A1, 12A2, and 12A3) remain unstacked and thus intermediate portions 12A1, 12A2, and 12A3 of the overlay sheet 12A between adjacent ones of the tunnels 14A1-14A4 have the first thickness T1 from the exposed exterior surface 13C of the overlay sheet 12A at the second side 13B to the first side 13A of the overlay sheet 12A disposed on the base 20 outside of the respective tunnel 14A1-14A4.

Because the folded overlay sheet 12A is thinner at the intermediate portions 12A1, 12A2, and 12A3, this may enable different aesthetics to be achieved. For example, the overlay sheet 12A may be at least partially translucent such that the cable 16 is visible in the tunnels 14A1-14A4 from the exterior of the article of footwear 10. As such, the overlay sheet 12A will appear lighter at the intermediate portions 12A1, 12A2, 12A3 than at the tunnels 14A1-14A4 due to the folding of the overlay sheet 12A creating three portions of the overlay sheet 12A stacked at the tunnels 14A1-14A4. Accordingly, the overlay sheet 12A may have a first color value at the tunnels 14A1-14A4 (between the respective folds OF1, IF1; OF2, IF2, OF3, IF3; and OF4, IF4). The overlay sheet 12A may have a second color value lighter than the first color value at portions of the overlay sheet 12A between adjacent tunnels 14A1-14A4 (e.g., at the intermediate portions 12A1, 12A2, 12A3).

Although the above description of FIGS. 7-8 is made with respect to the first overlay sheet 12A, it applies equally to the second overlay sheet 12B. That is, the second overlay sheet 12B has a first side and a second side and is folded to define the second plurality of tunnels 14B at which portions of the first side of the second overlay sheet 12B face one another such that the second plurality of tunnels 14B are bordered and surrounded by the first side of the second overlay sheet 12B with the one or more second cables 16B disposed within the second plurality of tunnels 14B. As described with respect to folding of the overlay sheet 12A in FIG. 5 and shown in FIG. 1, the outer folds OF1-OF4 are disposed rearward of their respective inner folds IF1-IF4 at each of the tunnels 14A1-14A4. Alternatively, as shown with respect to the second overlay sheet 12B in FIG. 1, the outer folds OF1-OF4 may be disposed forward of their respective inner folds IF1-IF4. In still another alternative, the first and second overlay sheets 12A, 12B may both have the outer folds OF1-OF4 rearward of the inner folds IF1-IF4 or may both have the outer folds OF1-OF4 forward of the respective inner folds IF1-IF4.

FIG. 9 is a plan view of the folded overlay sheet 12A of FIG. 1, prior to securement to the base 20, with the cable 16A in the tunnels 14A1-14A4 and with an arrangement of stitching different than that of FIG. 6. Specifically, the second series of stitches 82 is the same, but the first series of stitches 80 is replaced with a first series of stitches 80A that defines gaps 81 at the tunnels 14A1, 14A2, 14A3, and 14A4. Specifically, each gap 81 is sufficiently wide such that the end portions 16C of the cable 16A extend out at the gaps 81. The cable 16A extends out of the tunnels 14A1, 14A2, 14A3, and 14A4 at the gaps 81 such that the stitches 80A do not extend through the cable 16A. The first series of stitches 80A thus only secure the folds OF1-OF4 and IF1-IF4 but not the cable 16A. The cable 16A is not secured to the overlay sheet 12A at the first series of stitches 80A, but is secured to the overlay sheet 12A by the second series of stitches 82 at or near the opposite end of the tunnels 14A1-14A4. The stitching 31 used to secure the overlay sheet 12A to the base 20 near the upper edge 70, also follows the pattern of the stitching 80A to provide like gaps at the tunnels 14 through which the cable 16A extends. The entire cable 16A can shift within each tunnel 14A1-14A4 from the end portions 16C to where the cable 16A is secured at the second series of stitches 82. When the lace 48 is cinched, pulling on the cable 16A via the loops 16D, the ability of the cable 16A to shift may be better able to provide targeted support to a wearer's foot with more variability in placement than with the series of stitches 80.

FIG. 10 is a plan view of the folded overlay sheet 12A of FIG. 1, prior to securement to the base 20, with the cable 16A in the tunnels 14A1-14A4 and with still another arrangement of stitching different than that of FIGS. 6 and 9. Specifically, the first series of stitches 80A is the same as described with respect to FIG. 9, but the second series of stitches 82 is replaced with a second series of stitches 82A that extend through the cable 16A only at the segments with the ends 16E, 16F and defines gaps 83 at the tunnels 14A1, 14A2, 14A3, and 14A4. The stitching 31 used to secure the overlay sheet 12A to the base 20 near the upper edge 70 and the lower edge 72, also follows the pattern of the stitching 80A and 82A, respectively, to provide like gaps at the tunnels 14 through which the cable 16A extends. Accordingly, the cable 16A is secured only at its two ends 16E and 16F by the second series of stitches 82A and by the initial stitches 79 shown in FIG. 5 (i.e., which may be made prior to folding the overlay sheet 12A) and is not otherwise secured by stitches within any of the tunnels 14A1-14A4.

FIG. 11 is a plan view of an alternative folded overlay sheet 12AA for the article of footwear of FIG. 1, prior to securement to the base 20, with the cable 16A in the tunnels 14A1-14A4 and with an arrangement of stitching. The folded overlay sheet 12AA is configured like the overlay sheet 12A and folded in the same manner but is different in that an aperture 90 extends through the overlay sheet 12AA from the first side 13A to the second side 13B at each of the tunnels 14A1-14A4. The same stitching (first series of stitches 80A and second series of stitches 82) is used to secure the folds OF1-OF4 and IF1-IF4, with the second series of stitches 82 extending through the cable 16A as well. The first series of stitches 80A includes the gaps 81 with the apertures 90 are disposed at the gaps 81, allowing the end portions 16C of the cable 16A to extend outward through the apertures 90 (rather than at the end of the tunnels at the upper edge 70). Alternatively, the series of stitches 80 could be used if disposed between the apertures 90 and the upper edge 70, with the end portions 16C temporarily moved out of the way to allow the series of stitches 80 to proceed without extending through the end portions 16C. The stitching 31 used to secure the overlay sheet 12AA to the base 20 near the upper edge 70 also follows the pattern of the stitching 80A to provide like gaps at the tunnels 14 through which the cable 16A extends.

FIG. 12 is a plan view of the folded overlay sheet 12AA and cable 16A of FIG. 11 with another arrangement of stitching. Specifically, the first series of stitches 80A is used, as described with respect to FIG. 11, but the second series of stitches 82 is replaced with the second series of stitches 82A that includes the gaps 83 at the tunnels 14A1-14A4. Similar to FIG. 10, the cable 16A is secured only at its two ends 16E and 16F by the second series of stitches 82A and by the initial stitches 79 (i.e., which may be made prior to folding the overlay sheet 12A) and is not secured within any of the tunnels 14A1-14A4. The stitching 31 used to secure the overlay sheet 12AA to the base 20 near the upper edge 70 and the lower edge 72, also follows the pattern of the stitching 80A and 82A, respectively, to provide like gaps at the tunnels 14 through which the cable 16A extends.

FIG. 13 is a plan view of the folded overlay sheet 12A of FIG. 1, prior to securement to the base 20, with separate cables 116 in each of the tunnels 14A1-14A4 and with an arrangement of stitching including the first series of stitches 80 and the second series of stitches 82 previously described.

Accordingly, a plurality of cables 116 are utilized, each cable 116 disposed in a different one of the tunnels, as indicated by cable 116A, 116B, 116C, and 116D in respective tunnels 14A1, 14A2, 14A3, and 14A4. Similar to the single cable 16, each different cable 116 is a single, separate cable disposed in each respective tunnel 14A1, 14A2, 14A3, 14A4 is doubled over to include a first cable segment 116A1 and a second cable segment 116A2 extending alongside one another in the tunnel, and a loop segment 116E (also referred to as an end portion) extending out of the tunnel and connecting the first cable segment 116A1 and the second cable segment 116A2.

The loop portions 116E may be referred to as first end portions, and each cable 116 also has a second end portion 116F nearer to at an opposite end 115A, 115B, 115C, 115D of the respective tunnel 14A1, 14A2, 14A3, 14A4 than to the end 117A, 117B, 117C, and 117D of the tunnel 14A1-14A4 through which the first end portion 116E of the respective cable 116 extends. In fact, each second end portion 116F is two separate second end portions 116F1, 116F 2 due to the two segments 1 1 6A1 and 116A 2 in each tunnel 14A1, 14A2, 14A3, and 14A4.

Due to the series of stitches 80 and 82, the cables 116A are secured to the overlay sheet 12A near the first and second end portions 116E, 116F by the stitches 80, 82, respectively. The cables 116 are not secured to the overlay sheet 12A at the midportions 19 of the respective tunnels between the series of stitches 80 and 82 such that the cables 116 are not constrained within the respective tunnels 14A1-14A4 at the midportions 19 of the respective tunnels, similarly as described with respect to the cable 16. Stated differently, the cables 116 are not stitched, bonded, or otherwise secured to the overlay sheet 12A within the respective tunnels 14A1-14A4 at the midportions 19.

FIG. 14 is a plan view of the folded overlay sheet 12A and cables 116 of FIG. 13 with another arrangement of stitching. Specifically, the second series of stitches 82 is used as described in FIG. 13, but the first series of stitches 80 is replaced with the first series of stitches 80A previously described, having the gaps 81 disposed so that the first series of stitches 80A does not extend through any of the cables 116. The cables 116 are thus anchored to the overlay sheet 12A only at their second end portions 116F (not at their first end portion 116E, nor at the midportions 19 of the tunnels 14A1, 14A2, 14A3, and 14A4). The cables 116 are thus able to shift within the tunnels 14A1, 14A2, 14A3, and 14A4 as may be needed to provide targeted support to the wearer's foot when cinched by the lace 48. The stitching 31 used to secure the overlay sheet 12A to the base 20 near the upper edge 70 also follows the pattern of the stitching 80A to provide like gaps at the tunnels 14 through which the cables 116 extend.

FIG. 15 is a plan view of the folded overlay sheet 12AA of FIG. 11, prior to securement to the base 20 via stitches like stitches 31 in FIG. 4 but modified to have gaps 81 I the stitches 80A at the apertures 90. Stitches like stitches 28 of FIG. 4 would also be used to secure the base 20 and the overlay sheet 12AA to the midsole 24. FIG. 15 shows the separate cables 116 in each of the tunnels 14A1-14A4 rather than the single cable 16. The same stitching as described with respect to FIG. 11 is used. More specifically, the first series of stitches 80A and the second series of stitches 82 are used, with the cables 116 extending out of the apertures 90. Accordingly, the cables 116 are able to shift within the tunnels 14A1, 14A2, 14A3, and 14A4 and are thus anchored to the overlay sheet 12AA only by the stitches 82 near their second end portions 116F (not at their first end portion 116E, nor at the midportions 19 of the tunnels 14A1, 14A2, 14A3, and 14A4). The stitching 31 used to secure the overlay sheet 12AA to the base 20 near the upper edge 70 also follows the pattern of the stitching 80A to provide like gaps around the apertures 90 through which the cable 16A extends.

FIG. 16 is a cross-sectional view of another article of footwear 210 having an alternative folded overlay sheet 212 showing a cable 216 extending in a tunnel 214 defined by the folded overlay sheet 212. Some of the same components as in the article of footwear 10 are used and are shown with like reference numbers. An upper 218 shown includes a base 220 and the overlay sheet 212. The base 220 is configured as a sock-like upper, extending under the foot-receiving cavity 23 as well as on the medial side 34 and the lateral side 36.

The overlay sheet 212 is a single overlay sheet that is sized and dimensioned to provide support at both the medial and lateral sides 34, 36 of the foot. For example, the overlay sheet 212 includes a medial side portion 212A disposed at the medial side 34 of the base 20, a lateral side portion 212B disposed at the lateral side 36 of the base 20, and an underfoot portion 212C extending under the foot-receiving cavity 23 from the medial side portion 212A to the lateral side portion 212B as indicated in FIG. 16.

FIG. 17 is a plan view of the folded overlay sheet 212 of FIG. 16 showing multiple tunnels 214 like the tunnel 214 shown at the cross_-section in FIG. 16. The multiple tunnels 214 are indicated as tunnels 214A, 214B, 214C, and 214D. The tunnels 214A-214D extend continuously along the medial side portion 212A, the underfoot portion 212C, and the lateral side portion 212B as best shown in FIG. 17.

The tunnels 214 are defined by the folded overlay sheet 212 via folding in the same manner as described with respect to the overlay sheet 12A, with outer folds OF1-OF4 and inner folds IF1-IF4, to create the tunnels 214 bounded by the first side 213A of the overlay sheet 212, with the second side 213B of the overlay sheet 212 at the exterior surface 213C of the overlay sheet 212 and the article of footwear 210.

A different respective cable 216 is disposed in each tunnel 214. For example, cable 216A is disposed in tunnel 214A, cable 216B is disposed in tunnel 214B, cable 216C is disposed in tunnel 214C, and cable 216D is disposed in tunnel 214D. The cables 216A-216D are configured as single cables. Each cable 216A-216D has a first end portion 216E forming a loop 216G extending out of a first end of each tunnel 214 (first end 219A of tunnel 214 shown in FIG. 16) at a first edge 270 of the overlay sheet 212 at the medial side portion 212A. Each cable 216A-216B has a second end portion 216F forming a loop 216G extending out of a second end of each tunnel 214 (second end 219B of tunnel 214 shown in FIG. 16) at a second edge 272 of the overlay sheet 212 at the lateral side portion 212B. The cables 216 thus extend through the tunnels 214 at the underfoot portion 212C from the medial side portion 212A to the lateral side portion 212B. The loops 216G are also referred to as looped ends or loop segments. The portion of each single cable 216 extending in the respective tunnel 214 between the loop segments may be referred to as a single cable segment. The first edge 270 is an upper edge at the medial side 34 in FIG. 16 when the overlay sheet 212 is secured to the base 220 with stitching 230 shown in FIG. 16. The second edge 272 is an upper edge at the lateral side 36 in FIG. 16. Additional stitching extends along the side edges 273, 274 of the overlay sheet 212, through the overlay sheet 212 and the base 20 to secure the overlay sheet 212 to the base 20, but does not extend through the cables 216. The lace 48 extends through the loops 216G of the first and second end portions 216E, 216F and may tighten the overlay sheet 212 to the foot.

The cables 216 are secured in the respective tunnels 214 with an arrangement of stitching 280, 282, including a first series of stitches 280 and a second series of stitches 282. The first series of stitches 280 extend through both the overlay sheet 212 and the cables 216 near the first edge 270. The second series of stitches 282 extend through both the overlay sheet 212 and the cables 216 near the second edge 272. The cables 216 are unsecured in the tunnels 214 at midportions 219 of the tunnels 214. The midportions 219 are defined as the entire portion of each tunnel 214 between the series of stitches 280, 282.

FIG. 18 is a plan view of the folded overlay sheet 212 and cables 216 of FIG. 17 with another arrangement of stitching. Specifically, a series of stitching 80A and 80AA (both as described with respect to stitching 80A in FIGS. 9 and 14) is utilized near both the first and second edges 270, 272. The gaps 81 in the stitching 80A align with the tunnels 214 and the stitching 80A does not extend through the cables 216 but secures the folds OF1-OF4 and IF1-IF4. The stitching 230 used to secure the overlay sheet 212 to the base 220 near the first and second edges 270, 272 also follows the pattern of the stitching 80A to provide like gaps at the tunnels 214 through which the cables 216 extend. A series of stitches 82 may be referred to as a second series of stitches and is configured as described with respect to FIGS. 9 and 14 and extends through both the folds and the cables 216. The series of stitches 82 is disposed about midway along the lengths of the tunnels 214 in the underfoot portion 212C.

FIG. 19 is a plan view of the folded overlay sheet 212 and cables 216 of FIG. 17 with still another arrangement of stitching. Specifically, the series of stitching 80A of FIG. 18 disposed near both edges 270, 272 is utilized, but the series of stitches 82 of FIG. 18 is not used. The stitching 230 as described with respect to FIG. 18 is used to secure the overlay sheet 212 to the base 20. The stitching 230 used to secure the overlay sheet 212 to the base 220 near the first edge 270 and the second edge 272 also follows the pattern of the stitching 80A to provide like gaps at the tunnels 214 through which the cables 216 extend. In this embodiment, the sizes of the looped ends 216E, 216F may be sufficiently large in comparison to the width of the tunnels 214 such that they do not fit through the openings at the ends of the tunnels 214 to prevent the cables 216 from being pulled out of the tunnels 214.

FIG. 20 is a plan view of an alternative folded overlay sheet 212AA for the article of footwear 210 of FIG. 16, prior to securement to the base 220, with the separate cables 216 in each of the tunnels 214 and with an arrangement of stitching 80A. The folded overlay sheet 212AA has the outer folds OF1-OF4 and inner folds IF1-IF4 as described herein, and has apertures 90, similar to those described with respect to FIG. 11, extending through the folded overlay sheet 212AA from the first side 213A to the second side 213B near each end of each tunnel 214. The cables 216 extend through the apertures 90 so that the looped ends 216E, 216F extend out of the tunnels 214 at the apertures 90. The gaps 81 in the series of stitching 80A are at the apertures 90 so that the series of stitching 80A does not extend through the cables 216. The stitching 230 used to secure the overlay sheet 212A to the base 220 near the first edge 270 and the second edge 272 also follows the pattern of the stitching 80A to provide like gaps around the apertures 90 through which the cables 216 extend. Similar to the embodiment of FIG. 19, the sizes of the looped ends 216E, 216F may be sufficiently large in comparison to the apertures 90 such that they do not fit through the apertures 90 to prevent the cables 216 from being pulled out of the tunnels 214.

The following Clauses provide example configurations of an article of footwear and of a footwear upper disclosed herein.

Clause 1. An article of footwear comprising: a footwear upper including a base and an overlay sheet disposed on an exterior surface of the base; one or more cables; wherein the overlay sheet has a first side and a second side; wherein the overlay sheet is folded to define tunnels at which portions of the first side of the overlay sheet face one another such that the tunnels are bordered and surrounded by the first side of the overlay sheet; and wherein the one or more cables are disposed within the tunnels.

Clause 2. The article of footwear of clause 1, wherein the first side of the overlay sheet interfaces with the exterior surface of the base between adjacent ones of the tunnels.

Clause 3. The article of footwear of any of clauses 1-2, wherein the second side of the overlay sheet defines an exposed exterior surface of the overlay sheet both at the tunnels and between adjacent ones of the tunnels.

Clause 4. The article of footwear of any of clauses 1-2, wherein, at each tunnel, the overlay sheet includes a first fold extending along one side of a length of the tunnel and a second fold extending along an opposite side of a length of the tunnel, and the portions of the first side facing one another are between the first fold and the second fold.

Clause 5. The article of footwear of clause 4, wherein, at each tunnel, portions of the second side face one another between the tunnel and the base.

Clause 6. The article of footwear of any of clauses 1-2, wherein: the overlay sheet has a first thickness between the first side and the second side; and at each of the tunnels, a thickness from an exposed exterior surface of the overlay sheet to the first side of the overlay sheet disposed on the base is at least three times the first thickness.

Clause 7. The article of footwear of clause 6, wherein portions of the overlay sheet between adjacent ones of the tunnels have the first thickness from the exposed exterior surface of the overlay sheet at the second side of the overlay sheet to the first side of the overlay sheet disposed on the base.

Clause 8. The article of footwear of any of clauses 1-2, wherein the base at least partially defines a foot-receiving cavity and has an ankle opening configured for foot entry into the foot-receiving cavity; and the article of footwear further comprising: a sole structure secured to the footwear upper and defining a biteline between the footwear upper and the sole structure; wherein the overlay sheet has a lower extent disposed below the biteline when the article of footwear is positioned with the ankle opening above the sole structure.

Clause 9. The article of footwear of clause 8, wherein an upper extent of the overlay sheet is disposed forward of the ankle opening and the tunnels angle forward from the lower extent to the upper extent.

Clause 10. The article of footwear of any of clauses 1-2, wherein the one or more cables each define end portions extending out of the tunnels at an outer edge of the overlay sheet or through apertures that extend through the overlay sheet from the first side to the second side at the tunnels.

Clause 11. The article of footwear of clause 10, wherein the end portions each form respective loops.

Clause 12. The article of footwear of clause 11, wherein the base defines a foot-receiving cavity, and the article of footwear further comprising: a lace extending through the loops; and wherein cinching the lace pulls on at least the end portions to tighten the base around the foot-receiving cavity.

Clause 13. The article of footwear of clause 10, wherein: the end portions are first end portions; the one or more cables includes a plurality of cables; each cable of the plurality of cables is disposed in a different respective one of the tunnels and has a second end portion nearer to at an opposite end of the tunnel than to the end of the tunnel through which the first end portion of the cable extends.

Clause 14. The article of footwear of clause 13, wherein at least some of the cables are not secured to the overlay sheet at midportions of the respective tunnels between the first end portion and the second end portion such that the cables are not constrained within the respective tunnels at the midportions of the respective tunnels.

Clause 15. The article of footwear of any of clauses 1-2, further comprising: stitches extending through the overlay sheet at least where the overlay sheet is folded near a first end of the tunnel and near an opposite second end of the tunnel to secure folds extending alongside the tunnels; and wherein the folds are unstitched alongside midportions of the tunnels between the stitches at the first end and at the opposite second end.

Clause 16. The article of footwear of clause 15, wherein the stitches further extend through the one or more cables.

Clause 17. The article of footwear of clause 15, wherein the stitches define gaps at the tunnels and the one or more cables extend out of the tunnels at the gaps such that the stitches do not extend through the one or more cables.

Clause 18. The article of footwear of clause 15, wherein: the overlay sheet has an upper portion and a lower portion; the tunnels extend from the upper portion to the lower portion without intersecting one another; the stitches are a first series of stitches extending along the upper portion of the overlay sheet; and the article of footwear further comprising: a second series of stitches extending along the lower portion of the overlay sheet and configured to further secure the folds extending alongside the tunnels.

Clause 19. The article of footwear of any of clauses 1-2, wherein the first side of the overlay sheet has a first coefficient of friction and the second side of the overlay sheet has a second coefficient of friction greater than the first coefficient of friction.

Clause 20. The article of footwear of any of clauses 1-2, wherein the one or more cables are inextensible.

Clause 21. The article of footwear of any of clauses 1-2, wherein the overlay sheet is a first overlay sheet at a medial side of the base, the one or more cables are one or more first cables; and the tunnels are a first plurality of tunnels, and the article of footwear further comprising: a second overlay sheet disposed on the exterior surface of the base at a lateral side of the base; one or more second cables; wherein the second overlay sheet has a first side and a second side; wherein the second overlay sheet is folded to define a second plurality of tunnels at which portions of the first side of the second overlay sheet face one another such that the second plurality of tunnels are bordered and surrounded by the first side of the second overlay sheet; and wherein the one or more second cables are disposed within the second plurality of tunnels.

Clause 22. The article of footwear of any of clauses 1-2, wherein: the base defines a foot-receiving cavity; the overlay sheet includes a medial side portion disposed at a medial side of the base, a lateral side portion disposed at a lateral side of the base, and an underfoot portion extending under the foot-receiving cavity from the medial side portion to the lateral side portion; the tunnels extend along the medial side portion, the underfoot portion, and the lateral side portion; and the one or more cables define first end portions extending out of the tunnels at the medial side portion and second end portions extending out of the tunnels at the lateral side portion, the one or more cables extending through the tunnels at the underfoot portion from the medial side portion to the lateral side portion.

Clause 23. The article of footwear of any of clauses 1-2, wherein, at each of the tunnels, the one or more cables include a first cable segment and a second cable segment extending alongside one another in the tunnel, and a loop segment extending out of the tunnel and connecting the first cable segment and the second cable segment.

Clause 24. The article of footwear of any of clauses 1-2, wherein at each of the tunnels, the one or more cables include a single cable segment extending through the tunnel and a loop segment extending from the single cable segment out of the tunnel.

Clause 25. The article of footwear of any of clauses 1-2, wherein the overlay sheet is a non-woven textile.

Clause 26. The article of footwear of any of clauses 1-2, wherein the overlay sheet is at least partially translucent and has a first color value at the tunnels between the folds and a second color value lighter than the first color value at portions of the overlay sheet between adjacent tunnels.

Clause 27. The article of footwear of any of clauses 1-2, wherein: the overlay sheet includes an upper edge, a lower edge, and side edges extending between and connecting the upper and lower edges; the upper and lower edges of the overlay sheet are nonlinear in an unfolded state of the overlay sheet and include linear segments extending nonorthogonal to the side edges of the overlay sheet; and the linear segments correspond with ends of the tunnels when the overlay sheet is folded to define the tunnels.

Clause 28. The article of footwear of any of clauses 1-2, wherein the folds are both nonparallel with one another and nonintersecting with one another such that the tunnels are wider at a first end of the tunnels than at a second end of the tunnels.

Clause 29. A footwear upper comprising: one or more cables; an overlay sheet having a first side and a second side; wherein the overlay sheet is folded to define tunnels at which portions of the first side of the overlay sheet face one another such that the tunnels are bordered and surrounded by the first side of the overlay sheet; and wherein the one or more cables are disposed within the tunnels.

Clause 30. The footwear upper of clause 29, wherein the second side of the overlay sheet defines an exposed exterior surface of the overlay sheet both at the tunnels and between adjacent ones of the tunnels.

Clause 31. The footwear upper of any of clauses 29-30, wherein, at each tunnel, the overlay sheet includes a first fold extending along one side of a length of the tunnel and a second fold extending along an opposite side of a length of the tunnel, and the portions of the first side facing one another are inside of the tunnel between the first fold and the second fold.

Clause 32. The footwear upper of clause 31, wherein, at each tunnel, portions of the second side face one another between the first fold and the second fold outside of the tunnel.

Clause 33. The footwear upper of any of clauses 29-30, wherein: the overlay sheet has a first thickness between the first side and the second side; and at each of the tunnels, a thickness from an exposed exterior surface of the overlay sheet to the first side of the overlay sheet outside of the tunnel is at least three times the first thickness.

Clause 34. The footwear upper of clause 33, wherein portions of the overlay sheet between adjacent ones of the tunnels have the first thickness from the exposed exterior surface of the overlay sheet to the first side of the overlay sheet.

Clause 35. The footwear upper of any of clauses 29-30, wherein the one or more cables each define end portions extending out of the tunnels at an outer edge of the overlay sheet or through apertures that extend through the overlay sheet from the first side to the second side at the tunnel.

Clause 36. The footwear upper of clause 35, wherein the end portions each form respective loops.

Clause 37. The footwear upper of clause 35, wherein: the end portions are first end portions; the one or more cables includes a plurality of cables; each cable of the plurality of cables is disposed in a different respective one of the tunnels and has a second end portion nearer to at an opposite end of the tunnel than to the end of the tunnel through which the first end portion of the cable extends.

Clause 38. The footwear upper of clause 37, wherein at least some of the cables are not secured to the overlay sheet at midportions of the respective tunnels between the first end portion and the second end portion such that the cables are not constrained within the respective tunnels at the midportions of the respective tunnels.

Clause 39. The footwear upper of any of clauses 29-30, further comprising: stitches extending through the overlay sheet at least where the overlay sheet is folded near a first end of the tunnel and near an opposite second end of the tunnel to secure folds extending alongside the tunnels; and wherein the folds are unstitched alongside midportions of the tunnels between the stitches at the first end and at the opposite second end.

Clause 40. The footwear upper of clause 39, wherein the stitches further extend through the one or more cables.

Clause 41. The footwear upper of clause 39, wherein the stitches define gaps at the tunnels and the one or more cables extend out of the tunnels at the gaps such that the stitches do not extend through the one or more cables.

Clause 42. The footwear upper of clause 39, wherein: the overlay sheet has an upper portion and a lower portion; the tunnels extend from the upper portion to the lower portion without intersecting one another; the stitches are a first series of stitches extending along the upper portion of the overlay sheet; and the footwear upper further comprising: a second series of stitches extending along the lower portion of the overlay sheet and configured to further secure the folds extending alongside the tunnels.

Clause 43. The footwear upper of any of clauses 29-30, wherein the first side of the overlay sheet has a first coefficient of friction and the second side of the overlay sheet has a second coefficient of friction greater than the first coefficient of friction.

Clause 44. The footwear upper of any of clauses 29-30, wherein the one or more cables are inextensible.

Clause 45. The footwear upper of any of clauses 29-30, wherein the overlay sheet is sized and dimensioned to extend on one of a lateral side or a medial side of an article of footwear without extending on both of the lateral side and the medial side of the article of footwear.

Clause 46. The footwear upper of any of clauses 29-30, wherein: the overlay sheet includes a medial side portion, a lateral side portion, and an underfoot portion extending from the medial side portion to the lateral side portion; the tunnels extend along the medial side portion, the underfoot portion, and the lateral side portion; and the one or more cables define first end portions extending out of the tunnels at the medial side portion and second end portions extending out of the tunnels at the lateral side portion, the one or more cables extending through the tunnels at the underfoot portion from the medial side portion to the lateral side portion.

Clause 47. The footwear upper of any of clauses 29-30, wherein, at each of the tunnels, the one or more cables include a first cable segment and a second cable segment extending alongside one another in the tunnel, and a loop segment extending out of the tunnel and connecting the first cable segment and the second cable segment.

Clause 48. The footwear upper of any of clauses 29-30, wherein at each of the tunnels, the one or more cables include a single cable segment extending through the tunnel and a loop segment extending from the single cable segment out of the tunnel.

Clause 49. The footwear upper of any of clauses 29-30, wherein the overlay sheet is a non-woven textile.

Clause 50. The footwear upper of any of clauses 29-30, wherein the overlay sheet is at least partially translucent and has a first color value at the tunnels between the folds and a second color value lighter than the first color value at portions of the overlay sheet between adjacent tunnels.

Clause 51. The footwear upper of any of clauses 29-30, wherein: the overlay sheet includes an upper edge, a lower edge, and side edges extending between and connecting the upper and lower edges; the upper and lower edges of the overlay sheet are nonlinear in an unfolded state of the overlay sheet and include linear segments extending nonorthogonal to the side edges of the overlay sheet; and the linear segments correspond with ends of the tunnels when the overlay sheet is folded to define the tunnels.

Clause 52. The footwear upper of any of clauses 29-30, wherein the folds are both nonparallel with one another and nonintersecting with one another such that the tunnels are wider at a first end of the tunnels than at a second end of the tunnels.

Clause 53. The footwear upper of any of clauses 29-30, further comprising: a base at least partially a foot-receiving cavity and an ankle opening configured for foot entry into the foot-receiving cavity; wherein the overlay sheet is disposed on an exterior surface of the base.

Clause 54. A footwear upper comprising: an overlay sheet having a first side and a second side; wherein the overlay sheet is folded to define tunnels at which portions of the first side of the overlay sheet face one another, the tunnels extending adjacent to one another without intersecting one another, and the overlay sheet including intermediate portions extending between adjacent ones of the tunnels, the folded overlay sheet being at least three times thicker at the tunnels than at the intermediate portions.

To assist and clarify the description of various embodiments, various terms are defined herein. Unless otherwise indicated, the following definitions apply throughout this specification (including the claims). Additionally, all references referred to are incorporated herein in their entirety.

An “article of footwear”, a “footwear article of manufacture”, and “footwear” may be considered to be both a machine and a manufacture. Assembled, ready to wear footwear articles (e.g., shoes, sandals, boots, etc.), as well as discrete components of footwear articles (such as a midsole, an outsole, an upper component, etc.) prior to final assembly into ready to wear footwear articles, are considered and alternatively referred to herein in either the singular or plural as “article(s) of footwear”.

“A”, “an”, “the”, “at least one”, and “one or more” are used interchangeably to indicate that at least one of the items is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters (e.g., of quantities or conditions) in this specification, unless otherwise indicated expressly or clearly in view of the context, including the appended claims, are to be understood as being modified in all instances by the term “about” whether or not “about” actually appears before the numerical value. “About” indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, a disclosure of a range is to be understood as specifically disclosing all values and further divided ranges within the range.

The terms “comprising”, “including”, and “having” are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Orders of steps, processes, and operations may be altered when possible, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of” is understood to include any possible combination of referenced items, including “any one of” the referenced items. The term “any of” is understood to include any possible combination of referenced claims of the appended claims, including “any one of” the referenced claims.

For consistency and convenience, directional adjectives may be employed throughout this detailed description corresponding to the illustrated embodiments. Those having ordinary skill in the art will recognize that terms such as “above”, “below”, “upward”, “downward”, “top”, “bottom”, etc., may be used descriptively relative to the figures, without representing limitations on the scope of the invention, as defined by the claims.

The term “longitudinal” particularly refers to a direction extending a length of a component. For example, a longitudinal direction of a shoe extends between a forefoot region and a heel region of the shoe. The term “forward” or “anterior” is used to particularly refer to the general direction from a heel region toward a forefoot region, and the term “rearward” or “posterior” is used to particularly refer to the opposite direction, i.e., the direction from the forefoot region toward the heel region. In some cases, a component may be identified with a longitudinal axis as well as a forward and rearward longitudinal direction along that axis. The longitudinal direction or axis may also be referred to as an anterior-posterior direction or axis.

The term “transverse” particularly refers to a direction extending a width of a component. For example, a transverse direction of a shoe extends between a lateral side and a medial side of the shoe. The transverse direction or axis may also be referred to as a lateral direction or axis or a mediolateral direction or axis.

The term “vertical” particularly refers to a direction generally perpendicular to both the lateral and longitudinal directions. For example, in cases where a sole is planted flat on a ground surface, the vertical direction may extend from the ground surface upward. It will be understood that each of these directional adjectives may be applied to individual components of a sole. The term “upward” or “upwards” particularly refers to the vertical direction pointing towards a top of the component, which may include an instep, a fastening region and/or a throat of an upper. The term “downward” or “downwards” particularly refers to the vertical direction pointing opposite the upwards direction, toward the bottom of a component and may generally point towards the bottom of a sole structure of an article of footwear.

The “interior” of an article of footwear, such as a shoe, particularly refers to portions at the space that is occupied by a wearer's foot when the shoe is worn. The “inner side” of a component particularly refers to the side or surface of the component that is (or will be) oriented toward the interior of the component or article of footwear in an assembled article of footwear. The “outer side” or “exterior” of a component particularly refers to the side or surface of the component that is (or will be) oriented away from the interior of the shoe in an assembled shoe. In some cases, other components may be between the inner side of a component and the interior in the assembled article of footwear. Similarly, other components may be between an outer side of a component and the space external to the assembled article of footwear. Further, the terms “inward” and “inwardly” particularly refer to the direction toward the interior of the component or article of footwear, such as a shoe, and the terms “outward” and “outwardly” particularly refer to the direction toward the exterior of the component or article of footwear, such as the shoe. In addition, the term “proximal” particularly refers to a direction that is nearer a center of a footwear component, or is closer toward a foot when the foot is inserted in the article of footwear as it is worn by a user. Likewise, the term “distal” particularly refers to a relative position that is further away from a center of the footwear component or is further from a foot when the foot is inserted in the article of footwear as it is worn by a user. Thus, the terms proximal and distal may be understood to provide generally opposing terms to describe relative spatial positions.

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. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

While several modes for carrying out the many aspects of the present teachings have been described in detail, those familiar with the art to which these teachings relate will recognize various alternative aspects for practicing the present teachings that are within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and exemplary of the entire range of alternative embodiments that an ordinarily skilled artisan would recognize as implied by, structurally and/or functionally equivalent to, or otherwise rendered obvious based upon the included content, and not as limited solely to those explicitly depicted and/or described embodiments.

Claims

1. An article of footwear comprising:

a footwear upper including a base and an overlay sheet disposed on an exterior surface of the base;

one or more cables;

wherein the overlay sheet has a first side and a second side;

wherein the overlay sheet is folded to define tunnels at which portions of the first side of the overlay sheet face one another such that the tunnels are bordered and surrounded by the first side of the overlay sheet; and

wherein the one or more cables are disposed within the tunnels.

2. The article of footwear of claim 1, wherein the first side of the overlay sheet interfaces with the exterior surface of the base between adjacent ones of the tunnels.

3. The article of footwear of claim 1, wherein the second side of the overlay sheet defines an exposed exterior surface of the overlay sheet both at the tunnels and between adjacent ones of the tunnels.

4. The article of footwear of claim 1, wherein, at each tunnel, the overlay sheet includes a first fold extending along one side of a length of the tunnel and a second fold extending along an opposite side of a length of the tunnel, and the portions of the first side facing one another are between the first fold and the second fold.

5. The article of footwear of claim 4, wherein, at each tunnel, portions of the second side face one another between the tunnel and the base.

6. The article of footwear of claim 1, wherein the base at least partially defines a foot-receiving cavity and has an ankle opening configured for foot entry into the foot-receiving cavity; and the article of footwear further comprising:

a sole structure secured to the footwear upper and defining a biteline between the footwear upper and the sole structure;

wherein the overlay sheet has a lower extent disposed below the biteline when the article of footwear is positioned with the ankle opening above the sole structure.

7. The article of footwear of claim 1, wherein the one or more cables each define end portions extending out of the tunnels at an outer edge of the overlay sheet or through apertures that extend through the overlay sheet from the first side to the second side at the tunnels.

8. The article of footwear of claim 7, wherein the end portions each form respective loops.

9. The article of footwear of claim 8, wherein the base defines a foot-receiving cavity, and the article of footwear further comprising:

a lace extending through the loops; and

wherein cinching the lace pulls on at least the end portions to tighten the base around the foot-receiving cavity.

10. The article of footwear of claim 1, further comprising:

stitches extending through the overlay sheet at least where the overlay sheet is folded near a first end of the tunnels and near an opposite second end of the tunnels to secure folds extending alongside the tunnels; and

wherein the folds are unstitched alongside midportions of the tunnels between the stitches at the first end and at the opposite second end.

11. The article of footwear of claim 10, wherein the stitches further extend through the one or more cables.

12. The article of footwear of claim 10, wherein the stitches define gaps at the tunnels and the one or more cables extend out of the tunnels at the gaps such that the stitches do not extend through the one or more cables.

13. The article of footwear of claim 1, wherein the first side of the overlay sheet has a first coefficient of friction and the second side of the overlay sheet has a second coefficient of friction greater than the first coefficient of friction.

14. The article of footwear of claim 1, wherein the one or more cables are inextensible.

15. The article of footwear of claim 1, wherein the overlay sheet is a first overlay sheet at a medial side of the base, the one or more cables are one or more first cables; and the tunnels are a first plurality of tunnels, and the article of footwear further comprising:

a second overlay sheet disposed on the exterior surface of the base at a lateral side of the base;

one or more second cables;

wherein the second overlay sheet has a first side and a second side;

wherein the second overlay sheet is folded to define a second plurality of

tunnels at which portions of the first side of the second overlay sheet face one another such that the second plurality of tunnels are bordered and surrounded by the first side of the second overlay sheet; and

wherein the one or more second cables are disposed within the second plurality of tunnels.

16. The article of footwear of claim 1, wherein:

the base defines a foot-receiving cavity;

the overlay sheet includes a medial side portion disposed at a medial side of the base, a lateral side portion disposed at a lateral side of the base, and an underfoot portion extending under the foot-receiving cavity from the medial side portion to the lateral side portion;

the tunnels extend along the medial side portion, the underfoot portion, and the lateral side portion; and

the one or more cables define first end portions extending out of the tunnels at the medial side portion and second end portions extending out of the tunnels at the lateral side portion, the one or more cables extending through the tunnels at the underfoot portion from the medial side portion to the lateral side portion.

17. The article of footwear of claim 1, wherein:

the overlay sheet includes an upper edge, a lower edge, and side edges extending between and connecting the upper and lower edges;

the upper and lower edges of the overlay sheet are nonlinear in an unfolded state of the overlay sheet and include linear segments extending nonorthogonal to the side edges of the overlay sheet; and

the linear segments correspond with ends of the tunnels when the overlay sheet is folded to define the tunnels.

18. The article of footwear of claim 1, wherein the folds are both nonparallel with one another and nonintersecting with one another such that the tunnels are wider at a first end of the tunnels than at a second end of the tunnels.

19. A footwear upper comprising:

one or more cables;

an overlay sheet having a first side and a second side;

wherein the overlay sheet is folded to define tunnels at which portions of the first side of the overlay sheet face one another such that the tunnels are bordered and surrounded by the first side of the overlay sheet; and

wherein the one or more cables are disposed within the tunnels.

20. The footwear upper of claim 19, wherein the second side of the overlay sheet defines an exposed exterior surface of the overlay sheet both at the tunnels and between adjacent ones of the tunnels.