Article of footwear incorporating winding elements

Abstract

A method of manufacturing an article of footwear defining a forefoot region, a midfoot region, and a heel region includes providing a sole structure and an upper. The method further includes coupling the sole structure to the upper at least in part by winding a first continuous thread around the sole structure and the upper in a first direction in the midfoot region and the forefoot region, winding the first continuous thread around the sole structure and the upper in a second direction in the heel region, and receiving the first continuous thread within a channel of a plurality of channels that are defined by a sole surface of the sole structure. Winding the first continuous thread around the sole structure and the upper is, at least in part, configured to couple the sole structure to the upper. The first direction is different than the second direction.

We claim: 
     
         1 . A method of manufacturing an article of footwear defining a forefoot region, a midfoot region, and a heel region, the method comprising:
 providing a sole structure and an upper;   coupling the sole structure to the upper at least in part by:
 winding a first continuous thread around the sole structure and the upper in a first direction in the midfoot region and the forefoot region, and 
 winding the first continuous thread around the sole structure and the upper in a second direction in the heel region; and 
   receiving the first continuous thread within a channel of a plurality of channels that are defined by a sole surface of the sole structure,   wherein winding the first continuous thread around the sole structure and the upper is, at least in part, configured to couple the sole structure to the upper, and   wherein the first direction is different than the second direction.   
     
     
         2 . The method of  claim 1 , wherein winding the first continuous thread in the first direction includes winding the first continuous thread from a lateral side of the article of footwear to a medial side of the article of footwear across the upper. 
     
     
         3 . The method of  claim 1 , wherein winding the first continuous thread in the first direction includes winding the first continuous thread from a medial side of the article of footwear to a lateral side of the article of footwear along each channel of the plurality of channels. 
     
     
         4 . The method of  claim 3 , wherein each channel of the plurality of channels extends laterally along the sole surface of the sole structure from the lateral side to the medial side. 
     
     
         5 . The method of  claim 1 , wherein the first direction is substantially perpendicular with respect to the second direction. 
     
     
         6 . The method of  claim 1  further comprising providing a thread supply system, wherein the thread supply system is configured to provide the first continuous thread. 
     
     
         7 . The method of  claim 6 , wherein the thread supply system comprises a moveable arm that is configured to dispense the first continuous thread. 
     
     
         8 . The method of  claim 1  further comprising:
 winding a second continuous thread around a support structure to define a formed shape; 
 curing the first continuous thread so that the first continuous thread firmly holds the formed shape; and 
 removing the second continuous thread from the support structure in the formed shape to define the upper. 
 
     
     
         9 . A method of manufacturing an article of footwear defining a forefoot region, a midfoot region, and a heel region, the method comprising:
 providing a sole structure and an upper;   coupling the sole structure to the upper at least in part by:
 winding a first continuous thread around the sole structure and the upper in a first direction in the midfoot region and the forefoot region, and 
 winding the first continuous thread around the sole structure and the upper in a second direction in the heel region that is different than the first direction; and 
   receiving the first continuous thread within a first channel of a plurality of channels that are defined by a sole surface of the sole structure,   wherein the first channel is disposed within the heel region and points in a direction upward and toward the midfoot region.   
     
     
         10 . The method of  claim 9 , wherein the first channel extends laterally along the sole surface of the sole structure from a medial side of the article of footwear to a lateral side of the article of footwear. 
     
     
         11 . The method of  claim 9 , wherein winding the first continuous thread in the first direction includes winding the first continuous thread from a lateral side of the article of footwear to a medial side of the article of footwear across the upper. 
     
     
         12 . The method of  claim 9 , wherein winding the first continuous thread in the first direction includes winding the first continuous thread from a medial side of the article of footwear to a lateral side of the article of footwear along each channel of the plurality of channels. 
     
     
         13 . The method of  claim 9  further comprising providing a reinforcement component along each channel within the plurality of channels; and
 hardening the reinforcement component to retain the first continuous thread within each channel of the plurality of channels. 
 
     
     
         14 . The method of  claim 13 , wherein the reinforcement component comprises a layer of polymeric resin. 
     
     
         15 . A method of manufacturing an article of footwear defining a forefoot region, a midfoot region, and a heel region, the method comprising:
 providing a sole structure and an upper; and   coupling the sole structure to the upper at least in part by:
 winding a first continuous thread around the sole structure and the upper in a first direction in the midfoot region and the forefoot region; and 
 winding a second continuous thread around the sole structure and the upper in a second direction in the heel region that is different than the first direction, 
   wherein the second continuous thread overlaps the first continuous thread at least partially along a medial side of the sole structure.   
     
     
         16 . The method of  claim 15 , wherein the first direction is substantially perpendicular to the second direction. 
     
     
         17 . The method of  claim 15 , wherein the first continuous thread covers at least a portion of each of the forefoot region, the midfoot region, and the heel region. 
     
     
         18 . The method of  claim 15 , wherein the second continuous thread covers at least a portion of each of the midfoot region and the heel region. 
     
     
         19 . The method of  claim 15  further comprising receiving the first continuous thread within a plurality of channels that are defined by a sole surface of the sole structure. 
     
     
         20 . The method of  claim 19  further comprising providing a reinforcement component along each channel within the plurality of channels; and
 hardening the reinforcement component to fixedly retain the first continuous thread within each channel of the plurality of channels.