Composite textile with improved resistance to wrinkling or creasing in an area of repeated flexion

Abstract

A composite textile can include a stacked arrangement of material layers and can be used to form an upper. The composite textile can include an abrasion resistant layer, an elastically resilient layer, and a stretch resistant layer positioned between the abrasion resistant layer and the elastically resilient layer. When the composite textile is incorporated into an upper, the composite textile generally resists stretch along a surface plane of the upper but is elastically resilient in directions orthogonal to the surface plane. The stacked configuration of material layers provides support and structure to the upper while minimizing the formation of wrinkles and creases in high flexion area of the upper.

Description

COMPOSITE TEXTILE WITH IMPROVED RESISTANCE TO WRINKLING OR CREASING IN AN AREA OF REPEATED FLEXIONBACKGROUND OF THE INVENTION

[0001] Composite textiles are used in various applications, some of which include synthetic leather. For example, a nonwoven fiber web can be combined with one or more other layers, such as a protective skin (e.g., to be oriented towards an outer surface) or a lining layer (e.g., to form an inner layer). Traditional synthetic leathers (e.g., when used in uppers of traditional articles of footwear, bags, belts, and other articles) may be prone to wrinkles and / or creasing in areas of the articles that are subject to a high amount of flexion during normal use and wear such as, for example, the instep area of the upper. The heel region of the upper may also be prone to wrinkles and / or creasing in examples where a wearer dons an article of footwear by pressing down on the heel region and sliding their foot into the article of footwear. In some instances this may detract from the aesthetic appeal of the article and / or decrease the useable life of the article.BRIEF DESCRIPTION OF THE DRAWINGS

[0002] The present systems and methods for a composite textile are described in detail below with reference to these figures.

[0003] FIG. 1 illustrates a medial side of an article of footwear in accordance with aspects herein;

[0004] FIG. 2 illustrates a lateral side of the article of footwear of FIG. 1 in accordance with aspects herein;

[0005] FIG. 3 illustrates a top view of the article of footwear of FIG. 1 in accordance with aspects herein;

[0006] FIG. 4 illustrates a rear view of the article of footwear of FIG. 1 in accordance with aspects herein;

[0007] FIG. 5 illustrates a cross-section of materials used to form an upper of the article of footwear of FIG. 1 before processing in accordance with aspects herein;

[0008] FIG. 6 illustrates a cross-section of the materials used to form the upper of the article of footwear of FIG. 1 after processing in accordance with aspects herein;

[0009] FIG. 7 illustrates a perspective view of a first example abrasion resistant layer used to form the upper of the article of footwear of FIG. 1 in accordance with aspects herein;

[0010] FIG. 8A illustrates a cross-section view of a second example abrasion resistant layer used to form the upper of the article of footwear of FIG. 1 before the second example abrasion resistant layer has been processed in accordance with aspects herein;

[0011] FIG. 8B illustrates a cross-section view of the second example abrasion resistant layer used to form the upper of the article of footwear of FIG. 1 after the second example abrasion resistant layer has been processed in accordance with aspects herein;

[0012] FIG. 9A illustrates a cross-section view of a first example stretch resistant layer used to form the upper of the article of footwear of FIG. 1 before the first example stretch resistant layer has been processed in accordance with aspects herein;

[0013] FIG. 9B illustrates a cross-section view of the first example stretch resistant layer used to form the upper of the article of footwear of FIG. 1 after the first example stretch resistant layer has been processed in accordance with aspects herein;

[0014] FIG. 10A illustrates a cross-section view of a second example stretch resistant layer used to form the upper of the article of footwear of FIG. 1 before the second example stretch resistant layer has been processed in accordance with aspects herein;

[0015] FIG. 10B illustrates a cross-section view of the second example stretch resistant layer used to form the upper of the article of footwear of FIG. 1 after the second example stretch resistant layer has been processed in accordance with aspects herein;

[0016] FIG. 11A illustrates a perspective view of a third example stretch resistant layer used to form the upper of the article of footwear of FIG. 1 before the third example stretch resistant layer has been processed in accordance with aspects herein;

[0017] FIG. 1 IB illustrates a cross-section view of the third example stretch resistant layer used to form the upper of the article of footwear of FIG. 1 after the third example stretch resistant layer has been processed in accordance with aspects herein;

[0018] FIG. 12 illustrates a perspective view of a fourth example stretch resistant layer used to form the upper of the article of footwear of FIG. 1 in accordance with aspects herein;

[0019] FIG. 13 illustrates a perspective view of a first example elastically resilient layer used to form the upper of the article of footwear of FIG. 1 in accordance with aspects herein;

[0020] FIG. 14A illustrates a front perspective view of a second example elastically resilient layer used to form the upper of the article of footwear of FIG. 1 in accordance with aspects herein;

[0021] FIG. 14B illustrates a back perspective view of the second example elastically resilient layer used to form the upper of the article of footwear of FIG. 1 in accordance with aspects herein;

[0022] FIG. 15 illustrates a schematic of an instep area of the article of footwear of FIG. 1 undergoing flexion during a normal walking / running motion and resiliently returning to a resting state in accordance with aspects herein;

[0023] FIG. 16 illustrates a schematic of a heel region of the article of footwear of FIG. 1 undergoing flexion during a donning motion and resiliently returning to a resting state in accordance with aspects herein;

[0024] FIG. 17 illustrates a plan view of the upper of the article of footwear of FIG. 1 in which the upper includes different thicknesses of the elastically resilient layer at different areas of the upper in accordance with aspects herein;

[0025] FIG. 18A illustrates a perspective view of an inner-facing surface of an upper in which an example elastically resilient layer includes ridges in accordance with aspects herein;

[0026] FIG. 18B illustrates a cross-section view of the upper of FIG. 18A in accordance with aspects herein;

[0027] FIG. 19 illustrates a schematic of an article of footwear incorporating the ridged elastically resilient layer of FIG. 18A in which the ridges are oriented in different directions at different areas of the article of footwear;

[0028] FIG. 20 illustrates a cross-section of a second example of materials used to form the upper of the article of footwear of FIG. 1 in which a textile comprising ridges is positioned interior to the elastically resilient layer in accordance with aspects herein; and

[0029] FIG. 21 illustrates a flow diagram of an example method of manufacturing an upper in accordance with aspects herein.DETAINED DESCRIPTION OF THE INVENTION

[0030] This detailed description is related to a composite textile with improved resistance to wrinkling or creasing in an area of repeated elastic flexion. The composite textile can construct at least part of a wearable article (e.g., an upper for an article of footwear or a belt), a bag, or other products that are commonly constructed from leather or synthetic leather. In examples, the composite textile of the present disclosure generally maintains its shape over time and is generally resistant to the formation of wrinkles and / or creases in areas of the productthat are prone to high amounts of repeated flexion (e.g., an instep area of the upper and / or a heel region of the upper). As such, the composite textile can enhance the aesthetic appeal of the article and prolong the useable life of the article.

[0031] Some conventional composite textiles can include one or more layers of mechanically interlocked staple fibers, and sometimes a staple fiber layer can be relatively dimensionally stable and resistant to stretch in one or more directions. However, because the staple fibers often retain the ability to move freely (at the fiber level and based on the mechanical interlocking), these composite textiles can be prone to wrinkle over time, such as along inflexion points that repeatedly elastically deform. Some conventional approaches attempt to limit the tendency of the staple fibers to freely move with heavy reinforcement and / or coatings. However, these additional layers can add cost, can detract from other desirable properties of the fiber web, and / or can introduce their own undesirable properties. In addition, with repeated elastic bending and flexion, the staple fibers can still move and migrate over time to create creases and wrinkles in the outer face of the additional layer(s).

[0032] In examples, the composite textile can include a stacked configuration of materials that includes an abrasion resistant layer, an elastically resilient layer, and a stretch resistant layer positioned between the abrasion resistant layer and the elastically resilient layer. The layers are secured to each other to form a cohesive structure.

[0033] The abrasion resistant layer may form an outer-facing surface, including an outermost-facing surface when the composite textile is incorporated into an article. The abrasion resistant layer is formed of materials that are able to withstand the normal wear-and- tear forces that an article might be subjected to during everyday use. Before being formed into the composite textile, the materials selected for the abrasion resistant layer are generally elastically resilient along an x, y plane, and possibly in a z-direction. In addition, these materials can often retain at least some elastic resilience after being coupled to an underlying layer, even if the overall stretchability of the resulting composite is reduced by the underlying layer.

[0034] The elastically resilient layer may form an inner-facing surface, including an innermost-facing surface when the composite textile is incorporated into an article. Before being integrated into the composite textile, materials selected for the elastically resilient layer are typically elastically resilient along the x, y plane, and possibly in the z-direction. In addition, these materials can often retain at least some elastic resilience after being coupled to another, overlaying layer, even if the overall stretchability of the resulting composite is reducedby the overlaying layer. In examples, to avoid the composite textile being too stretchy such that the composite fails to provide sufficient support and containment for an intended use (e.g., for a wearer’s foot or ankle), a stretch resistant layer can be positioned between the abrasion resistant layer and the elastically resilient layer. However, the elastic resilience of the elastically resilient layer can still contribute to the overall properties of the composite, including the ability to return to a neutral state, condition, or orientation after being flexed. As described in greater detail below, the stretch resistant layer may be formed of a nonwoven layer in which fibers of the nonwoven layer are at least partially encapsulated by, or embedded in, a thermoplastic polymer layer, which helps to lock the fibers into place and at least partially or fully inhibits stretching of the nonwoven layer along the x, y plane and / or can increase the tear strength. The thermoplastic polymer layer can include various types of layers, such as a hotmelt layer that might be used to couple the stretch resistant layer to one or more of the other layers or a thermoplastic polymer layer that is integrated into a nonwoven layer, and in some instances, once the layers are processed (e.g., heat pressed) the thermoplastic polymer layer can form a matrix in which the fibers of the nonwoven layer are at least partially embedded.

[0035] The stretch resistant layer generally constrains the stretch of the stacked configuration in the x, y plane but does not affect the elastic resilience of the stacked configuration in the z-direction (e.g., the elastic resilience that can be based at least in part on the properties of the elastically resilient layer and / or the abrasion resistant layer). When the stacked configuration is formed into the upper, stretch is generally constrained along a surface plane of the upper such that the upper maintains its shape and provides support for and containment of a wearer’s foot, but the stacked configuration is elastically resilient in a direction orthogonal to the surface plane of the upper. Thus for example, at an instep area of an upper, which typically undergoes repeated flexion during normal walking and running motions, the upper constructed of the composite textile elastically flexes and returns to its resting state due to the presence of the abrasion resistant layer and the elastically resilient layer. This reduces the overall appearance of wrinkles and / or creases and enhances the aesthetic appeal and useable life of the article of footwear. In instances where a wearer dons the article of footwear by compressing the heel region downward and sliding their foot into the upper, the upper constructed of the composite textile elastically deforms and returns to its resting state and the formation of wrinkles and / or creases is reduced in the heel region.

[0036] Variables associated with the different layers described above may be adjusted or fine-tuned to achieve different functional effects at different areas or regions of the upper. Forexample, materials for the different layers may be selected to achieve different functional effects. As an example, the abrasion resistant layer may comprise a film (e.g., bonded via hot- melt adhesive), coating (e.g., liquid coating that is applied directly to an underlying layer via spray , printing, brushing, knife spreading, etc.), flocking, fiber-deposition layer, powderdeposition layer, etc. that is generally resistant to abrasion. In another example, the abrasion resistant layer may comprise a knit textile formed from yarns having a core of a high-melting material (e.g., polyethylene terephthalate) and a sheath of a low-melting thermoplastic material (e.g., thermoplastic polyurethane). The knit textile may be processed such that the sheath of low-melting thermoplastic material melts, flows, and at least partially encapsulates the core of high-melting material before being cooled and forming a thermoformed layer. The result is a layer that not only is relatively resistant to abrasion but also has a relatively high coefficient of friction suitable to “grip” an object such as a soccer ball that comes into contact with the layer allowing a wearer to achieve a greater degree of ball control. Additionally, a texture may be applied to the abrasion resistant layer to achieve a desired aesthetic and / or surface feel. For example, when the composite is laminated or otherwise pressed (e.g., heat pressed), a relief paper can be positioned against the face of the abrasion resistant layer to impress a pattern.

[0037] To achieve an even greater resistance to stretch along the surface plane of the upper and / or to increase the tear strength, an additional layer may be added to the stretch resistant layer. For example, when a spunbond nonwoven layer comprising high-melting fibers (e.g., fibers that have a relatively high melt temperature or softening temperature), such as polyamide and / or polyester (e.g., polyethylene terephthalate) fibers, is used as the stretch resistant layer, an additional or second spunbond nonwoven layer comprising high-melting fibers may be positioned overtop the first spunbond nonwoven layer. Fibers of the second spunbond nonwoven layer may also be at least partially encapsulated by a thermoplastic polymer layer (e.g., the matrix) to help lock the fibers into place. Moreover, to help achieve a generally uniform resistance to stretch in both the x-direction and the y-direction of the stacked configuration, the second spunbond nonwoven layer may be oriented such that a machine direction of the second spunbond nonwoven layer is oriented generally orthogonal to the machine direction of the first spunbond nonwoven layer. As used herein when referring to the orientation of the machine direction of one nonwoven layer to the machine direction of another nonwoven layer, the term “orthogonal” means substantially perpendicular (e.g., + / - 10 degrees of perpendicular). In another example, a nonwoven layer comprising low-melting fibers (e.g., fibers that have a relatively low melting temperature of softening temperature, such asthermoplastic polyurethane fibers) may be incorporated into at least a portion of the stretch resistant layer (e.g., as a standalone layer or in combination with other nonwovens). After processing, at least some of the fibers may melt, flow, and solidify to form a thermoplastic polymer layer that is generally resistant to stretch along both the x-direction and the y-direction of the surface plane of the upper.

[0038] Regarding the elastically resilient layer, the layer may be processed to have different thicknesses at different areas or regions of the upper. In areas of the upper more prone to flexion (e.g., the instep area and / or the heel region in some instances), the elastically resilient layer may have a greater thickness compared to areas less prone to flexion such as the medial and lateral sides of the midfoot region of the upper. The greater thickness may enhance the elastic resilience, or “spring-back” in these areas of the upper making wrinkles and / or creases less likely.

[0039] In another, or additional example, the elastically resilient layer may be processed to include a plurality of ridges where each ridge is separated from an adjacent ridge by a valley. The use of ridges separated by valleys increases the relative surface area of the elastically resilient layer which effectively makes the elastically resilient layer less stiff and facilitates elastic bending of the elastically resilient layer. The ridges may be oriented in a portion of the upper (e.g., across a toe box, vamp, or instep) such that common or typical flexion of the upper in that portion (e.g., the orientation of the inflexion point or inflexion line) typically occur in the same or similar direction as the ridge(s) and / or valley(s) (e.g., along-ridge or along-valley direction). This contrasts with other examples, in which the ridges might be oriented such that common flexion (e.g., the orientation of the fold or inflexion point) is cross-ridge, such that the ridges essentially act as beams that resist flexing. For example, in the vamp area, the ridges can be oriented such that they longitudinally extend between a medial side and a lateral side of the upper, as opposed to a toe end-to-heel end direction. In such an example, flexion in the vamp area would generally occur in the valleys between the ridges (e.g., the point or line of elastic folding or inflexion generally occurs in the valleys). Similarly, in the heel region, the ridges can be oriented such that they longitudinally extend back and forth between the medial side and the lateral side of the upper and flexion in the heel region would generally occur in the valleys between the ridges. In examples in which greater stiffness might be desired, such as along the medial side and the lateral side of the midfoot region of the upper, the ridges may be oriented such that flexion in these areas (e.g., the orientation of the line along which the flex, bend, or fold occurs) would occur in the cross-ridge direction (which is stiffer) as opposedto the along-ridge direction. The uses of ridges to facilitate, or inhibit, flexion may also occur through the application of a lining textile to an exposed surface of the elastically resilient layer where the lining textile includes ridges separated by valleys. Orientation of the ridges of the lining textile would be similar to that described above for the elastically resilient layer.

[0040] The stacked configuration described above may incorporate low cost materials such as, for example, the use of a foam material for the elastically resilient layer and the use of a spunbond nonwoven for the stretch resistant layer which may reduce the overall cost of manufacturing the article of footwear. The use of a low basis weight spunbond nonwoven layer may also reduce the overall weight of the article of footwear and may also reduce the overall energy used to make the article of footwear as nonwoven materials in general typically consume less energy to make as compared to materials such as knit or woven layers. Furthermore, the use of relatively thin nonwoven textiles in the stretch resistant layer can contribute to a thinner stacked configuration.

[0041] A composite textile of the present disclosure can construct one or more various articles. For example, a composite textile can construct an article of apparel. As used herein, the term “article of apparel” is intended to encompass articles worn by a wearer, which can also be referred to as “wearable articles” or “wearable apparel articles”. Wearable articles can include, among other things, upper-body / upper-torso garments (e.g., tops, t-shirts, tank tops, pullovers, hoodies, jackets, coats, vests, bras, and the like); lower-body / lower-torso garments (e.g., pants, shorts, tights, capris, unitards, joggers, underwear, and the like); hats (e.g., ball caps, trucker-style hats, etc.); gloves; sleeves (e.g., arm sleeves, calf sleeves); articles of footwear (e.g., uppers for shoes, socks, etc.); undergarments; belts; and the like. A composite textile of the present disclosure can also construct one or more portions of a bag, such as a backpack, a duffel, a shoulder bag or cross-shoulder bag, and the like.

[0042] Examples of the present disclosure can include an article of footwear constructed of the composite textile. The article of footwear described herein may comprise any article of footwear, such as a running shoe, a baseball shoe, a basketball shoe, a skateboarding shoe, a cycling shoe, an American football shoe, a tennis shoe, a global football shoe, a lifestyle shoe, a training shoe, a walking shoe, a hiking shoe, and the like. The concepts described herein may also be applied to other footwear types that are considered non-athletic such as dress shoes, loafers, sandals, and work boots.

[0043] As used herein, the article of footwear may be divided into different general regions. A forefoot region generally includes portions of the article of footwear that correspond to thetoes and joints connecting the metatarsals with the phalanges; the forefoot region terminates in a toe end of the article of footwear. A midfoot region generally includes portions of the article of footwear corresponding with an arch area and an instep area of the foot. As used herein, the instep area is generally the area of the upper that overlies the top of a wearer’ s foot. It may generally extend at least partially between the toe end a forward edge of an ankle collar of an upper. A heel region generally corresponds with rear portions of the foot including the calcaneus bone; the heel region terminates in a heel end of the article of footwear. The article of footwear described herein may include a lateral side which corresponds with an outside area of the foot (i.e., the surface that faces away from the other foot) and a medial side which corresponds with an inside area of the foot (i.e., the surface that faces toward the other foot). The different regions and sides described above are intended to represent general areas of footwear to aid in the following discussion and are not intended to demarcate precise areas. The different regions and sides may be applied to the article of footwear as a whole, to the upper, and to a sole structure(s).

[0044] The article of footwear described herein generally includes one or more sole structures that are secured to the upper. The sole structures may include a midsole, a cushioning element, an outsole, or any combination of the above including a unitary structure that functions as a midsole and an outsole. The sole structures may provide cushioning, support, force attenuation, and the like. The term “biteline” as used herein refers to the boundary between the upper and the sole structure(s), and in some examples, the biteline includes a point on the upper at which the topline edge of the sole attaches to the upper (e.g., such that the upper overlaps with the sole).

[0045] The term “outer-facing surface” as used herein means a surface of the upper or article of footwear that faces the external environment. In some aspects, the outer-facing surface may mean the outermost-facing surface or outermost surface of the upper or article of footwear. The term “inner-facing surface” as used herein means a surface of the upper or article of footwear that faces a void for receiving the wearer’s foot. In some aspects, the inner-facing surface may mean the innermost-facing surface or the innermost surface of the upper or article of footwear. The terms “external” and “internal” as used herein are relative terms such that a layer that is external is positioned external to one or more internal layers, and a layer that is internal is positioned internal to one or more external layers.

[0046] Aspects herein describe a knit textile that may be used to form the abrasion resistant layer. In example aspects, yams used to knit the abrasion resistant layer may include acore / sheath yam comprising a core of a high-melting polymer yam (e.g., yarns that melt or at least partially soften at a temperature relatively higher than other yarns, such as at about 175 degrees Celsius or higher) including polyethylene terephthalate yarns (commonly known as polyester), recycled polyethylene terephthalate yams, polyamide yarns (commonly known as nylon), elastane yarns, and other high-melting synthetic yarns. In example aspects, the sheath of the core / sheath yarn in the abrasion resistant layer may comprise a synthetic polymeric material formed from a polymer that melts at relatively low temperatures (e.g., less than about 175 degrees Celsius). In example aspects, the sheath may comprise a thermoplastic material that is capable of melting upon the application of heat having a temperature greater than the temperature of the thermoplastic material. The thermoplastic material hardens or solidifies upon cooling and is capable of re-melting when heat having a temperature greater than the temperature of the thermoplastic material is re-applied. The melting temperature of the thermoplastic material forming the sheath of the core / sheath yam may be sufficiently different from the melting temperature of the yarn used to form the core of the core / sheath yarn such that the yarn forming the core is not adversely affected (e.g., burning, melting, charring, or singeing) when heat is applied to the knit textile during processing.

[0047] The term “thermoplastic polymer layer” refers to a generally unitary structure that includes a solidified thermoplastic polymer. Often, the solidified thermoplastic polymer can at least partially encapsulate fibers or yarns of a textile, such as for example, fibers of a nonwoven layer or a yam(s) of a knit textile or woven textile. In these instances, the solidified thermoplastic polymer can also be referred to as a matrix. Thermoplastic polymer layers can be formed in various manners, such as where a thermoplastic polymer material is heated to a softened or melted state, during which the thermoplastic polymer material at least partially flows around fibers (e.g., of a nonwoven layer) and / or yarns (e.g., of a knit and / or woven textile), after which the thermoplastic polymer material solidifies to at least partially encapsulate the fibers and / or yarns. In some examples, the bond between the matrix and the fiber or yarn can be mechanical in nature, such as where the thermoplastic polymer material has a lower melting temperature than the material of the fiber or yarn, and the softened or melted thermoplastic polymer material at least partially flows around the fiber or yam structure and solidifies. In some examples, the bond between the matrix and the fiber or yam can be chemical in nature (e.g., include cross-linking), such as when reactive functional groups form bonds between the matrix and the fiber or yam upon the application of heat.

[0048] In some examples, the connection between components of the composite textile can include a thermal weld, such as the connection between fibers, yarns, films, foam sheets, coatings, and the like. As used in this disclosure, a thermal weld can include a bond between two components that is formed when at least one of the two components is heated to at least a softening point and is brought into contact with the other of the two components, such that upon cooling, the two components are bonded. In some examples, the two components are bonded by a chemical bond, by a mechanical bond, or by a combination of chemical bonds and mechanical bonds. For example, in some cases, a thermal weld can include chemical bonding based on van der Waals forces, dipole interactions, and / or dispersion forces, although covalent bonding of the components might not necessarily be modified or changed (e.g., neither created or destroyed). In at least some examples, a thermal weld can include a mechanical bond, such as where the softened material of the heated component flows around a portion of the other component and, upon cooling, is solidified to at least partially encapsulate the portion. In at least some examples, at least a small amount of material from a first component might mix with at least a small amount of material from the first component. An extent of mixing can depend on various factors, such as the extent to which one or both components are heated and / or the amount of time during which heat is applied.

[0049] In examples, the combination of the thermoplastic polymer material and the fibers and / or yarns of a textile that is consolidated with the thermoplastic polymer material can be used in various manners in a composite textile. For example, the combination can form a discrete textile layer; can form a layer of a composite textile with multiple other layers (e.g., an innermost layer, an intermediate layer, or an outermost layer); can be used to join one layer to another layer; and the like. In at least some examples, a thermoplastic polymer layer can at least partially form the abrasion resistant layer, the stretch resistant layer, and / or the elastically resilient layer. A thermoplastic polymer layer can, in some cases join the stretch resistant layer to the abrasion resistant layer. In addition, a thermoplastic polymer layer can join the stretch resistant layer to the elastically resilient layer.

[0050] The thermoplastic polymer layer may be a thermo fomred layer, as further described herein. In some examples, the thermoplastic polymer layer may be derived from a thermoplastic polymer adhesive, film, or web used to bond the abrasion resistant layer, the stretch resistant layer, and the elastically resilient layer together. In this example, a first thermoplastic polymer adhesive or film may be positioned between the abrasion resistant layer and the stretch resistant layer, and a second thermoplastic polymer adhesive or film may bepositioned between the stretch resistant layer and the elastically resilient layer. Heat and / or pressure applied to the stacked configuration causes the first and second polymer adhesives or films to at least partially melt creating a bond between the different layers such that the different layers resist delamination. When a nonwoven layer comprising, for example, polyamide and / or polyethylene terephthalate fibers is used for the stretch resistant layer, the melted polymer adhesive or film at least partially or fully encapsulates the fibers of the nonwoven layer. When the melted polymer adhesive or film solidifies to form the thermoplastic polymer layer, the encapsulated fibers are generally locked into place and stretch resistance is imparted to the stretch resistant layer. In some examples, the combination of the polymer with the fibers of the nonwoven can form a fiber-reinforced layer.

[0051] The term “thermoformed layer” refers to a unitary structure formed after pressure is applied to the melted thermoplastic material of the sheath of the core / sheath yarn when a knit textile is used for the abrasion resistant layer. The pressure causes the melted thermoplastic material to flow. The melted thermoplastic material solidifies or hardens upon cooling. As such, the thermoformed layer may comprise the same polymeric material as the thermoplastic material used to form the sheath of the yams used to form the abrasion resistant layer.

[0052] The term “abrasion resistant layer” as used herein generally means a layer that resists surface wear or deterioration caused by contact with another material. In one example, abrasion resistance may be measured using the test standard ASTM D4966-22, ASTM D3886, or other similar Stoll Abrasion Test Methodology and expressed in Martindale units, such that an abrasion resistant layer is one that scores at least a threshold number of cycles pursuant to the testing methodology (c.g., where the threshold number is consistent with footwear specification norms or common practice). In some examples, an abrasion resistant layer comprises a layer that, when subjected to the ASTM D3886 or similar methodology, scores at least 300 cycles before formation of an abraded area having a 1 cm diameter.

[0053] The term “stretch resistant layer” as used herein generally means a layer that resists stretch or elongation along one or more axes (e.g., an x-axis and a y-axis) or in a machine direction and / or a cross-machine direction when a tensioning force is applied in the machine direction and / or cross-machine direction. The resistance to stretch may be measured using the test standard ASTM D5034 and expressed as force / cross-sectional area. In example aspects, the stretch resistant layer as described herein may have an elongation of about less than 15% in both the machine direction and the cross-machine direction when subject to a force that is consistent with footwear specification norms or common practice.

[0054] The term “elastically resilient layer” as used herein generally means a layer that has the ability to absorb energy when it is deformed elastically and release the energy upon unloading. Elastic resilience may be measured, for example, using the test standard ASTM D3574 and expressed in the units joule per cubic meter (modulus of resilience).

[0055] An example of an elastically resilient layer can include a layer of foamed material (e.g., a sheet of foamed material that is coupled with one or more other layers in a composite textile) that compositionally includes an elastomer. In at least some examples, this type of elastically resilient layer can be referred to as a foamed elastomer layer. A foamed material can include a substance (e.g., solid or semi-solid) that includes gas dispersed within a continuous solid matrix, forming a cellular or cell-like structure (e.g., open or closed). In examples, the substance can be polymer, and various foaming agents can be used (e.g., chemical, physical, thermal expansion, etc.).

[0056] The term “knit” such as used herein to describe the some or all portions of the upper refers to a textile piece that is formed from at least one yarn that is manipulated (e.g., with a knitting machine) to form a plurality of intermeshed loops (also known as interlooping) that define courses and wales. Knit can include weft knit and warp knit.

[0057] The term “nonwoven” as used herein refers to a textile formed from a collection of fibers and / or filaments that are mechanically, thermally, or chemically manipulated to form a mat-like material. Stated differently nonwoven textiles are directly made from fibers and / or filaments. The nonwoven textile may include different webs of fibers formed into a cohesive structure, where the different webs of fibers may have a different or similar composition of fibers and / or different properties. Examples of nonwoven textiles can include a fiber web formed with staple fibers, spunbond nonwovens, spunlace nonwovens, melt-blown nonwovens, airlaid nonwovens, web-laid nonwovens, and the like, and any and all combinations thereof. Spunbond nonwovens in general are commercially available, inexpensive, and lightweight.

[0058] The fibers used to form the nonwoven layers described herein may comprise different materials (e.g., cotton, nylon and the like) including polyester, such as polyethylene terephthalate. The fibers may include virgin material fibers (fibers that have not been recycled) and / or recycled material fibers and / or filaments. Recycled fibers include “shredded-article fibers” and / or “re-pelletized-polymer fibers.” As used herein, shredded- article fibers include fibers that are direct by-products of shredding a fiber-containing article (e.g., knit, woven, nonwoven, etc.). In some examples, shredded-article fibers may be derived without pelletizingand extrusion through processes that consume less energy, and as such, textiles that incorporate shredded-article fibers may have a lower carbon footprint. Re-pelletized-polymer fibers include fibers that are extraded from pelletized or chipped by-products derived from polymer- containing sources (e.g., polymer-containing bottles or containers; polymer-fiber articles that are knit, woven, nonwoven; roll goods; textile manufacturing scrap; fiber webs at various stages of carding, lapping, pre-needling, and needling; etc.).

[0059] The term “about” as used herein generally means within ±10% of an indicated value unless stated otherwise.

[0060] FIGs. 1 and 2 respectively schematically depict a medial view and a lateral view of an example article of footwear 100 having an upper 110, and a sole structure 112 secured to the upper 110. The upper 110 includes an outermost-facing surface 111 and an innermost- facing surface (not readily seen in the views but should be understood to be opposite the outermost-facing surface 111). The upper 110 may be partially or entirely formed from a composite textile of the present disclosure (e.g., stacked configuration of different material layers). The article of footwear 100 is shown in the form of an athletic shoe but other types of shoes (e.g., sandals, leisure shoes, and the like) are contemplated herein.

[0061] The article of footwear 100 includes a forefoot region 114 having a toe end 115, a midfoot region 116, and a heel region 118 having a heel end 119, a medial side 120 (seen in FIG. 1), and a lateral side 122 (seen in FIG. 2). The article of footwear 100 includes an ankle collar 124 defining an opening to a void 126 for receiving a wearer’s foot, and an instep area 128. In example aspects, the instep area 128 may extend at least partially between the toe end 115 and a forward edge 125 of the ankle collar 124 and is configured to cover or overlie an instep area of a wearer’s foot when the article of footwear 100 is worn. In example aspects, the instep area 128 may comprise a tongue (not shown) where the tongue may be integrally formed with the upper 110, or the tongue may comprise a separate element that is secured to the upper 110. In some examples, a footwear article 100 can include a vamp that generally extends in the toe box and towards the laces, throat, or instep region. In some examples, there may not be precise, black and white delineations between these regions, and they can be used to generally orient the relative positions of elements of the footwear article 100.

[0062] Although not shown, aspects herein contemplate that the article of footwear 100 may include additional elements layered on top of the upper 110 including, for example, leather materials, synthetic leather materials, knitted or woven textiles, polymer skins, and the like. The additional elements may be positioned at discrete locations of the upper 110 including, forexample, the toe end 115 (e.g., a toe cap), the heel end 119 (e.g., a heel counter), and the like. FIG. 3 illustrates a top down view of the article of footwear 100 and further depicts the instep area 128 of the upper 1 10 extending between the toe end 115 and the forward edge 125 of the ankle collar 124. FIG. 4 depicts a rear view of the article of footwear 100 and illustrates the heel end 119 of the article of footwear 100.

[0063] In example aspects, all or portions of the upper 110 may comprise a composite textile including a stacked configuration of material layers. FIG. 5 schematically depicts a cross-section of an example stacked configuration 500 that may be used to form all or portions of the upper 110 where the stacked configuration 500 has not yet been processed. In examples, the stacked configuration 500 comprises an abrasion resistant layer 510, an elastically resilient layer 512 (e.g., foamed elastomer layer), and a stretch resistant layer 514 positioned between the abrasion resistant layer 510 and the elastically resilient layer 512. Further description of the abrasion resistant layer 510, the elastically resilient layer 512, and the stretch resistant layer 514 is provided below.

[0064] FIG. 5 further depicts a first adhesive layer 516 positioned between the stretch resistant layer 514 and the abrasion resistant layer 510 and a second adhesive layer 518 positioned between the stretch resistant layer 514 and the elastically resilient layer 512. The material composition of the first and / or second adhesive layers 516 and / or 518 is selected to achieve a desired adherence or bonding between the abrasion resistant layer 510, the elastically resilient layer 512, and the stretch resistant layer 514.

[0065] The first adhesive layer 516 can include various elements. For example, the first adhesive layer 516 can include a thermoplastic material in one or more various forms. In some instances, the thermoplastic material can be a thermoplastic elastomer. The thermoplastic material can, in some examples, include a liquid applied through spraying, printing, knife coating, etc. In some instances, the thermoplastic material can include a fdm, such as a hotmelt film. In at least one example, the first adhesive layer 516 may comprise a thermoplastic polyurethane film (commonly known as a TPU hotmelt) having a basis weight from about 20 grams per square meter (gsm) to about 40 gsm, from about 25 gsm to about 38 gsm, or about 30 gsm. In some examples, the first adhesive layer 516 can include a polyether-block-amide (commonly known as PEBA or PEBAX®). In at least some examples, the first adhesive layer 516 can include a melt-blown, low-melt TPU.

[0066] The second adhesive layer 518 can include various elements. For example, the second adhesive layer 518 can include a thermoplastic material in one or more various forms.In some instances, the thermoplastic material can be a thermoplastic elastomer. The thermoplastic material can, in some examples, include a liquid applied through spraying, printing, knife coating, etc. In some instances, the thermoplastic material can include a fdm, such as a hotmelt film. In at least one example, the second adhesive layer 518 can include a polyether-block- amide film having a basis weight from about 20 gsm to about 40 gsm, from about 25 gsm to about 38 gsm, or about 30 gsm. Alternatively, the second adhesive layer 518 can include a thermoplastic polyurethane film. In at least some examples, the second adhesive layer 518 can include a melt-blown, low-melt TPU.

[0067] In at least some examples, the first adhesive layer 516 and / or the second adhesive layer 518 can include a thermoset adhesive, such as (but not limited to) a PU thermoset adhesive. For example, the thermoset adhesive can be applied across the stretch resistant layer 514 in one or more different forms, such as a liquid, film, powder, etc., which is then stacked with the elastically resilient layer 512 and / or the abrasion resistant layer 510 and heated or exposed to some other curing catalyst. Upon curing, the adhesive can bond to the stretch resistant layer 512 (e.g., fibers of a nonwoven) and to one or more of the other layers 510 and / or 514. In some examples, the adhesive can also form a polymer matrix that reinforces the stretch resistant layer 512 (e.g., the fibers and / or web of a nonwoven layer).

[0068] In some examples, the first adhesive layer 516 and / or the second adhesive layer 518 can be omitted as a layer that is discrete from the other layers. For instance, the first adhesive layer 516 might be omitted in an example of the composite textile in which the abrasion resistant layer 510 includes a liquid coating or top coat that is applied and then solidified by drying, curing, cooling, etc. In another instance, the second adhesive layer 518 might be omitted if the stretch resistant layer 514 is embedded or otherwise combined with an adhesive (e.g., a thermoplastic or thermoset matrix).

[0069] FIG. 6 schematically depicts, as a composite textile, a cross-section of the stacked configuration 500 of FIG. 5 (also referred to herein as “composite textile 500”) after processing which may involve the application of heat and / or pressure to the stacked configuration 500 for a predetermined period of time. In one example, the processing of the stacked configuration 500 causes the first adhesive layer 516 to soften and / or melt which secures the abrasion resistant layer 510 to the stretch resistant layer 514 once the stacked configuration 500 has cooled and the material from the first adhesive layer 516 has solidified. The processing of the stacked configuration 500 further causes the second adhesive layer 518 to soften and / or melt which secures the elastically resilient layer 512 to the stretch resistant layer 514 once thestacked configuration 500 has cooled and the material from the second adhesive layer 518 has solidified. The result is a cohesive structure (e.g., composite textile) that resists delamination. As depicted in FIG. 6, the abrasion resistant layer 510 forms the outermost-facing surface 1 11 of the upper 110, and the elastically resilient layer forms an innermost-facing surface 610 of the upper 110.

[0070] FIG. 7 schematically depicts a perspective view of an example material layer that can form at least part of the abrasion resistant layer 510. As described, the abrasion resistant layer 510 forms the outer-facing surface, and in examples, the outermost-facing surface 111 of the upper 110. In examples, the abrasion resistant layer 510 may comprise a smooth texture as shown at area 710. In other examples, the abrasion resistant layer 510 may comprise one or more textures 711 (e.g., leather grain or other pattern) as shown at area 712 to impart a desired surface feel, a desired aesthetic, and the like. The texture 711 may be imparted using a textured release paper although other ways of imparting texture to a substrate such as printing are contemplated herein. The abrasion resistant layer 510 can, in some examples, include a pigment or a dye, which can impart a color to the composite textile.

[0071] In examples, the abrasion resistant layer 510 may exhibit elastic resilience in the x, y plane and in the z-direction. The abrasion resistant layer 510 may be formed of materials that are able to resist surface wear or deterioration caused by contact with another material or object or surface such as a ground surface.

[0072] In one example, the abrasion resistant layer 510 may be formed of a polymer material, which can be applied in various forms, such as but not limited to, a sheet of a polymer material (e.g., a film); a liquid polymer that is applied as a coating (e.g., sprayed, printed, direct extrusion, knife coating, etc.) and solidified or cured; polymer-material deposition (e.g., fiber deposition or particle deposition); and the like. In some examples, although the polymer material can be coupled to an underlying substrate (e.g., a stretch resistant layer 514, such as a nonwoven or reinforced nonwoven) in different manners (e.g., any of the above manners or other manners, such as a preformed sheet or as a liquid coating / topcoat), when fully incorporated into the composite textile 500, the polymer material forms a continuous polymer layer on the outer surface of the composite textile, and the continuous polymer layer can impart abrasion resistance to the composite textile. The continuous polymer layer can impart other properties in various examples, such as color, texture, water-resistance, and the like.

[0073] In at least some examples, a polymer film can include a continuous sheet of a polymer material that is preformed, prior to integration into the composite textile. In addition,a polymer film is often coupled to an underlying substrate (e.g., the stretch resistant layer 514) via a separate bonding layer, such as an adhesive, hotmelt, and the like. In some examples, a polymer coating can include a non-solid polymer material (e.g., liquid, paste, power, etc.) that is applied directly to the underlying substrate, after which the polymer coating solidifies. That is, the polymer coating couples directly to the substrate without a separate bonding layer, often at least partially penetrating into the substrate and bonding via chemical and / or physical adhesion. For example, when the stretch resistant layer 514 includes a nonwoven layer with fibers, the polymer coating can at least partially penetrate into the fiber web and bond directly to the fibers of the nonwoven layer. Both the polymer film and the polymer coating can form a continuous polymer layer.

[0074] In some examples, the abrasion resistant layer 510 can include one or more layers of the polymer material. For example, the abrasion resistant layer 510 can include a single layer of a polymer material or a plurality of layers of a polymer material. In at least some examples, the one or more layers of the polymer material can be applied via screen print (e.g., screen printing of a paste) or other techniques that are effective to apply a coating or topcoat. For example, a first layer of the polymer material can be applied via a first screen print pass or set of passes. In addition, one or more layers of polymer material can be added on top of the first layer via one or more additional screen print passes to build up the abrasion resistance layer 510. These passes can be used in different combinations to apply coatings with different properties (e.g., thickness, color, composition, etc.) to impart zonal properties to the upper.

[0075] The polymer of the abrasion resistant layer 510 can be one or more various polymers. For example, the polymer can include a polyolefin (“PO”) (e.g., polyethylene, polypropylene, etc.), a polyester (e.g., polyethylene terephthalate), a polyamide (e.g., nylon), or a polyurethane. In some examples, the polymer can include a thermoplastic polymer (e.g., TPU, TPO, TPE, etc.), an elastomer, a thermoset polymer, a thermoplastic elastomer, a thermoset elastomer, or any combination thereof.

[0076] In at least some examples, the abrasion resistant layer 510 can include a polyurethane film (commonly known as a PU skin). In other aspects, the abrasion resistant layer 510 may be formed from a thermoplastic polyurethane (e.g., TPU) film or a thermoplastic polyolefin (e.g., TPO) film. Any and all aspects, and any variation thereof, are contemplated as being within the scope herein.

[0077] FIGs. 8A and 8B schematically depict a cross-section of a knit textile 800 that alternatively may be used for the abrasion resistant layer 510. FIG. 8 A schematically depictsthe knit textile 800 before processing, and FIG. 8B schematically depicts the knit textile 800 after processing. With respect to FIG. 8A, in one example, the knit textile 800 before processing may be formed of a yam(s) 805 having a core / sheath configuration as shown in the enlarged view which depicts a core 810 extending longitudinally along a length of the yarn 805 and a sheath 812 that surrounds the core 810. The core 810 may comprise a high-melting polymer yarn (e.g., a polymer having a relatively higher melting temperature) including polyethylene terephthalate yams, recycled polyethylene terephthalate yarns, polyamide yams, elastane yams, and other high-melting synthetic yarns. The sheath 812 may comprise a thermoplastic material having a melting point lower than a melting point of the core 810. For example, the sheath 812 may comprise a synthetic polymeric material formed from a polymer that melts at relatively low temperatures. In example aspects, the sheath 812 may comprise a thermoplastic polyurethane (TPU) material, a thermoplastic polyethylene (TPE) material, and other synthetic polymeric materials having a low melting point.

[0078] FIG. 8B schematically depicts a cross-section of the knit textile 800 after processing. During processing, heat and pressure are applied to at least the knit textile 800. The application of heat is adjusted such that, in example aspects, it is equal to or greater than the melting point of the thermoplastic material of the sheath 812 of the yam 805 and is less than the melting point of the core 810 of the yam 805. The application of heat causes the thermoplastic material of the sheath 812 to melt, and the application pressure causes the melted material to flow. Thus, after processing, the yarn 805 that is interlooped can include the core 810 and a lesser amount of the sheath 812 (or no amount of the sheath) as shown in the enlarged view (since the sheath is thcrmo-proccsscd into the matrix).

[0079] After cooling the knit textile 800, a thermoformed layer 814 is formed. Although FIG. 8B depicts the thermoformed layer 814 fully encapsulating the knit textile 800, aspects herein contemplate that the thermoformed layer 814 partially encapsulates the knit textile 800. In examples where the thermofonned layer 814 fully encapsulates the knit textile 800, a first surface 816 of the thermoformed layer 814 may form, at least in part, the outermost-facing surface 111 of the upper 110. An opposite second surface 818 of the thermoformed layer 814 is secured to the stretch resistant layer 514. For example, the second surface 818 of the thermoformed layer 814 can be coupled by way of the polymer material of the sheath forming mechanical and / or chemical bonds with the structures (e.g., fibers, yams, etc.) of the stretch resistant layer 514. In some examples, another adhesive layer can bond the thermoformed layer 814 with the stretch resistant layer 514. In aspects where the thermoformed layer 814 partiallyencapsulates the knit textile 800, the loops of the knit textile 800 may form, at least in part, the outermost-facing surface 111 of the upper 110.

[0080] Tn examples, the structure depicted in FIG. 8B may provide abrasion resistance by way of the thermoformed layer 814. Additionally, the thermoformed layer 814 in combination with the knit textile 800 may provide a relatively greater coefficient of friction to the outermost- facing surface 111 of the upper 110 compared to, for example, the abrasion resistant layer 510 formed from the polyurethane, thermoplastic polyurethane, and / or olefin materials. This may be at least partially due to various elements, such as the interlooping of the yarn 805 and the texture provided by the knit structure, the coefficient of friction imparted by the polymer of the melted sheath, etc. This may be advantageous when the article of footwear 100 is used for sports such as global football (i.e., soccer), where the increased coefficient of friction may help to “grip” a soccer ball and achieve greater ball control for the wearer.

[0081] FIG. 9A schematically depicts a cross-section of an example nonwoven layer 900 with fibers 905 before the stacked configuration 500 has been processed, where the nonwoven layer 900 is used to form, at least in part, the stretch resistant layer 514. The nonwoven layer 900 may comprise a spunbond nonwoven formed from, for example, fibers such as fiber 905. In some examples, the nonwoven layer 900 can include other nonwoven textiles, such as an airlaid nonwoven, wet-laid nonwoven, meltblown, spunlace, needle-punched staple fiber webs, and the like. The fibers may comprise high-melting fibers such as polyamide fibers, polyethylene terephthalate fibers, recycled polyethylene terephthalate fibers, and the like. The fibers that form the nonwoven layer 900 may be thermally bonded to each other as one example although aspects herein also (or alternatively) contemplate the fibers being chemically bonded to each other and / or mechanically entangled with each other.

[0082] In at least some examples, the fibers 905 can include silicone-infused fibers. As used herein, silicone-infused fibers can include a fiber can be formed by a dispersion (e.g., solid dispersion) of a first synthetic polymer (e.g., polyester or PET or polyamide) with a silicone polymer. For example, fibers can be formed by a solid dispersion of the first synthetic polymer and silicone. In at least some examples, the first synthetic polymer and the silicone can be mixed or blended prior to the resulting polymer matrix being extruded into the fiber form. In some examples, fibers can be “infused” with silicone (e.g., silicone-infused fibers), and as used herein “infused” describes that the silicone is included in the solid dispersion that forms the fiber. In some examples, the silicone can be homogenously mixed throughout the solid dispersion (e.g., the silicone mixed with one or more other synthetic polymers, such aspolyester or polyamide). In addition, the silicone can be included in various amounts, and in some examples, the fiber comprises between 0.1 and 20 weight % silicone (and one or more other synthetic polymers). In at least some examples, the silicone is present at room temperature (25° C.) in the form of dispersed, compacted inclusions which as a result of thermoplastic processing, e.g. by blending in the melt extruder, are distributed substantially homogeneously in the polymer matrix of the polymer fibers. In examples, the silicone may or may not chemically bond with other polymers in the solid dispersion.

[0083] In some examples, spunbond nonwovens may be desirable because they are widely commercially available, they are breathable, and are relatively inexpensive. In addition, spunbond nonwoven textiles can be relatively thin, which can contribute to a thin overall composite. In examples, the spunbond nonwoven may be lightweight which helps to reduce the overall weight of the article of footwear 100. For example, the spunbond nonwoven may have a basis weight of from about 20 gsm to about 60 gsm, or from about 30 gsm to about 50 gsm, although other weights are contemplated herein.

[0084] Because nonwovens are generally formed from fibers that are interlocked through, for example, thermal bonding, mechanical entanglement, or chemical bonding, the fibers may pull apart or disengage from one another when the nonwovens are subject to a tensioning force in either the machine direction or the cross-machine direction of the nonwoven. This can result in the textile tearing. To help lock the fibers into place, aspects herein contemplate embedding some or all of the fibers of the nonwoven layer 900 within a polymer matrix, which can include a thermoplastic polymer matrix, a thermoset polymer matrix, an elastomeric polymer matrix, or a hybrid matrix with a blend of polymers combining any two or more of these polymer matrices. This is illustrated in FIG. 9B which schematically depicts, after the stacked configuration 500 has been processed, a cross-section of the nonwoven layer 900 with the fibers 905 embedded in a polymer layer 910, which is represented by the diagonal hatch fill. In at least some examples, the nonwoven layer 900 with the fibers 905 at least partially incorporated in the polymer matrix can be referred to as a “fiber-reinforced layer.”

[0085] Although FIG. 9B depicts the nonwoven layer 900 fully embedded in the polymer layer 910, aspects herein contemplate that the nonwoven layer 900 may be only partially embedded within the polymer layer 910. Although the polymer layer 910 is not shown in FIG. 6, in at least some examples associated with FIG. 6 in which the stretch resistant layer 514 includes fibers, the fibers can be at least partially embedded in the polymer layer 910.

[0086] In examples, the material of the polymer layer 910 may derive from one or more of the first adhesive layer 516 and / or the second adhesive layer 518. For example, during processing of the stacked configuration 500, one or more of the first adhesive layer 516 and the second adhesive layer 518 melts and penetrates the nonwoven layer 900. After cooling, the melted material from the first adhesive layer 16 and / or the second adhesive layer 518 solidifies thereby encapsulating some or all of the fibers of the nonwoven layer 900 and locking the fibers into place such that the entrapped fibers do not pull apart and / or disengage when subject to a tensioning force. In some examples, the polymer layer 910 can derive from the thermoformed layer 814.

[0087] In examples, the material of the polymer layer 910 may derive from one or more polymer webs (e.g., meltblown, low-melt polymer) or other polymer sheets that can be stacked with the nonwoven layer 900. For example, during processing of the stacked configuration 500, the polymer web(s) stacked with the nonwoven layer 900 can melt and mechanically and chemically bond with the nonwoven layer 900. After cooling, the melted material from the polymer solidifies, thereby encapsulating some or all of the fibers 905 of the nonwoven layer 900 and locking the fibers into place such that the entrapped fibers do not pull apart and / or disengage when subject to a tensioning force. In at least some examples, the polymer web can include a TPU.

[0088] In at least some examples, the nonwoven layer 900 can include a nonwoven textile (e.g., spunbond, wetlaid, airlaid, etc.) that, prior to being integrated into the stacked configuration, is pre -integrated with a thermoplastic sheet, such as another nonwoven that includes fibers made of a thermoplastic polymer material. For example, the nonwoven layer 900 can include a first nonwoven textile with fibers made of a first polymer having a higher melting point, and the first nonwoven textile can be combined with a second nonwoven textile having fibers made of a second polymer having a lower melting point, such as by heating the layers and pressing the first nonwoven into the softened or melted fibers of the second nonwoven. In examples, a large part of the fiber network can be locked in place by the entire low melt matrix. The consolidated first nonwoven layer and second nonwoven layer can form the stretch resistant layer 514 and can be combined with the abrasion resistant layer 510 and the elastically resilient layer 512. For example, the thermoplastic polymer of the consolidated layers can be used to bond with the other layers and / or the first adhesive layer 516 and / or the second adhesive layer 518 can join the layers.

[0089] In some examples, the nonwoven layer can be combined with a hotmelt, which forms the polymer layer 910, to form the fiber- reinforced layer.

[0090] FIG. 10A schematically depicts a cross-section of a second example nonwoven layer 1000 before the stacked configuration 500 has been processed, where the nonwoven layer 1000 is used to form, at least in part, the stretch resistant layer 514. The nonwoven layer 1000 can include any one or more combinations of features described with respect to the first nonwoven layer 900. In some examples, the second nonwoven layer 1000 can include a spunbond non woven formed from low-melting fibers, such as fiber 1005. One example of low- melting fibers may comprise thermoplastic polyurethane fibers. After the stacked configuration 500 has been processed, the low-melting fibers of the nonwoven layer 1000 melt, and upon cooling the melted material solidifies to form a thermoplastic polymer layer 1010 as schematically depicted in the cross-section view of FIG. 10B. In this example aspect, the stretch resistant layer 514 comprises the thermoplastic polymer layer 1010.

[0091] As described, the stretch resistant layer 514 is generally resistant to stretch in an x, y plane (e.g., a machine direction and a cross-machine direction) when subject to a tensioning force and is used to impart structural stability to the upper 110 which not only helps to support a wearer’s foot but also helps the upper 110 to maintain its shape over the lifespan of the article of footwear 100. For example, both the abrasion resistant layer 510 and the elastically resilient layer 512 by themselves (i.e., when not in the stacked configuration 500) exhibit resilient stretch in the x, y plane when subject to a tensioning force. Using these two layers by themselves (i.e., without the stretch resistant layer 514) to form the upper 110 would, in at least some instances, cause the upper 110 to lack desired structure and support for certain use cases, and the upper 110 would not provide sufficient containment of a wearer’s foot for certain activities. Stated differently, there would be a relatively high degree of stretch along the surface plane of the upper 110. The stretch resistant layer 514 is used to minimize stretch along the surface plane of the upper 110 such that it provides needed support and structure to the upper 110 and provides containment of the wearer’s foot.

[0092] Continuing, placement of the stretch resistant layer 514 between the abrasion resistant layer 510 and the elastically resilient layer 512 enables each of the abrasion resistant layer 510 and the elastically resilient layer 512 to resiliently compress and / or elongate in a direction orthogonal to the surface plane of the upper 110 when the upper 110 is subject to flexion while still providing resistance to stretch along the surface plane of the upper 110. The ability of the abrasion resistant layer 10 and the elastically resilient layer 512 to resilientlycompress and / or elongate enables the upper 110 to “spring-back" after flexion, or extension, thus reducing the formation of wrinkles and / or creases.

[0093] By contrast, if the stretch resistant layer 514 was positioned on the inner- facing surface of the stacked configuration 500, and if the elastically resilient layer 512 was positioned between the abrasion resistant layer 510 and the stretch resistant layer 514, the stretch resistant layer 514 would constrain at least the compression of the abrasion resistant layer 510 when the upper 110 is subject to flexion toward an interior of the article of footwear 100 in a direction orthogonal to the surface plane of the upper 110. This, in turn, may lead to creasing or buckling of the abrasion resistant layer 510. Thus, placement of the stretch resistant layer 514 between the abrasion resistant layer 510 and the elastically resilient layer 512 is an intentional choice to achieve a desired functional effect.

[0094] FIG. 11 A schematically depicts a perspective view of a third example structure used to form, at least in part, the stretch resistant layer 514. To provide an even greater resistance to stretch in the x, y plane, a first nonwoven layer 1100 and a second nonwoven layer 1110 may both be used, where the second nonwoven layer 1110 is positioned overtop the first nonwoven layer 1 100. Each of the first nonwoven layer 1 100 and the second nonwoven layer 1110 may be formed of high-melting fibers such as polyethylene terephthalate fibers, recycled polyethylene terephthalate fibers, polyamide fibers, and the like. To ensure that the resistance to stretch is generally uniform in both the x-direction and the y-direction, a machine direction 11 12 of the second nonwoven layer 1 110 may be positioned orthogonal to a machine direction 1114 of the first non woven layer 1100.

[0095] FIG. 11B schematically depicts a cross-section of the first nonwoven layer 1100 and the second nonwoven layer 1110 after the stacked configuration 500 has been processed. One or more of the first nonwoven layer 1100 and the second nonwoven layer 1110 are embedded in a thermoplastic polymer layer 1116. Although FIG. 1 IB depicts each of the first nonwoven layer 1100 and the second nonwoven layer 1110 fully embedded in the thermoplastic polymer layer 1116, aspects herein contemplate that the first and / or second nonwoven layers 1100 and 1110 may be only partially embedded within the thermoplastic polymer layer 11 16. In examples, the material of the thermoplastic polymer layer 1 1 16 may derive from one or more of the first adhesive layer 516, the second adhesive layer 518, and / or another thermoplastic polymer web or sheet that is stacked with or consolidated with the first nonwoven layer 1100 and / or the second nonwoven layer 1110. The thermoplastic polymer layer 1116 encapsulates one or more of the fibers of the first nonwoven layer 1100 and / or thesecond nonwoven layer 1110 helping to lock these fibers into place and provide generally uniform stretch resistance to the stretch resistant layer 514 in both the machine direction 1114 of the first nonwoven layer 1100 and the machine direction 1 112 of the second nonwoven layer 1110.

[0096] FIG. 12 schematically depicts a perspective view of yet another example layer that may be used for the stretch resistant layer 514. In FIG. 12, a woven textile 1200 is depicted. In aspects, the woven textile 1200 may comprise a lightweight or ultra-lightweight woven textile having a weight of about 100 gsm or less, about 80 gsm or less, or about 60 gsm or less. The woven textile 1200 may be tightly woven (e.g., 200 threads / inch or higher) and may be formed from high tenacity yams such as nylon monofilament yams. The result is a textile that is lightweight and resistant to stretch. The woven textile 1200 is secured to each of the abrasion resistant layer 510 and the elastically resilient layer 512 by way of the first adhesive layer 516 and the second adhesive layer 518.

[0097] FIG. 13 schematically depicts a perspective view of a foam layer 1300 that may be used for the elastically resilient layer 512. The foam layer 1300 may comprise an open cell foam or a closed cell foam having a thickness ranging from, for example, about 0.5 mm to about 5.0 mm, or from about 1.0 mm to about 4.0 mm, or from about 1.5 mm to about 3.5 mm, or from about 2.0 mm to about 3.0 mm, or about 2.5 mm. The thickness selected for the foam layer 1300 may add a desired body thickness to the upper 110. In some examples, the foam layer can contribute to the upper holding its three-dimensional shape and / or to preventing the upper from collapsing in on itself.

[0098] The foam layer 1300 that makes up the elastically resilient layer 512 can include various forms. In at least some examples, the foam layer 1300 comprises a sheet or slab of a foamed material, such as a foamed polymer material. In at least some examples, the foam layer 1300 comprises a foamed elastomer layer, which can include a base elastomer material subjected to a foaming process to create a closed-cell or open-cell foam. The base elastomer can include one or more various elastomers, such as PU, EVA, thermoplastic elastomers, silicone rubber, neoprene, and the like.

[0099] The foam layer 1300 may comprise a polyurethane foam, an ethylene vinyl acetate foam, a polyethylene foam, a polystyrene foam, a thermoplastic polyurethane foam, and the like. The foam layer 1300 before the stacked configuration 500 is processed is generally elastically resilient in the x, y plane and in the z-direction. After the stacked configuration 500 is processed, the foam layer 1300 maintains its elastic resilience in the z-direction but its stretchin the x, y plane is restricted due to the stretch resistant layer 514. When the stacked configuration 500 is formed into the upper 110, the foam layer 1300 is elastically resilient in a direction orthogonal to the surface plane of the upper 1 10 such that it “springs back” after being flexed. As described, this feature reduces the formation of wrinkles and / or creases.

[0100] In at least one example, the foam layer 1300 can include a polyurethane foam (e.g., open-cell polyurethane foam), which includes an Asker C hardness in a range from 5 to 40, or from 10 to 35, or from 15 to 30, or from 20 to 25, or about 23 and which includes a density (g / cm3) that is in a range from 0.05 to 0.60, or from 0.10 to 0.55, or from 0.15 to 0.50, or from 0.20 to 0.45, or from 0.25 to 0.40, or from 0.30 to 0.35. In some examples, the polyurethane foam can include a Shore hardness in a range of 50 to 90, or from 60 to 80, or about 70 and include a density (g / cm3) in a range from 0.10 to 0.20, or from 0.12 to 0.18, or about 0.15.

[0101] In at least one example, the foam layer 1300 can include a polyurethane foam (e.g., open-cell polyurethane foam), which includes an Asker C hardness in a range from 25 to 40, or from 29 to 37, or about 33 and which includes a density (g / cm3) that is equal to or less than 0.20, or equal to or less than 0.18, or equal to or less than 0.16. An example of a foamed material that can construct the foam layer 1300 is the Dreamcell® Performance foam, version 3R P33 (by Dahsheng) or an equivalent thereof.

[0102] In at least some examples, the foam layer 1300 can include a polyurethane foam (e.g., open-cell PU foam), which includes an Asker C hardness in a range from 10 to 22, or from 13 to 19, or about 16 and which includes a density (g / cm3) that is in a range from 0.05 to 0.20, or 0.07 to 0.17, or 0.10 to 0.15. An example of a foamed material that can construct the foam layer 1300 is the Drcamccll® foam, version 3R HR 16 or version HR 16 (by Dahsheng) or an equivalent thereof.

[0103] In at least one example, the foam layer 1300 can include a polyurethane foam (e.g., open-cell PU foam), which includes an Asker C hardness in a range from 15 to 30, or from 19 to 27, or about 23 and which includes a density (g / cm3) that is equal to or less than 0.20, or equal to or less than 0.17, or equal to or less than 0.15. An example of a foamed material that can construct the foam layer 1300 is the Dreamcell® Performance foam, version 3R P23 (by Dahsheng) or an equivalent thereof.

[0104] In at least one example, the foam layer 1300 can include an EVA foam (e.g., closedcell EVA foam), which includes an Asker C hardness in a range from 15 to 50, or from 20 to 45, or from 25 to 40, or from 30 to 35, or about 33 and which includes a density (g / cm3) thatis in a range from 0.05 to 0.60, or from 0.10 to 0.55, or from 0.15 to 0.50, or from 0.20 to 0.45, or from 0.25 to 0.40, or from 0.30 to 0.35..

[0105] In at least one example, the foam layer 1300 can include an EVA foam (e.g., closedcell EVA foam), which includes a Asker C hardness in a range of 20 to 30, or from 22 to 28, or about 25 and which includes a density (g / cm3) that is in a range of about 0.050 to about 0.110, or about 0.060 to about 0.100 or about 0.064 to about 0.096. An example of a foamed material that can construct the foam layer 1300 is the Durapontex® Qinetiq foam, version QS25 (by Dahsheng) or an equivalent thereof.

[0106] In at least one example, the foam layer 1300 can include an EVA foam (e.g., closedcell EVA foam), which includes a Asker C hardness in a range of 25 to 35, or from 27 to 33, or about 30 and which includes a density (g / cm3) that equal to or less than 15, or equal to or less than 13, or equal to or less than 11. An example of a foamed material that can construct the foam layer 1300 is the Durapontex® Shield foam, version SH30 (by Dahsheng) or an equivalent thereof.

[0107] In at least one example, the foam layer 1300 can include an EVA foam (e.g., closedcell EVA foam), which includes a Asker C hardness in a range of 16 to 30, or from 20 to 26, or about 23 and which includes a density (g / cm3) that equal to or less than 12, or equal to or less than 10, or equal to or less than 8. An example of a foamed material that can construct the foam layer 1300 is the Durapontex® Supreme foam, version 3R S23 (by Dahsheng) or an equivalent thereof.

[0108] FIGs. 14A and 14B respectively depict perspective views of front and back surfaces of a knit spacer textile 1400 that may be used for the elastically resilient layer 512. The term “knit spacer textile” is meant to encompass both warp knit and weft knit spacer textiles as is known in the art of textiles. The knit spacer textile 1400 is generally formed by utilizing at least one tie yarn 1405 to interknit a first knit layer 1410 and a second knit layer 1412. More specifically, each of the first knit layer 1410 and the second knit layer 1412 may be knit separately, and the tie yarn(s) 1405 is used to connect the first knit layer 1410 and the second knit layer 1412. For instance, the tie yam(s) 1405 may have “loop” portions that extend into each of the first knit layer 1410 and the second knit layer 1412 where the loop portions are interlooped with yarns in the first knit layer 1410 and the second knit layer 1412 to connect the two layers 1410 and 1412. In example aspects, the tie yam(s) 1405 is oriented generally orthogonal to the surface planes of the first and second knit layers 1410 and 1412 and acts to space apart the first and second knit layers 1410 and 1412.

[0109] In examples, one or more of the first knit layer 1410, the second knit layer 1412, and the tie yarn(s) 1405 may comprise an elastic yarn. The term “elastic” as used herein when describing yarns means the ability of a strained or stretched yam (e.g., stretched up to about 400% of its original length) to substantially recover its original length (e.g., within about 10% or more of its original length) within about 60 seconds or less after removing the stress. A nonelastic yarn may exhibit a degree of mechanical stretch but does not substantially recover its original length (e.g., within about 10% or more of its original length) within 60 seconds after removing the stress. Examples of elastic yarn types include, for instance, spandex (also known as elastane), rubber, TPU polymer yarns, LYCRA®, and the like. Due to the presence of the elastic yarns, the knit spacer textile 1400 before the stacked configuration 500 is processed is generally elastically resilient in the x, y plane and in the z-direction. After the stacked configuration 500 is processed, the knit spacer textile 1400 maintains its elastic resilience in the z-direction but its stretch in the x, y plane is restricted by the stretch resistant layer 514. When the stacked configuration 500 is formed into the upper 110, the knit spacer textile 1400 is elastically resilient in at least a direction orthogonal to the surface plane of the upper 110 such that it “springs back” after being flexed.

[0110] Various examples of the composite textile 500 have been described, including various types of layers that can form the abrasion resistant layer 510, the elastically resilient layer 512, and the stretch resistant layer 514. The composite textile 500 can include any combination of these various layers with any combination of the various properties.

[0111] In at least one example of the composite textile 500, the abrasion resistant layer 510 can include a polymer film or skin (e.g., PU film, TPU film, PO film, TPO film, etc.), and the polymer film can be coupled to the stretch resistant layer 514 via a first adhesive layer 516, which can include a hotmelt adhesive. In addition, the elastically resilient layer 512 can include a foamed elastomer layer, which is coupled to the stretch resistant layer 514 via the second adhesive layer 518, which can include a hotmelt adhesive. Further, the stretch resistant layer 514 can include a spunbond nonwoven layer. In some examples, the hotmelt of the first adhesive layer 516 and / or the hotmelt of the second adhesive layer 518 form a matrix that at least partially encapsulates fibers of the spunbond nonwoven.

[0112] In at least one example of the composite textile 500, the stretch resistant layer 514 can include a fiber-reinforced layer, including a non woven textile (e.g., spunbond) with fibers that are at least partially incorporated in a polymer matrix, such as a thermoplastic matrix, thermoset matrix, blended-polymer matrix, etc. The polymer matrix can include one or morevarious types of layers configured to be combined with the nonwoven textile, such as a hotmelt layer, a low-melt polymer web, etc. In addition, the composite textile 500 can include, as the abrasion resistant layer 510, a coating that is applied directly to the fiber-reinforced layer, and the coating can include a polymer coating that is sprayed, screen printed (e.g., as a paste), knife coated / spread, brushed, etc. In some examples, the polymer coating can include one or more layers that are screen printed (e.g., as a paste) directly on the fiber-reinforced layer. That is, a single layer can be screen printed on the fiber-reinforced layer, or multiple layers can be screen printed (e.g., one on top of the next) to build up the abrasion resistant layer 510. The polymer coating can include various thermoset polymers or thermoplastic polymers, such as PU, TPU, PO, TPO, and the like. In at least some examples, the polymer of the polymer matrix can couple the fiber- reinforced layer to an elastically resilient layer 514, which can include a foamed elastomer layer. In at least some examples, an adhesive layer can couple the fiber- reinforced layer to the foamed elastomer layer. For example, the adhesive layer can include a thermoset adhesive layer or a thermoplastic adhesive layer (e.g., hotmelt).

[0113] FIG. 15 schematically depicts the article of footwear 100 in a typical walking and / or running motion. As depicted on the left, along the longitudinal middle of the upper 1 10, the instep area 128 and / or vamp region of the upper 110 (e.g., the portion of the upper extending across the forefoot 114 or toe box) often elastically deforms (e.g., elastically flexes) as the forefoot region 114 of the article of footwear 100 strikes the ground and the heel region 118 and the midfoot region 116 of the article of footwear 100 are elevated. This area that elastically deforms can be referred to as a flex zone. This motion can be described in various manners and might have different components depending on the upper materials and the activity. In some instances, the upper 110 might generally flex inward at the inflexion point. In some examples, the innermost surface of the upper 110 (e.g., formed by the elastically resilient layer 512) can become more convex, whereas the outermost surface of the upper 110 (e.g., formed by the abrasion resistant layer 510) can become more concave. The flexion of the upper 110 in the instep area 128 can be generally asymmetric such that the instep area 128 is flexed inwardly during walking or running but does not flex outward during these motions. That is, the innermost surface may transition between a neutral state and a more convex state, but may not generally flex in the opposite direction between a neutral state and a more concave state. Likewise, the outermost surface may transition between the neutral state and a more concave state, but may not generally flex in the opposite direction between a neutral state and a move convex state. Described differently, the instep area 128 might sometimes flex in a directiontoward the interior of the article of footwear 100 and orthogonal to a surface plane of the instep area 128 of the upper 110. In many instances, this motion of the upper at the inflexion point can cause the elastically resilient layer 512 to elongate as indicated by arrow 1500 and the abrasion resistant layer 510 to compress as indicated by arrow 1510. The stretch resistant layer 514 inhibits or reduces stretch of the upper 110 along the surface plane of the upper 110 thus facilitating support and containment of the wearer’s foot. The composite textile(s) described in this disclosure reduce(s) the likelihood of wrinkles and / or creases developing along the inflexion point.

[0114] The right side of FIG. 15 depicts the article of footwear 100 in a resting state where the forefoot region 114, the midfoot region 116, and the heel region 118 are in contact with the ground surface and the instep area 128 is no longer flexed inward. Because each of the abrasion resistant layer 510 and the elastically resilient layer 512 are elastically resilient in directions orthogonal to the surface plane of the instep area 128, the layers 510 and 512 spring back to a neutral state thereby reducing the formation of wrinkles and / or creases in the instep area 128 of the upper 110.

[0115] FIG. 16 schematically depicts an example of when a wearer dons the article of footwear 100 by pressing down on the heel end 119 of the upper 110 while sliding their foot into the article of footwear 100. When the heel end 119 of the upper 110 is depressed down, it flexes inward (e.g., in a direction orthogonal to the surface plane of the heel region 118 and toward an interior of the article of footwear 100) which causes elongation of the elastically resilient layer 512 as indicated by arrow 1600 and causes compression of the abrasion resistant layer 510 as indicated by arrow 1610. Similar to the instep area 128, flexion at the heel end 119 is also generally asymmetric with flexion occurring toward an interior of the article of footwear 100 and not occurring outward. Ihe stretch resistant layer 514 inhibits or reduces stretch of the upper 110 along the surface plane of the heel end 119 thus facilitating support in this area of the article of footwear 100. The composite textile(s) described in this disclosure reduce(s) the likelihood of wrinkles and / or creases developing along the inflexion point.

[0116] The right side of FIG. 16 depicts the article of footwear 100 in a resting state where the heel end 1 19 is no longer flexed inward. Because each of the abrasion resistant layer 510 and the elastically resilient layer 512 are elastically resilient in directions orthogonal to the surface plane of the heel region 118, the layers 510 and 512 spring back to a neutral state thereby reducing the formation of wrinkles and / or creases in the heel region 118 of the upper 110.

[0117] In one aspect, and as schematically depicted in FIG. 17, the elastically resilient layer 512 may comprise different thicknesses at different areas of the upper 110. This may be desirable if a greater amount of resilience is needed at particular areas of the upper 1 10 and a relatively less amount of resilience is needed at other parts of the upper 110. The upper 110 is depicted as not secured to the sole structure 112 and in a laid-flat configuration for illustrative purposes. In one example, and as described above, the instep area 128 of the upper 110 may be subjected to repeated flexion inward during normal walking or running motions and, as such, may be prone to creasing or wrinkling. In the instep area 128 and as shown in the enlarged cross-section view, the elastically resilient layer 512 may have a relatively greater thickness 1710 compared to, for example, the medial side 120 (or the lateral side 122) of the midfoot region 1 16 of the upper 110 which may undergo relatively less flexion during normal wear. On the medial side 120 of the upper 110 and as shown in the enlarged cross-section view, the elastically resilient layer 512 may have a thickness 1712 that is less than the thickness 1710 of the elastically resilient layer 512 in the instep area 128. This may also be true of the lateral side 122 of the upper 110 in the midfoot region 116. Similarly, although not shown, the elastically resilient layer 512 may have a relatively greater thickness at the heel region 118 of the upper 110 when the article of footwear 100 is configured to be donned by depressing the heel end 119 and sliding the foot into the article of footwear 100.

[0118] In examples of the present disclosure, the elastically resilient layer 512 can include a sheet or layer of a foamed material, which can form an innermost face of the composite textile. In at least some instances, the innermost face that is formed by the sheet or layer of the foamed material can include a texture and / or a contour. That is, a texture and / or contour can be constructed into the surface of the foam that forms the innermost surface, such as by pressing a texture or form into the surface with or without heat. In some examples, the texture or the contour can include an ornamental texture, such as a texture that has the appearance of leather grain, knit textile, woven textile, polygonal shapes, organic shapes, lines, dots, etc. In some examples, the contours can include waves, ridges, and the like.

[0119] FIGs. 18A and 18B respectively schematically depict, in an example of the present disclosure, a bottom perspective view and a cross-section view of a stacked configuration 1800 after processing, where the stacked configuration 1800 comprises the abrasion resistant layer 510, the stretch resistant layer 514, and the elastically resilient layer 512. The abrasion resistant layer 510 can include any elements of the abrasion resistant layer 510 described in any other portions of this disclosure. The stretch resistant layer 514 can include any elements of thestretch resistant layer 514 described in any other portions of this disclosure. The elastically resilient layer 512 can include any elements of the elastically resilient layer 512 described in any other portions of this disclosure.

[0120] In this example of the stacked configuration 1800, the elastically resilient layer 512 may comprise a plurality of ridges 1810 and a plurality of valleys 1812. Each of the ridges 1810 is separated from an adjacent ridge 1810 by a valley 1812. The ridges 1810 and the valleys 1812 may be created by, for example, a molding process. For instance, the elastically resilient layer 512 may be molded to form the ridges 1810 and the valleys 1812 before incorporation into the stacked configuration 1800, or the elastically resilient layer 512 may be molded after incorporation into the stacked configuration 1800. In one example, the molding process may cause the elastically resilient layer 512 to have a reduced thickness in the valleys 1812 compared to the thickness of the ridges 1810. In addition, in some examples, the foamed material that is in the valleys 1812 is denser as compared to the foamed material in the ridges 1810. The ridges 1810 and the valleys 1812 in FIG. 18A and 18B are an example, and in other examples, the ridges 1810 and the valleys 1812 can have different wave properties, such as a different amplitude (e.g., smaller amplitude or larger amplitude), different wavelength (e.g., smaller wavelength or larger wavelength), etc.

[0121] In examples, the ridges 1810 and the valleys 1812 may modify one or more of the stiffness and flexion qualities of the stacked configuration 1800. For example, the ridges 1810 and the valleys 1812 may increase the relative surface area of the elastically resilient layer 512 making it effectively less stiff and providing less resistance to flexion. If the ridges 1810 are molded to have a reduced thickness, this may also reduce resistance to flexion. Additionally, the ridges 1810 and valleys 1812 may be oriented on the upper 110 to facilitate flexion at some areas of the upper 110 and to provide resistance to flexion at other areas of the upper 110. For example, the stacked configuration 1800 can elastically deform more easily when the inflexion line of the stacked configuration 1800 extends more in an along-ridge direction 1816, as compared to the flexion line extending more in a cross-ridge direction 1814. In at least some instances, points or lines of inflexion can often be positioned in the valleys 1812. When the stacked configuration 1800 is flexed in the ridge direction 1816 (e.g., the line of inflexion is in the cross-ridge direction 1814), the ridges 1810 act as beams or support structures which resist bending.

[0122] FIG. 19 schematically depicts an example article of footwear 1900 having an upper 1910 formed from the stacked configuration 1800 shown in FIGs. 18A and 18B. The articleof footwear 1900 includes a forefoot region 1902, a midfoot region 1904, and a heel region 1906. As shown, the ridges 1810 (shown in dashed line to indicate that they are on the interior of the upper 110) are oriented in different directions at different portions of the upper 1910. For example, at an instep area 1912 of the upper 1910 or along a vamp, the ridges 1810 longitudinally extend from a medial side 1905 to a lateral side (not shown in this view) of the upper 1910 as opposed to a toe end-to-heel end direction. Flexion at the instep area 1912 or the vamp due to walking or running would occur, such that the line of inflexion would occur more in an along-ridge direction 1816, such as depicted in FIG. 15, thus facilitating flexion of the upper 1910 in this area.

[0123] Continuing with FIG. 19, at a heel end 1914 of the upper 1910, the ridges 1810 also extend from the medial side 1905 to the lateral side of the upper 1910. In this example, the line of inflexion at the heel end 1914 due to downward compression during shoe donning could occur in the along-ridge direction 1816, which facilitates flexion of the upper 1910 in this area. At the midfoot region 1904 of the article of footwear 1900, the ridges 1810 extend from an ankle collar 1916 to a biteline 1918 of the article of footwear 1900. This orientation may provide increased support to the upper 1910 at the midfoot region 1904. For example, compression of the ankle collar 1916 toward the biteline 1918 (e.g., in the ridge direction) would be reduced due to the structural support provided by the ridges 1810. There may be areas of the upper 1910, such as areas 1920 and / or 1922 that do not include the ridges 1810. Stated differently, the ridges 1810 may be formed at one or more discrete locations on the upper 1910.

[0124] FIG. 20 schematically depicts a cross-section of an alternative stacked configuration 2000 after processing. The stacked configuration 2000 includes the abrasion resistant layer 510, the elastically resilient layer 512, and the stretch resistant layer 514. The stacked configuration 2000 further includes a textile 2010 having a plurality of ridges 2012 separated from each other by a plurality of valleys 2014. The textile 2010 is secured to an exposed surface of the elastically resilient layer 512 using, for example an adhesive. In this aspect, the textile 2010 may form an innermost- facing surface of an upper formed from the stacked configuration 2000. The ridges 2012 and the valley 2014 function similar to the ridges 1810 and the valleys 1812 of the stacked configuration 1800 and may be oriented on an upper similar to that depicted in FIG. 19. Use of the textile 2010 as an innermost-facing surface of an upper may create a desirable hand feel in the interior of the upper.

[0125] In at least some examples, both the textile 2010 and the elastically resilient layer 512 (e.g., a layer of a foamed material) can include the ridges and valleys. For example, during the process of coupling the textile 2010 to the foamed-material layer, such as via an adhesive, a textured or contoured mold can be placed in the compression tool and pressed into the textile 2010 when pushing the textile 2010 against the layer of foamed material.

[0126] FIG. 21 depicts a flow diagram of an example method 2100 of manufacturing an upper, such as the upper 110, for an article of footwear such as the article of footwear 100. At step 2110, a stacked configuration, such as the stacked configuration 500 or the stacked configuration 1800, is created. For example, at sub-step 2112 a first nonwoven layer, such as the nonwoven layer 900, the nonwoven layer 1000, or the first nonwoven layer 1100 is positioned between an abrasion resistant layer and an elastically resilient layer. The abrasion resistant layer may comprise the abrasion resistant layer 510 shown in FIG. 7, or the knit textile 800. The elastically resilient layer may comprise the foam layer 1300 or the knit spacer textile 1400. At sub-step 2114, a first adhesive layer, such as the first adhesive layer 516 is positioned between the first nonwoven layer and the abrasion resistant layer. At sub-step 2116, a second adhesive layer, such as the second adhesive layer 518 is positioned between the first nonwoven layer and the elastically resilient layer.

[0127] At step 2118, one or more of heat and pressure are applied to the stacked configuration such that the first nonwoven layer is secured to the abrasion resistant layer and the elastically resilient layer. The heat and pressure may be applied to the stacked configuration when the stacked configuration is in a two-dimensional form. Alternatively, the stacked configuration may be positioned within a three-dimensional mold before the heat and pressure are applied. At step 2120, after the heat and pressure are applied to the stacked configuration, the stacked configuration is formed into the upper. When the heat and pressure are applied to the stacked configuration when it is in a two-dimensional form, the processed stacked configuration is then manipulated to form a three-dimensional upper. Alternatively, when the heat and pressure are applied to the stacked configuration when positioned within a three- dimensional mold, minimal manipulation may be needed to complete the formation of the upper.

[0128] In example aspects, a second nonwoven layer such as the second non woven layer 1110 may be positioned overtop the first non woven layer prior to applying the heat and pressure. In aspects, the second nonwoven layer may be positioned such that a machine direction of the second nonwoven layer is orthogonal to the machine direction of the firstnonwoven layer as described with respect to FIGs. 11A and 11B. In an alternative aspect, instead of using the first nonwoven layer, a woven textile, such as the woven textile 1200 may be positioned between the abrasion resistant layer and the elastically resilient layer.

[0129] In example aspects, a texture may be applied to the abrasion resistant layer either before or after processing to impart a desired surface feel or aesthetic to the abrasion resistant layer. The texture may be applied by way of, for example, a textured release paper, printing, and the like. Since the abrasion resistant layer forms an outermost-facing surface of the upper, the texture is visible when viewing the outermost-facing surface of the upper.

[0130] As described above, aspects herein contemplate imparting different thicknesses to the elastically resilient layer either before or after processing as described with respect to FIG. 17. The different thicknesses may be created through a molding or a pressing process and may be used to modify the resilience properties of the stacked configuration. Aspects herein also contemplate creating ridges and valleys on at least an exposed surface of the elastically resilient layer as described with respect to FIGs. 18A and 18B through, for example, a molding process. The ridges and valleys may be used to modify the bending and stiffness properties of the stacked configuration.

[0131] In an additional manufacturing step, a textile, such as the textile 2010, comprising ridges and valleys may be secured to an exposed surface of the elastically resilient layer as described with respect to FIG. 20. The ridges and the valleys of the textile may be used to modify the bending properties of the stacked configuration.

[0132] The following clauses represent example aspects of concepts contemplated herein. Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are examples and are not limiting. The following clauses may be rewritten as claims.

[0133] Clause 1. An article of footwear comprising : a sole structure; and an upper secured to the sole structure, the upper comprising: an abrasion resistant layer, an elastically resilient layer that forms, at least in part, an innermost-facing surface of the upper, and a stretch resistant layer positioned between the abrasion resistant layer and the elastically resilient layer, the stretch resistant layer secured to each of the abrasion resistant layer and the elastically resilient layer.

[0134] Clause 2. The article of footwear of clause 1, wherein the abrasion resistant layer comprises an outer-facing layer of the upper.

[0135] Clause 3. The article of footwear of clause 2, wherein the abrasion resistant layer comprises an outermost-facing layer of the upper.

[0136] Clause 4. The article of footwear of any of clauses 1 through 3, wherein the abrasion resistant layer is elastically resilient.

[0137] Clause 5. The article of footwear of any of clauses 1 through 4, wherein the abrasion resistant layer comprises a polyurethane material.

[0138] Clause 6. The article of footwear of any of clauses 1 through 5, wherein the abrasion resistant layer comprises a knit layer comprising yarns that are at least partially encapsulated by a thermoformed material.

[0139] Clause 7. The article of footwear of any of clauses 1 through 4, wherein the abrasion resistant layer comprises an olefin material.

[0140] Clause 8. The article of footwear of any of clauses 1 through 5, wherein the abrasion resistant layer comprises a thermoplastic polyurethane material.

[0141] Clause 9. The article of footwear of any of clauses 1 through 8, wherein the abrasion resistant layer is secured to the stretch resistant layer by a first adhesive layer.

[0142] Clause 10. The article of footwear of clause 9, wherein the first adhesive layer comprises a thermoplastic polyurethane material.

[0143] Clause 1 1. The article of footwear of clause 9, wherein the first adhesive layer comprises a poly ether-block- amide material.

[0144] Clause 12. The article of footwear of any of clauses 1 through 11, wherein the stretch resistant layer comprises a thermoplastic polymer layer.

[0145] Clause 13. The article of footwear of any of clauses 1 through 12, wherein the stretch resistant layer comprises a first nonwoven layer having a machine direction and a crossmachine direction, the first nonwoven layer comprising fibers, and wherein at least a portion of the fibers of the first nonwoven layer are embedded within a thermoplastic polymer layer.

[0146] Clause 14. The article of footwear of clause 13, wherein the first nonwoven layer comprises a spunbond non woven.

[0147] Clause 15. The article of footwear of any of clauses 13 or 14, wherein the first nonwoven layer comprises a basis weight from about 20 grams per square meter (gsm) to about 60 gsm.- W -

[0148] Clause 16. The article of footwear of any of clauses 13 through 15, wherein the fibers of the first nonwoven layer comprises one or more of polyamide fibers and polyethylene terephthalate fibers.

[0149] Clause 17. The article of footwear of any of clauses 13 through 16, wherein the stretch resistant layer further comprises a second nonwoven layer having a machine direction and a cross-machine direction, the second nonwoven layer positioned overtop the first nonwoven layer such that the machine direction of the first nonwoven layer is oriented generally perpendicular to the machine direction of the second nonwoven layer.

[0150] Clause 18. The article of footwear of clause 17, wherein the second nonwoven layer comprises fibers, and wherein at least a portion of the fibers of the second non woven layer are embedded within the thermoplastic polymer layer.

[0151] Clause 19. The article of footwear of clause 17 or clause 18, wherein the second nonwoven layer comprises a spunbond nonwoven.

[0152] Clause 20. The article of footwear of any of clauses 1 through 12, wherein the stretch resistant layer comprises one or more of a lightweight and an ultra-lightweight woven textile.

[0153] Clause 21. The article of footwear of clause 20, wherein the woven textile comprises polyamide yarns.

[0154] Clause 22. The article of footwear of any of clauses 1 through 21, wherein the elastically resilient layer is secured to the stretch resistant layer by a second adhesive layer.

[0155] Clause 23. The article of footwear of clause 22, wherein the second adhesive layer comprises a thermoplastic polyurethane material.

[0156] Clause 24. The article of footwear of clause 22, wherein the second adhesive layer comprises a polyether-block-amide material.

[0157] Clause 25. The article of footwear of any of clauses 1 through 24, wherein the elastically resilient layer comprises a foam.

[0158] Clause 26. The article of footwear of clause 25, wherein the foam comprises one or more of a polyurethane foam and an ethylene vinyl acetate foam.

[0159] Clause 27. The article of footwear of clause 25 or clause 26, wherein the foam comprises one of an open cell foam or a closed cell foam.

[0160] Clause 28. The article of footwear of any of clauses 25 through 27, wherein the foam comprises a thickness from about 0.5 mm to about 6.5 mm.

[0161] Clause 29. The article of footwear of any of clauses 1 through 24, wherein the elastically resilient layer comprises a spacer mesh textile optionally comprising one or more elastic yams.

[0162] Clause 30. The article of footwear of any of clauses 1 through 29, wherein the upper comprises an instep area, and wherein at the instep area the upper is elastically resilient in a direction orthogonal to a surface plane of the instep area.

[0163] Clause 31. The article of footwear of clause 30, wherein at the instep area, the upper is resistant to stretch along the surface plane of the instep area in a medial-to-lateral direction.

[0164] Clause 32. The article of footwear of clause 30, wherein at the instep area, the upper is resistant to stretch along the surface plane of the instep area in a toe-to-heel direction.

[0165] Clause 33. The article of footwear of any of clauses 30 through 32, wherein in at least the instep area of the upper, the elastically resilient layer comprises a plurality of ridges that extend in a direction between a medial side and a lateral side of the article of footwear, each of the plurality of ridges separated from an adjacent ridge by a valley.

[0166] Clause 34. The article of footwear of clause 33, wherein the plurality of ridges do not extend in a direction between a toe end and a heel end of the article of footwear.

[0167] Clause 35. An article of footwear comprising: a sole structure; and an upper secured to the sole structure, the upper comprising: an abrasion resistant layer forming, at least in part, an outermost-facing surface of the upper; an elastically resilient layer forming, at least in part, an innermost-facing surface of the upper; and a stretch resistant layer positioned between the abrasion resistant layer and the elastically resilient layer, the stretch resistant layer secured to each of the abrasion resistant layer and the elastically resilient layer, the stretch resistant layer comprising a first nonwoven layer, wherein at least a portion of fibers of the first nonwoven layer are embedded within a thermoplastic polymer layer.

[0168] Clause 36. The article of footwear of clause 35, wherein the abrasion resistant layer is elastically resilient.

[0169] Clause 37. The article of footwear of clause 35 or clause 36, wherein the abrasion resistant layer comprises a polyurethane material.

[0170] Clause 38. The article of footwear of clause any of clauses 35 through 37, wherein the abrasion resistant layer comprises a knit layer comprising yarns that are at least partially encapsulated by a thermoformed material.

[0171] Clause 39. The article of footwear of clause 35, wherein the abrasion resistant layer comprises an olefin material.

[0172] Clause 40. The article of footwear of clause 35, wherein the abrasion resistant layer comprises a thermoplastic polyurethane material.

[0173] Clause 41. The article of footwear of any of clauses 35 through 40, wherein the abrasion resistant layer is secured to the stretch resistant layer by a first adhesive layer.

[0174] Clause 42. The article of footwear of clause 41, wherein the first adhesive layer comprises a thermoplastic polyurethane material.

[0175] Clause 43. The article of footwear of clause 41, wherein the first adhesive layer comprises a poly ether-block- amide material.

[0176] Clause 44. The article of footwear of any of clauses 35 through 43, wherein the first nonwoven layer comprises a spunbond nonwoven.

[0177] Clause 45. The article of footwear of any of clauses 35 through 44, wherein the first nonwoven layer comprises a basis weight from about 20 grams per square meter (gsm) to about 60 gsm.

[0178] Clause 46. The article of footwear of any of clauses 35 through 45, wherein the fibers of the first nonwoven layer comprise one or more of polyamide fibers and polyethylene terephthalate fibers.

[0179] Clause 47. The article of footwear of any of clauses 35 through 46, wherein the stretch resistant layer further comprises a second nonwoven layer having a machine direction and a cross-machine direction, the second nonwoven layer positioned overtop the first nonwoven layer such that a machine direction of the first nonwoven layer is oriented generally perpendicular to the machine direction of the second nonwoven layer.

[0180] Clause 48. The article of footwear of clause 47, wherein the second nonwoven layer comprises fibers, and wherein at least a portion of the fibers of the second non woven layer are embedded within the thermoplastic polymer layer.

[0181] Clause 49. The article of footwear of clause 47 or clause 48, wherein the second nonwoven layer comprises a spunbond nonwoven.

[0182] Clause 50. The article of footwear of any of clauses 35 through 49, wherein the elastically resilient layer is secured to the stretch resistant layer by a second adhesive layer.

[0183] Clause 51 . The article of footwear of clause 50, wherein the second adhesive layer comprises a thermoplastic polyurethane material.

[0184] Clause 52. The article of footwear of clause 50, wherein the second adhesive layer comprises a polyether-block-amide material.

[0185] Clause 53. The article of footwear of any of clauses 35 through 52, wherein the elastically resilient layer comprises a foam.

[0186] Clause 54. The article of footwear of clause 53, wherein the foam comprises one or more of a polyurethane foam and an ethylene vinyl acetate foam.

[0187] Clause 55. The article of footwear of clause 53 or clause 54, wherein the foam comprises one of an open cell foam or a closed cell foam.

[0188] Clause 56. The article of footwear of any of clauses 53 through 55, wherein the elastically resilient layer comprises a first thickness at a first part of the upper, and wherein the elastically resilient layer comprises a second thickness at a second part of the upper, the first thickness different from the second thickness.

[0189] Clause The article of footwear of any of clauses 35 through 52, wherein the elastically resilient layer comprises a spacer mesh textile having one or more elastic yarns.

[0190] Clause 58. The article of footwear of any of clauses 35 through 57, wherein the upper comprises an instep area, and wherein at the instep area the upper is elastically resilient in a direction orthogonal to a surface plane of the instep area.

[0191] Clause 59. The article of footwear of clause 58, wherein at the instep area, the upper is resistant to stretch along the surface plane of the instep area in a medial-to-lateral direction.

[0192] Clause 60. The article of footwear of clause 58, wherein at the instep area, the upper is resistant to stretch along the surface plane of the instep area in a toe-to-heel direction.

[0193] Clause 61. The article of footwear of any of clauses 35 through 560, wherein the upper comprises a heel region, and wherein at the heel region the upper is elastically resilient in a direction orthogonal to a surface plane of the heel region.

[0194] Clause 62. The article of footwear of clause 61 , wherein at the heel region, the upper is resistant to stretch along the surface plane of the heel region in a medial-to-lateral direction.

[0195] Clause 63. The article of footwear of clause 61, wherein at the heel region, the upper is resistant to stretch along the surface plane of the heel region in a direction extending from a biteline of the article of footwear to an ankle collar of the article of footwear.

[0196] Clause The article of footwear of any of clauses 35 through 63, wherein the elastically resilient layer comprises a plurality of ridges, each of the plurality of ridges separated from an adjacent ridge by a valley.

[0197] Clause 65. The article of footwear of clause 64, wherein an orientation of the plurality of ridges is dependent upon a location of the plurality of ridges on the upper.

[0198] Clause 66. A method of manufacturing an upper for an article of footwear, the method comprising: creating a stacked configuration by: positioning a first nonwoven layer between an abrasion resistant layer and an elastically resilient layer; positioning a first adhesive layer between the first nonwoven layer and the abrasion resistant layer; positioning a second adhesive layer between the first nonwoven layer and the elastically resilient layer; applying one or more of heat and pressure to the stacked configuration such that the first nonwoven layer is secured to the abrasion resistant layer and the elastically resilient layer; and after applying the one or more of heat and pressure to the stacked configuration, forming the stacked configuration into the upper.

[0199] Clause 67. The method of manufacturing the upper of clause 66, wherein the abrasion resistant layer comprises an outer-facing layer of the upper.

[0200] Clause 68. The method of manufacturing the upper of clause 67, wherein the abrasion resistant layer comprises an outermost-facing layer of the upper.

[0201] Clause 69. The method of manufacturing the upper of any of clauses 66 through 68, wherein the abrasion resistant layer is elastically resilient.

[0202] Clause 70. The method of manufacturing the upper of any of clauses 66 through 69, wherein the abrasion resistant layer comprises a polyurethane material.

[0203] Clause 71. The method of manufacturing the upper of any of clauses 66 through 70, wherein prior to applying the one or more of heat and pressure to the stacked configuration, the abrasion resistant layer comprises a knit layer comprising yams having a core of a high melting material and a sheath of a low melting thermoplastic material.

[0204] Clause 72. The method of manufacturing the upper of clause 71, wherein after applying the one or more of heat and pressure to the stacked configuration, the low melting thermoplastic material of the sheath melts and flows to form a thermoformed material that at least partially encapsulates the core of the high melting material of the yarns of the knit layer.

[0205] Clause 73. The method of manufacturing the upper of any of clauses 66 through 70, wherein the abrasion resistant layer comprises an olefin material.

[0206] Clause 74. The method of manufacturing the upper of any of clauses 66 through 70, wherein the abrasion resistant layer comprises a thermoplastic polyurethane material.

[0207] Clause 75. The method of manufacturing the upper of any of clauses 66 through 74, wherein one or more of the first adhesive layer and the second adhesive layer comprises a thermoplastic polyurethane material.

[0208] Clause 76. The method of manufacturing the upper of any of clauses 66 through 74, wherein one or more of the first adhesive layer and the second adhesive layer comprises a polyether-block-amide material.

[0209] Clause 77. The method of manufacturing the upper of any of clauses 66 through 76, wherein the first nonwoven layer comprises a basis weight from about 20 grams per square meter (gsm) to about 60 gsm.

[0210] Clause 78. The method of manufacturing the upper of any of clauses 66 through 77, wherein prior to applying the one or more of heat and pressure to the stacked configuration, the first nonwoven layer comprises thermoplastic polyurethane fibers.

[0211] Clause 79. The method of manufacturing the upper of clause 78, wherein after applying the one or more of heat and pressure to the stacked configuration, the thermoplastic polyurethane fibers melt and flow to form a thermoplastic polymer layer.

[0212] Clause 80. The method of manufacturing the upper of any of clauses 66 through 79, wherein the first nonwoven layer comprises a spunbond nonwoven.

[0213] Clause 81. The method of manufacturing the upper of clause 80, wherein fibers of the spunbond nonwoven comprise one or more of polyamide fibers and polyethylene terephthalate fibers.

[0214] Clause 82. The method of manufacturing the upper of clause 81, wherein after applying the one or more of heat and pressure to the stacked configuration, at least a portion of the fibers of the spunbond nonwoven are embedded within a thermoplastic polymer layer.

[0215] Clause 83. The method of manufacturing the upper of clause 82, wherein the thermoplastic polymer layer comprises material from one or more of the first adhesive layer and the second adhesive layer.

[0216] Clause 84. The method of manufacturing the upper of any of clauses 66 through 83, wherein the elastically resilient layer comprises a foam.

[0217] Clause 85. The method of manufacturing the upper of clause 84, wherein the foam comprises one or more of a polyurethane foam and an ethylene vinyl acetate foam.

[0218] Clause 86. The method of manufacturing the upper of clause 84 or clause 85, wherein the foam comprises one of an open cell foam or a closed cell foam.

[0219] Clause 87. The method of manufacturing the upper of any of clauses 84 through 86, wherein the foam comprises a thickness from about 0.5 mm to about 6.5 mm.

[0220] Clause 88. The method of manufacturing the upper of any of clauses 66 through 83, wherein the elastically resilient layer comprises a spacer mesh textile having one or more elastic yarns.

[0221] Clause 89. The method of manufacturing the upper of any of clauses 66 through 88, wherein the elastically resilient layer forms an inner-facing surface of the upper.

[0222] Clause 90. The method of manufacturing the upper of clause 89, wherein the elastically resilient layer forms an innermost-facing surface of the upper.

[0223] Clause 91. The method of manufacturing the upper of any of clauses 66 through 91 , wherein a texture is applied to the abrasion resistant layer such that the texture is visible when viewing an outermost-facing surface of the upper.

[0224] Clause 92. The method of manufacturing the upper of any of clauses 66 through 91 , further comprising forming a plurality of ridges at one or more locations on the elastically resilient layer.

[0225] Clause 93. The method of manufacturing the upper of clause 92, wherein the plurality of ridges is created using a molding process.

[0226] Clause 94. The method of manufacturing the upper of clause 92, wherein subsequent to forming the stacked configuration into the upper, the plurality of ridges extend between a medial side and a lateral side of the upper in at least an instep area of the upper.

[0227] Clause 95. The method of manufacturing the upper of clause 92, wherein subsequent to forming the stacked configuration into the upper, the plurality of ridges extend between a medial side and a lateral side of the upper in at least a heel region of the upper.

[0228] Clause 96. The method of manufacturing the upper of clause 92, wherein the plurality of ridges are formed at one or more discrete locations on the elastically resilient layer.

[0229] Clause 97. The method of manufacturing the upper of any of clauses 66 through 96, further comprising compressing the elastically resilient layer at one or more locations to create different thicknesses of the elastically resilient layer at the one or more locations.

[0230] Clause 98. The method of manufacturing the upper of clause 97, wherein a molding process is used to compress the elastically resilient layer at the one or more locations.

[0231] Clause 99. The method of manufacturing the upper of any of clauses 66 through 98, further comprising applying a textile comprising one or more ridges to the elastically resilient layer such that the textile forms an innermost-facing surface of the upper after the stacked configuration is formed into the upper.

[0232] Clause 100. The method of manufacturing the upper of clause 99, wherein the ridges of the textile extend between a medial side and a lateral side of the upper in at least an instep area of the upper.

[0233] Clause 101. The method of manufacturing the upper of clause 99 , wherein the ridges of the textile extend between a medial side and a lateral side of the upper in at least a heel region of the upper.

[0234] Clause 102. The method of manufacturing the upper of clause 99, wherein the textile comprising the one or more ridges is secured to the elastically resilient layer using an adhesive.

[0235] Clause 103. The method of manufacturing the upper of any of clauses 66 through 102, wherein creating the stacked configuration further comprises positioning a second nonwoven layer overtop the first nonwoven layer such that a machine direction of the second nonwoven layer is positioned generally perpendicular to a machine direction of the first nonwoven layer.

[0236] Clause 104. The method of manufacturing the upper of clause 103, wherein the first adhesive layer is positioned between the second nonwoven layer and the abrasion resistant layer.

[0237] Clause 105. The method of manufacturing the upper of clause 103, wherein the second adhesive layer is positioned between the second nonwoven layer and the elastically resilient layer.

[0238] Clause 106. An article of footwear comprising: a sole structure; and an upper secured to the sole structure, the upper comprising a composite textile that comprises: an abrasion resistant layer that comprises a continuous polymer layer; a foamed elastomer layer that comprises a sheet of a foamed material and that comprises an innermost surface of the composite textile, and a stretch resistant layer that comprises a nonwoven layer and that is positioned between the abrasion resistant layer and the foamed elastomer layer.

[0239] Clause 107. The article of footwear of clause 106, wherein the continuous polymer layer comprises a polyurethane material.

[0240] Clause 108. The article of footwear of clause 106 or clause 107, wherein the continuous polymer layer comprises a polymer coating.

[0241] Clause 109. The article of footwear of clause 108, wherein the polymer coating is bonded directly to fibers of the nonwoven layer.

[0242] Clause 110. The article of footwear of clause 106 or clause 107, wherein the continuous polymer layer comprises a polymer film.

[0243] Clause 11 1. The article of footwear of clause 1 10 further comprising, a first adhesive that bonds the polymer film directly to the stretch resistant layer.

[0244] Clause 112. The article of footwear of clause 111, wherein the first adhesive comprises a hotmelt, and optionally, wherein the hotmelt comprises a TPU hotmelt or a PEBA hotmelt.

[0245] Clause 113. The article of footwear of any of clauses 106 to 112, wherein the nonwoven layer comprises fibers, and wherein at least a portion of the fibers are encapsulated within a polymer matrix.

[0246] Clause 114. The article of footwear of any of clauses 106 to 1 13, wherein the nonwoven layer comprises a spunbond nonwoven.

[0247] Clause 115. The article of footwear of any of clauses 106 to 114, wherein the sheet of the foamed material is secured directly to the stretch resistant layer by a second adhesive.

[0248] Clause 116. The article of footwear of clause 115, wherein the second adhesive comprises a hotmelt adhesive, and optionally, wherein the hotmelt adhesive comprises a TPU hotmelt or a PEBA hotmelt.

[0249] Clause 117. The article of footwear of any of clauses 106 to 116, wherein the sheet of the foamed material comprises a thickness from about 0.5 mm to about 5.0 mm.

[0250] Clause 1 18. The article of footwear of any of clause 106 to 117, wherein the sheet of the foamed material comprises a plurality of ridges that longitudinally extend in a direction between a medial side and a lateral side of the article of footwear, each of the plurality of ridges separated from an adjacent ridge by a valley, and optionally, wherein a first thickness of the sheet of the foamed material at a first position aligned with a first ridge is larger than a second thickness of the sheet of the foamed material at a second position aligned with a second valley adjacent to the first ridge, and optionally, wherein at the first position the foamed material comprises a first density that is less than a second density at the second position, and optionally, wherein the sheet of the foamed material comprises a surface texture formed in a surface of the sheet of the foamed material.

[0251] Clause 119. An article of footwear comprising: a sole structure; and an upper secured to the sole structure, wherein the upper comprises a first portion that extends at least partially across a forefoot region from a medial side to a lateral side, and wherein the first portion comprises a first composite textile that comprises: a fiber-reinforced layer thatcomprises a nonwoven layer with fibers at least partially embedded in a polymer matrix; and a foamed elastomer layer comprising a sheet of a foamed elastomer material that is coupled to the fiber- reinforced layer and that comprises an innermost surface of the first composite textile.

[0252] Clause 120. The article of footwear of clause 119, wherein the polymer matrix comprises at least a portion of an adhesive that couples the fiber-reinforced layer to the foamed elastomer layer.

[0253] Clause 121. The article of footwear of clause 119 or clause 120 further comprising, a continuous polymer layer coupled to the fiber-reinforced layer.

[0254] Clause 122. The article of footwear of clause 121, wherein the continuous polymer layer comprises a polymer film.

[0255] Clause 123. The article of footwear of clause 121, wherein the continuous polymer layer comprises a polymer coating coupled directly to the fiber-reinforced layer.

[0256] Clause 124. The article of footwear of any of clauses 119 to 123, wherein the nonwoven layer comprises a spunbond nonwoven.

[0257] Clause 125. A method of manufacturing an upper for an article of footwear, the method comprising: constructing a composite textile by: bonding, via a first adhesive a nonwoven textile to a sheet of a foamed elastomer material by applying heat, pressure, or a combination of heat and pressure to a stacked arrangement of the nonwoven textile, the first adhesive, and the sheet of the foamed elastomer material; and forming a continuous polymer layer on the nonwoven textile, wherein the nonwoven textile is between the continuous polymer layer and the sheet of the foamed elastomer material; and constructing, as part of the upper, at least a portion of a vamp, an instep, a toe box, or any combination thereof from the composite textile.

[0258] Clause 126. The method of clause 125, wherein forming the continuous polymer layer on the nonwoven textile comprises bonding a polymer film to the nonwoven textile with a hotmelt film.

[0259] Clause 127. The method of clause 125, wherein forming the continuous polymer layer on the nonwoven textile comprises screen printing a polymer material on the nonwoven textile.

[0260] Clause 128. The method of any of clauses 125 to 127, further comprising, forming ridges in the sheet of foamed material and arranging the composite textile in the upper with the ridges comprising an innermost surface of the upper.

[0261] Clause 129. The method of clause 128, wherein the ridges are arranged to longitudinally extend in a medial-to-lateral orientation.

[0262] Aspects of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative aspects will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure.

[0263] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.

Claims

CLAIMSWhat is claimed is:

1. An article of footwear comprising: a sole structure; and an upper secured to the sole structure, the upper comprising a composite textile that comprises: an abrasion resistant layer that comprises a continuous polymer layer; a foamed elastomer layer that comprises a sheet of a foamed material and that comprises an innermost surface of the composite textile; and a stretch resistant layer that comprises a nonwoven layer and that is positioned between the abrasion resistant layer and the foamed elastomer layer.

2. The article of footwear of claim 1 , wherein the continuous polymer layer comprises a polyurethane material.

3. The article of footwear of claim 1 or claim 2, wherein the continuous polymer layer comprises a polymer coating.

4. The article of footwear of claim 3, wherein the polymer coating is bonded directly to fibers of the nonwoven layer.

5. The article of footwear of claim 1 or claim 2, wherein the continuous polymer layer comprises a polymer film.

6. The article of footwear of claim 5 further comprising, a first adhesive that bonds the polymer film directly to the stretch resistant layer.

7. The article of footwear of claim 6, wherein the first adhesive comprises a hotmelt.

8. The article of footwear of claim 7, wherein the hotmelt comprises a TPU hotmelt or a PEBA hotmelt.

9. The article of footwear of any of claims 1 through 8, wherein the nonwoven layer comprises fibers, and wherein at least a portion of the fibers are encapsulated within a polymer matrix.

10. The article of footwear of any of claims 1 through 9, wherein the nonwoven layer comprises a spunbond nonwoven.

11. The article of footwear of any of claims 1 through 10, wherein the sheet of the foamed material is secured directly to the stretch resistant layer by a second adhesive.

12. The article of footwear of claim 11, wherein the second adhesive comprises a hotmelt adhesive.

13. The article of footwear of claim 12, wherein the hotmelt adhesive comprises a TPU hotmelt or a PEBA hotmelt.

14. The article of footwear of any of claims 1 through 13, wherein the sheet of the foamed material comprises a thickness from about 0.5 mm to about 5.0 mm.

15. The article of footwear of any of claims 1 through 14, wherein the sheet of the foamed material comprises a plurality of ridges that longitudinally extend in a direction between a medial side and a lateral side of the article of footwear, each of the plurality of ridges separated from an adjacent ridge by a valley.

16. The article of footwear of claim 15, wherein a first thickness of the sheet of the foamed material at a first position aligned with a first ridge is larger than a second thickness of the sheet of the foamed material at a second position aligned with a second valley adjacent to the first ridge.

17. The article of footwear of claim 16, wherein at the first position the foamed material comprises a first density that is less than a second density at the second position.

18. The article of footwear of any of claims 1 through 17, wherein the sheet of the foamed material comprises a surface texture formed in a surface of the sheet of the foamed material.

19. The article of footwear of claim 18, wherein the surface texture comprises an appearance of leather grain, a knit textile, a woven textile, polygonal shapes, organic shapes, lines, or dots.

20. An article of footwear comprising: a sole structure; and an upper secured to the sole structure, wherein the upper comprises a first portion that extends at least partially across a forefoot region from a medial side to a lateral side, and wherein the first portion comprises a first composite textile that comprises: a fiber- reinforced layer that comprises a nonwoven layer with fibers at least partially embedded in a polymer matrix; and a foamed elastomer layer comprising a sheet of a foamed elastomer material that is coupled to the fiber- reinforced layer and that comprises an innermost surface of the first composite textile.

21. The article of footwear of claim 20, wherein the polymer matrix comprises at least a portion of an adhesive that couples the fiber-reinforced layer to the foamed elastomer layer.

22. The article of footwear of claim 20 or claim 21 further comprising, a continuous polymer layer coupled to the fiber-reinforced layer.

23. The article of footwear of claim 22, wherein the continuous polymer layer comprises a polymer film.

24. The article of footwear of claim 22, wherein the continuous polymer layer comprises a polymer coating coupled directly to the fiber-reinforced layer.

25. The article of footwear of any of claims 20 through 24, wherein the nonwoven layer comprises a spunbond nonwoven.

26. A method of manufacturing an upper for an article of footwear, the method comprising: constructing a composite textile by: bonding, via a first adhesive, a nonwoven textile to a sheet of a foamed elastomer material by applying heat, pressure, or a combination of heat and pressure to a stacked arrangement of the nonwoven textile, the first adhesive, and the sheet of the foamed elastomer material; and forming a continuous polymer layer on the nonwoven textile, wherein the nonwoven textile is between the continuous polymer layer and the sheet of the foamed elastomer material; and constructing, as part of the upper, at least a portion of a vamp, an instep, a toe box, or any combination thereof from the composite textile.

27. The method of claim 26, wherein forming the continuous polymer layer on the nonwoven textile comprises bonding a polymer film to the nonwoven textile with a hotmelt film.

28. The method of claim 26, wherein forming the continuous polymer layer on the nonwoven textile comprises screen printing a polymer material on the nonwoven textile.

29. The method of any of claims 26 to 28 further comprising, forming ridges in the sheet of foamed material and arranging the composite textile in the upper with the ridges comprising an innermost surface of the upper.

30. The method of claim 29, wherein the ridges are arranged to longitudinally extend in a medial-to-lateral orientation.

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