CLAIM OF PRIORITY

[001] This application claims the benefit of U.S. Provisional Application No. 63/272,435, filed on October 27, 2021 , the contents of which are hereby incorporated by reference for all purposes.

FIELD

[002] The present teachings generally relate to a material for providing cushioning, comfort, and/or moisture wicking and absorption, and more particularly, to a material for use within an article of footwear.

BACKGROUND

[003] Most people wear some type of footwear on a daily basis, and many people own multiple pairs of footwear for different purposes. In places with a variable climate, it may be desirable to own both boots for cold weather and/or snow and lightweight shoes or sandals for warm weather. Certain articles of footwear are worn for fashion, while others are suited for particular activities. Footwear, such as shoes and boots, provide protection, insulation, and/or comfort to the wearer. Footwear may allow a wearer to participate in everyday activities by providing necessary traction, cushioning, stabilization, and the like. Specialized activities or sporting activities may require a specific type of footwear.

[004] Many articles of footwear contain some sort of padding. The padding may be located at the insole. The padding may be located around the top, front, and/or back of the foot. The padding in most articles of footwear is a polyurethane foam. However, polyurethane foams are typically thermoset materials. A thermoset material tends to be more brittle under cyclic compression. Therefore, the foams will eventually fracture and break down, turning to dust.

[005] Polyurethane foams have a cellular structure, which may absorb and trap moisture. Polyurethane foams often have poor breathability, resulting in the absorbed moisture remaining in the material, promoting the growth of fungi or bacteria and causing odor. These materials may become heavy and hot for a wearer, thereby causing and accumulating more sweat.

[006] Typically, the softer or more flexible the padding, the sooner the padding will “break in,” but a tougher, less flexible material makes for a longer-lasting shoe. Polyurethane foams may be fairly rigid or inflexible, which may make new shoes uncomfortable to the wearer initially, requiring wearing many times and/or for long periods of time before “breaking in” the shoes.

[007] Therefore, there is a need for a product that provides cushioning while providing moisture absorption and wicking properties. There is a need for a material that is breathable. There is a need for a material that provides antimicrobial, antifungal, anti-odor, or mildew resistant properties. There is a need for a material that provides increased comfort and/or cushioning to the user while withstanding compressive forces of repeated or cyclic use. There is a need for a material that is durable while also conforming to the wearer or breaking in more quickly than a traditional shoe (e.g., a traditional shoe having a polyurethane foam padding).

SUMMARY

[008] The present teachings meet one or more of the above needs by the improved devices and methods described herein. The present teachings include a material that may provide cushioning, comfort, the ability to clean, or a combination thereof. The present teachings include a material that provides breathability; energy absorption; structure resiliency; comfortable product feel; moisture wicking; odor control, reduction, or inhibition; cooling effect to the wearer; quick drying properties; cleanability and/or washability; durability; capability to be formed into three- dimensional shapes; pressure distribution; or a combination thereof.

[009] The present teachings pertain to a pad material for a pad material for providing cushioning, guiding absorption and/or evaporation of moisture, or both. The pad material may include a fibrous material, such as a lofted nonwoven material. The lofted nonwoven material may be a carded and lapped fibrous material. The fibrous material may be a vertically lapped material. The lofted nonwoven material may be an air laid material. The pad material may be adapted for use within an article of footwear, such as to provide padding between the article of footwear and a wearer. The pad material may be adapted for use as an insole or part of an insole of an article of footwear. The pad material may be adapted for use with an upper of an article of footwear.

[0010] The pad material may include one or more air flow channels. An air flow channel may permit ventilation to and from the article of footwear. An air flow channel may permit air flow into the article of footwear. An air flow channel may be situated such that heat from within the article of footwear can escape from the article of footwear. For example, heat may rise from the article of footwear through the collar of the article of footwear. Air flow channels may be positioned (e.g., extending generally parallel to the leg of the wearer) to facilitate the release of heat at the top of the article of footwear. An air flow channel may be formed by a localized compression operation. An air flow channel may be formed by stitching. An air flow channel may be created via thermoforming. Air can also be cycled through the pad material through periodic load application and release. As the pad material is compressed, air is forced out of the material. As the pad material rebounds or returns to an uncompressed state, air returns to fill the interstitial spaces. This cycling of air exiting and returning to the material may provide additional air flow within the material.

[0011] The pad material may have a compression set, such that the pad material retains at least a partial form of the wearer (e.g., a part of the wearer’s foot, ankle, leg, or the like) upon removal of the article of footwear for at least a certain period of time (e.g., minutes, hours, days). The compression may occur over a period of time of wearing the article of footwear, such as a period of hours, days, or repeated wearing.

[0012] The pad material may include one or more contact portion between a wearer and the fibrous material. The contact portion may be adapted to contact a wearer directly or indirectly (e.g., via sock or hosiery). The pad material may include a contact portion located between an outer portion of the article of footwear and the fibrous material. One or more contact portion may be a wicking material. One or more contact portions may provide a soft or comfortable surface for the wearer. One or more contact portions may provide a surface that prevents or reduces slip of the foot within the article of footwear while walking. One or more contact portions may provide insulation and/or heat. One or more contact portions may provide cooling. It is also contemplated that the pad material may be free of a separate contact portion. The wearer may contact the fibrous portion and/or the fibrous portion may be secured or directly contact another part of the article of footwear, such as a portion of the sole or an outer material of the article of footwear.

[0013] The present teachings also contemplate an article of footwear having a sole and an upper. A portion of the sole, a portion of the upper, or both, may include the pad material as described herein. The upper may include a vamp. The upper may include a quarter. The pad material may be located in the vamp. The pad material may be located in the quarter. The pad material may be located in the insole.

[0014] The article of footwear may include one or more air flow channels. An air flow channel may be positioned at or near one or more openings or permeable portions in the article of footwear, such as the collar of the article or footwear, or one or more ventilation openings or mesh portions.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is a side view of an exemplary article of footwear in accordance with the present teachings. [0016] FIG. 2 is a side view of an exemplary pad material in accordance with the present teachings.

[0017] FIG. 3 is a photograph of an exemplary pad material having generally vertically oriented fibers and/or generally vertically oriented loops in accordance with the present teachings. [0018] FIG. 4 is a comparative example of a material having generally horizontally oriented fibers and/or horizontally oriented loops.

[0019] FIG. 5 is a photograph of an exemplary pad material having angularly oriented fibers and/or angularly oriented loops consistent with a generally vertical orientation in accordance with the present teachings.

[0020] FIG. 6 is a photograph of an exemplary pad material having angularly oriented fibers and/or angularly oriented loops consistent with a generally vertical orientation in accordance with the present teachings.

[0021] FIG. 7 is a top view of an exemplary article of footwear in accordance with the present teachings.

[0022] FIG. 8 is a top view of an exemplary insole or foot contact surface for an article of footwear in accordance with the present teachings.

[0023] FIG. 9 is a top view of an exemplary insole or foot contact surface for an article of footwear in accordance with the present teachings.

[0024] FIG. 10 is a top view of an exemplary insole or foot contact surface for an article of footwear in accordance with the present teachings.

[0025] FIGS. 11 A and 11 B illustrate a comparison of performance between polyurethane foam and a material in accordance with the present teachings.

[0026] FIG. 12 is a graph showing breathability of the samples tested using ASTM D737.

[0027] FIG. 13 is a graph showing moisture wicking uptake of samples tested.

[0028] FIG. 14 is a graph showing water evaporated from the surface of 4 inch by 4 inch samples versus time.

[0029] FIG. 15 is a graph showing the compression force deflection of the samples tested using ASTM D3574 Test C.

DETAILED DESCRIPTION

[0030] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the teachings, its principles, and its practical application. Those skilled in the art may adapt and apply the teachings in its numerous forms, as may be best suited to the requirements of a particular use. Accordingly, the specific embodiments of the present teachings as set forth are not intended as being exhaustive or limiting of the teachings. The scope of the teachings should, therefore, be determined not with reference to the description herein, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0031] The present teachings relate to materials suitable for use with footwear. The materials described herein may be used in one or more parts of an article of footwear. For example, the materials described herein by be used where polyurethane foam is traditionally used in an article of footwear. The materials described herein may be used in replacement of or in addition to a foam material, such as a polyurethane foam.

[0032] Footwear is a covering or item of clothing worn on a foot. Footwear includes, but is not limited to, sneakers, tennis shoes, running shoes, athletic shoes, slip-on shoes, clogs, sandals, oxfords, business shoes, dress shoes, moccasins, flats, slippers, boots (e.g., work boots, armed forces boots, hiking boots, cowboy boots, riding boots, snow boots, fashion boots, ankle boots, rain boots, mid-calf boots, knee-high boots, thigh-high boots, motorcycle boots), footwear for sporting activities (e.g., ski boots, snowboard boots, snowmobile boots, athletic cleats or spiked shoes (e.g., soccer cleats, baseball cleats, softball cleats, football cleats, track and field spikes, cross country spikes, lacrosse cleats, field hockey cleats, cricket shoes), cycling shoes, golf shoes, basketball shoes, volleyball shoes, bowling shoes, in-line skates, hockey skates, figure skates, dance shoes).

[0033] An article of footwear generally includes one or more components or parts. An article of footwear generally includes a sole and an upper.

[0034] A sole may be the part of the shoe that is located below the wearer’s foot. The sole may include one or more layers. The sole may include an outsole. The outsole may be the portion of the shoe that contacts the ground. In certain articles of footwear, spikes or cleats may extend from or be part of the outsole. The sole may include an insole. The insole may be the portion of the shoe that contacts the wearer’s foot. The insole may provide a comfortable layer between the wearer and the outsole. The insole may provide cushioning, shock absorption, stress minimization, arch support, proper fitment of the shoe to the wearer’s foot, or a combination thereof. The sole may include a midsole, though not required. The midsole may offer additional suspension. A midsole may be located between the outsole and the insole. [0035] The article of footwear may include an upper. The upper may be the entire part of the article of footwear that covers the foot. The upper may include one or more portions. The upper may include a vamp. The vamp may be the section of the upper that covers the front of the foot. The vamp may extend from a tongue to the toe of the article of footwear. The vamp and/or article of footwear may be free of a tongue. The article of footwear may be free of a portion covering one or more toes (e.g., sandals, peep-toe shoes). The upper may include a quarter. The quarter may include the rear and/or sides of the upper covering the heel. The quarter may be located behind or attach to the vamp. The quarter may include a collar. The collar may be a top edge of the quarter (e.g., where a wearer inserts his or her foot). The quarter may include a shaft between the heel and the collar. For example, the shaft may allow the article of footwear to extend up the wearer’s leg, such as in the case of boots (e.g., extending to or beyond the wearer’s ankle toward the knee or higher).

[0036] The outer portion of the article of footwear may be constructed of various materials, depending upon the needs of the wearer. For example, the article of footwear may have a rubber or elastomeric sole (e.g., outsole). The article of footwear may have a textured sole (e.g., outsole) or layer between the article of footwear and the ground to provide traction and/or prevent slipping. The upper of the article of footwear may be at least partially constructed of leather. The upper of the article of footwear may include man-made materials. The upper may include one or more mesh portions. The upper may include a waterproof or water-resistant material or coating. The upper may include one or more plastic portions. The upper may include, but is not limited to, one or more of synthetic materials, polyurethane, thermoplastic polyurethane (TPU), polyvinyl chloride (PVC), plastic, wool, ethylene vinyl acetate, plant-based materials, cotton, canvas, recycled materials, polyester, suede, or other common materials for articles of footwear. The article of footwear may have one or more features for securing the footwear to a wearer’s foot or leg, such as but not limited to laces, zippers, snaps, clasps, buckles, elastic, hook and loop fasteners.

[0037] The article of footwear may include padding or a pad material to provide support, comfort, protection, or the like to the wearer. The padding may include one or more fibrous materials. A fibrous material may be less rigid than a foam structure (e.g., a polyurethane foam structure), allowing the fibers to deform for better and/or more comfortable fit of the article of footwear.

[0038] A pad material may be located between the outer materials of the upper and the wearer’s foot, ankle, and/or leg. A pad material may be located between the outsole and the wearer’s foot. A pad material may be located between the wearer’s foot and one or more features for securing the footwear to the wearer’s foot or leg. For example, a tongue may provide cushioning and a barrier between the wearer’s foot and the laces. A pad material may be removable. A pad material may be replaceable. A pad material may be secured to another portion of the article of footwear (e.g., via adhesive, stitching, encapsulated between other layers).

[0039] The pad material may also provide additional benefits such as compression resilience and puncture resistance, protection (e.g., by providing cushioning), breathability, padding, pressure relief, pressure distribution, moisture transference (e.g., moisture is moved from a surface of a user through the material), odor inhibition, cooling effects, insulative effects, or a combination thereof. Moisture may include, but is not limited to, fluids in the form of liquid (e.g., water, sweat) or vapor. The material may be shaped to fit the area to which it will be worn or used. The pad material may also be soft feeling, lightweight, washable, reusable, or a combination thereof. For example, the materials may give a balance of cooling, insulating, sweat and/or moisture management, and improved comfortable fit of the article of footwear. The pad material may provide enhanced pressure distribution or pressure relief for a wearer.

[0040] The pad material as described herein may especially provide improved comfort to the wearer. The materials may provide cushioning at certain contact points between an article of footwear and a foot. The materials may provide cushioning anywhere footwear may cover, including the ball of the foot, heel, and ankles. The soft cushioning and resilient properties improve the comfort and durability of the material, as compared with traditional cushioning materials, such as polyurethane foam materials. Polyurethane foam materials tend to break down overtime under normal use conditions, particularly when exposed to moisture from sweat or outside conditions and must be replaced frequently. The materials described herein are more durable than polyurethane foam products, thereby saving cost and time replacing foam inserts or replacing the articles of footwear. Polyurethane foam is also a thermoset material that breaks down faster in hydrophilic conditions. Washing this material or exposing the material to moisture expedites the breakdown. The materials described herein may allow for a washable, reusable product. The materials described herein may provide a usable life that exceeds that of a traditional cushioning material, such as polyurethane foam.

[0041] The pad material may have a shape that is able to be positioned or installed within an article of footwear. The pad material may be integrated into the structure of the article of footwear. The pad material may be attachable into the article of footwear. For example, the pad material may be removably attachable (e.g., via hook and loop fastener, clips, snaps, or the like). The pad material may be situated within the article of footwear without additional fastening required. The pad material may be unattached to the article of footwear but able to be used in conjunction with the article of footwear. For example, the pad may be secured below the wearer’s foot and held in place due to the pressure from the wearer’s foot and or securing of the footwear around the foot via laces, snaps, buckles, elastic, or the like, without the need for additional fasteners, bands, straps, or the like.

[0042] The pad material may have any shape that allows the pad material to be used in its intended environment. The pad material may be part of an insole. The pad material may be the insole. The pad material may be part of the vamp. The pad material may be part of the quarter. The pad material may be adapted to contact at least a portion of the bottom of a wearer’s foot. The pad material may be adapted to contact at least a portion of the top and/or side of a wearer’s foot.

[0043] The total thickness of the pad material may depend on the location of the pad material within the article of footwear. The total thickness of the pad material may depend upon the number of layers or parts of the pad material. Certain areas may have a greater thickness than others. The total thickness may be variable across the material. The pad material may have one or more contours adapted to complement the area where the pad is to be worn. Certain areas may have a contoured shape to generally match the contours of the wearer’s foot, ankle, or leg. For example, in an article of footwear covering an ankle, there may be contoured portions to accommodate the ankle bone for a comfortable fit. The thickness may vary due to certain processing techniques, such as compression applied in certain areas. The thickness may vary due to the presence of air flow channels within and/or across the pad material (e.g., formed via localized compression, stitching, molding, or the like). The thickness may decrease when approaching an edge of the pad material, particularly if the edges are sealed by a heat and/or compression technique. The thickness may vary due to the presence or lack of certain layers in some areas and not others. The lack of a particular layer or an area of reduced thickness may provide flexibility of the material (e.g., to allow for proper fit within an article of footwear; to allow for folding or bending of the material), reduction of material (e.g., by positioning cushioning elements only where needed), increased comfort (e.g., by positioning cushioning elements only where needed or where sweat or moisture are most likely to be produced), or a combination thereof. The total thickness of certain areas may decrease upon wearing of the article of footwear over a certain period of time due to the compression set of the material.

[0044] The total thickness of the pad material at a particular point may be about 1 mm or greater, about 2 mm or greater, about 3 mm or greater, or about 5 mm or greater. The total thickness of the pad material at a particular point may be about 30 mm or less, about 25 mm or less, about 20 mm or less, about 15 mm or less, about 12 mm or less, about 10 mm or less, or about 8 mm or less. For example, in an area around an ankle of the article of footwear, such as a boot, the pad material may be about 5 mm or more, or even about 10 mm or more.

[0045] The pad material may include one or more fibrous portions. The pad material may include one or more nonwoven portions or nonwoven materials. The fibers of at least a portion of the pad material may be arranged in a generally vertical orientation (e.g., vertical in the thickness direction). The fibers may be in a generally vertical orientation when in an uncompressed state and/or prior to undergoing compression, sealing, localized compression, stitching, or the like.

[0046] One or more of the fibrous portions may have a high loft or thickness at least in part due to the orientation of the fibers and/or orientation of the loops (e.g., oriented generally transverse to the longitudinal axis of the layer prior to undergoing any compression operations) of the fibrous portion and/or the methods of forming the fibrous portion. The fibrous portion may exhibit good resilience and/or compression resistance. The fibrous portion may be resistant to puncturing. The fibrous portion, due to factors such as, but not limited to, unique fibers, surfaces, physical modifications to the three-dimensional structure (e.g., via processing), orientation of fibers, orientation of loops or laps from one loop to an opposing loop, fiber treatments (e.g., hydrophilic coatings or fiber treatments) or a combination thereof, may exhibit good moisture transfer and/or absorption characteristics versus traditional materials.

[0047] The fibrous portion may be adjusted based on the desired properties. The fibrous portion may be tuned to provide a desired weight, thickness, compression resistance, or other physical attributes. The fibrous portion may be tuned to provide a desired moisture absorption or moisture transfer rate. The fibrous portion may be tuned to provide a desired drying rate. The fibrous portion may be formed from nonwoven fibers. The fibrous portion may be a nonwoven structure. The fibrous portion may be a lofted material. The fibrous portion may be thermoformable so that the layers may be molded or otherwise manufactured into a desired shape to meet one or more application requirements.

[0048] The fibrous portion may have a generally uniform distribution of fibers. The fibrous portion may have a generally uniform density throughout the thickness of the material. The fibrous portion may have a varying structure of fiber distribution and/or density through the thickness or through portions of the thickness. The fibrous portion may have a gradient structure where the material becomes more rigid or has a greater density. The change in density may be gradual. The change in density may be generally abrupt. The gradient structure may be in the thickness direction. For example, the fibrous portion may have a softer interior surface (i.e., facing the foot or skin of the wearer), and a harder external surface (i.e., facing away from the wearer) for attaching to the outer portion of the article of footwear. The gradient structure may be across the length or width of the material. The gradient structure may further enhance moisture evaporation rate on one side.

[0049] The change in density between one surface of the fibrous portion and an opposing surface of the fibrous portion may be due to processing techniques, such as the application of heat and/or increased pressure. For example, application of heat and/or increased pressure at or near one surface and not at an opposing surface may result in a higher density material adjacent the surface with the heat and/or pressure, as compared to the opposing surface. In a construction with a fibrous portion sandwiched between two facing materials, application of heat and/or increased pressure at or near one surface may result in a different angle of approach of the fibers and/or loops to a facing material. For example, the fibers and/or loops may be closer to parallel with a facing material than the angle of approach of the fibers and/or loops to the opposing facing material.

[0050] The fibrous portion may have a gradient structure where different portions of the fibrous portion absorb or hold different amounts of fluid or moisture. Different portions or areas may have different saturation points. For example, the fibrous portion may have a gradient structure in the thickness direction. Toward one surface of the fibrous portion, a greater volume of fluid may be absorbed and/or held within the material. In areas having a greater fluid capacity or a higher saturation point, additional fluid may be drawn to that area, thereby pulling the fluid or moisture away from the wearer, toward an area of increased evaporation, or both. For example, an area capable of containing or absorbing more fluid may be located at or near an area where there is increased air flow. The ability to draw more moisture to an area that also more quickly achieves evaporation may further improve the drying rate of the material. The gradient structure may occur within a single layer of material (e.g., as a result of fibers or other fillers used, the density of the material, processing techniques, the like, or a combination thereof). The gradient structure may occur through two or more layers arranged in generally planar contact.

[0051] The drying rate or rate of evaporation for the fibrous portion (or the pad material as a whole) may be improved over other products, such as foams or cross-lapped products. This may be due, at least in part, to factors such as shape, porosity, permeability, fiber orientation of the fibrous portion, orientation of the loops of the fibrous portion, or a combination thereof. The fibrous portion may have a high porosity, high percentage of open areas, high permeability, or combination thereof. This may allow for air to flow more efficiently through the material, as opposed to a more tortuous material such as a foam or cross-lapped material. The fibrous portion may have a porosity of about 90% or greater, about 96% or greater, about 97% or greater, or about 98% or greater or about 99% or greater. The porosity of the fibrous portion may be less than 100%.

[0052] The fibrous portion may be permeable. The fibrous portion may be porous. The fibrous portion may have pores. The pores may be formed from interstitial spaces between the fibers and/or the shape (e.g., by having a multi-lobal or deep-grooved cross-sectional fiber) of the fibers. The pores may extend throughout the entire thickness of the fibrous portion. The pores may extend through a portion of the thickness of the fibrous portion. The pores and/or the vertical orientation of the fibers may create a capillary effect or chimney effect for absorbing moisture or removing moisture from one surface and transferring to another area (e.g., to a moisture wicking layer, to a contact layer, to another portion of the fibrous portion, and the like). For example, the fibrous portion may push and/or pull the moisture from a first surface of the fibrous portion to an opposing second surface of the fibrous portion through the thickness of the fibrous portion. Capillary effect, or capillary action, is the ascension of liquids through a tube, pore, cylinder, or permeable substance due to adhesive and cohesive forces interacting between the liquid and the surface. The diameter of the pores or channels defined by the fibers (e.g., forming a capillary) for movement of liquid may be selected based on the thickness of the material through which the liquid must travel. A thinner diameter capillary or channel may see the liquid rise higher than liquid in a larger diameter capillary or channel due to capillary action because of adhesive forces.

[0053] The fibrous portion comprises fibers. In describing fibers of the fibrous portion, the present description may refer to “the fibers.” It is contemplated that a reference to “the fibers” may be a reference to all of the fibers of the fibrous portion. It is contemplated that a reference to “the fibers” may be in reference to only a portion of the fibers of the fibrous portion.

[0054] The ability of the fibrous portion to pull or push moisture through the material may be, at least in part, due to the geometries of the fibers. The fibers may have a cross-section that is substantially circular or rounded. The fibers may have a cross-section that has one or more curved portions. The fibers may have a cross-section that is generally oval or elliptical. The fibers may have a cross-section that is non-circular. Such non-circular cross-sections may create additional tubes or capillaries within which the moisture can be transferred. For example, the fibers may have geometries with a multi-lobal cross-section (e.g., having 3 lobes or more, having 4 lobes or more, or having 10 lobes or more). The fibers may have a cross-section with deep grooves. The fibers may have a substantially “Y”-shaped cross-section. The fibers may have a polygonal cross-section (e.g., triangular, square, rectangular, hexagonal, and the like). The fibers may have a star shaped cross-section. The fibers may be serrated. The fibers may have one or more branched structures extending therefrom. The fibers may be fi bri Hated. The fibers may have a cross-section that is a nonuniform shape, kidney bean shape, dog bone shape, freeform shape, organic shape, amorphous shape, or a combination thereof. The fibers may be substantially straight or linear, hooked, bent, irregularly shaped (e.g., no uniform shape), or a combination thereof. The fibers may include one or more voids extending through a length or thickness of the fibers. The fibers may have a substantially hollow shape. The fibers may be generally solid. The shape of the fibers may define capillaries or channels through which moisture can travel (e.g., from one side of the fibrous portion to an opposing side of the fibrous portion).

[0055] The movement of the moisture within the fibrous portion is not limited to vertical movement in the thickness direction. Moisture may move at any angle relative to the thickness direction. Moisture may move at any angle relative to the longitudinal axis of the material along the length or width of the material. Due to the porous structure of the fibrous portion, moisture may move over, up, or both. Moisture may travel to areas of less moisture (e.g., toward areas at or near an air vent or opening of an article of footwear). Moisture may travel along fibers. Therefore, particular orientations of fibers may aid in the transfer and/or evaporation of moisture. In a lapped structure, such as a vertically lapped structure, moisture may travel across loops (e.g., via fibers therebetween), between opposing loops (e.g., from a lower loop to an upper loop), or both.

[0056] Fibers that make up the fibrous portion may have an average linear mass density of about 0.5 denier or greater, about 1 denier or greater, or about 5 denier or greater. The material fibers that make up the fibrous portions may have an average linear mass density of about 25 denier or less, about 20 denier or less, about 15 denier or less, or about 10 denier or less. Fibers may be chosen based on considerations such as cost, resiliency, desired moisture absorption/resistance, or the like. For example, a coarser blend of fibers (e.g., a blend of fibers having an average denier of about 12 denier) may help provide resiliency to the fibrous portions. A finer blend (e.g., having a denier of about 10 denier or less or about 5 denier or less) may be used, for example, if a softer material is required to contact a user’s skin.

[0057] Fibers may have a staple length of about 1 .5 millimeters or greater, or even about 80 millimeters or greater (e.g., for carded fibrous webs). For example, the length of the fibers may be between about 30 millimeters and about 75 millimeters. The fibers may have an average or common length of about 50 to 75 millimeters staple length, or any length typical of those used in fiber carding processes.

[0058] Short fibers may be used (e.g., alone or in combination with other fibers) in any nonwoven processes. For example, some or all of the fibers may be a powder-like consistency (e.g., with a fiber length of about 3 millimeters or less, about 2 millimeters or less, or even smaller, such as about 200 microns or greater or about 500 microns or greater). Fibers of differing lengths may be combined to provide desired properties. The fiber length may vary depending on the application; the moisture properties desired; the type, dimensions and/or properties of the fibrous material (e.g., density, porosity, desired air flow resistance, thickness, size, shape, and the like of the fibrous portion and/or any other portion of the pad material); or any combination thereof. The addition of shorter fibers, alone or in combination with longer fibers, may provide for more effective packing of the fibers, which may allow pore size to be more readily controlled in order to achieve desirable characteristics (e.g., moisture interaction characteristics).

[0059] The fibrous portion (or any other portion of the material) may include fiber blends. The fibrous portion may include natural, manufactured, or synthetic fibers. Suitable natural fibers may include cotton, jute, wool, flax, silk, cellulose, glass, and ceramic fibers. The fibrous portion may include eco-fibers, such as bamboo fibers or eucalyptus fibers. Suitable manufactured fibers may include those formed from cellulose or protein. Suitable synthetic fibers may include polyester, polypropylene, polyethylene, Nylon, aramid, imide, acrylate fibers, or combination thereof. The fibrous portion material may comprise polyester fibers, such as polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), and co-polyester/polyester (CoPET/PET) adhesive bi-component fibers. The fibers may include polyacrylonitrile (PAN), oxidized polyacrylonitrile (Ox-PAN, OPAN, or PANOX), olefin, polyamide, polyetherketone (PEK), polyetheretherketone (PEEK), polyethersulfone (PES), or other polymeric fibers. The fibers may be selected for their melting and/or softening temperatures. Fibers may be inorganic fibers. The fibers may include mineral or ceramic fibers. The fibers may be or may include elastomeric fibers. Elastomeric fibers may provide cushioning performance and/or compressibility and recovery properties. Exemplary elastomeric fibers include elastic bicomponent PET, PBT, PTT, or a combination thereof. The fibers may be formed of any material that is capable of being carded and lapped into a three-dimensional structure. The fibers may be 100% virgin fibers, or may contain fibers regenerated from postconsumer waste (for example, up to about 90% fibers regenerated from postconsumer waste or even up to 100% fibers regenerated from postconsumer waste). The fibers may have or may provide improved moisture absorption or moisture resistance characteristics, or both.

[0060] Fibers may have particles embedded therein. The particles may act to remove moisture in the vapor stage (e.g., before becoming liquid). The particles may be embedded through an extrusion process. These particles may provide breathability and/or waterproofing properties to the fibrous portion. The particles present in the fibers may increase the surface area of the fiber by 50% or more, about 100% or more, by 200% or more, or by 500% or more as compared with a fiber that is free of embedded particles. The particles may increase the surface area of the fiber by about 1200% or less, about 1000% or less, or about 900% or less. The high surface area of the fiber may provide high adsorption properties. These fibers may assist in providing heating and/or cooling. These fibers may provide odor control, humidity control (e.g., body humidity control), or both. The particles may assist in removing or driving moisture vapor away from the source (e.g., through the portion or layer). Embedded particles may include, but are not limited to, wood, shells (e.g., fruit and/or nut shells, such as coconut shells or fibers thereon, hazelnut shells), activated carbon, sand (e.g., volcanic sand), or a combination thereof. For example, the fiber may be a PET fiber extruded with active carbon and/or volcanic sand.

[0061] The fibers may be 100% virgin fibers or less. The fibers may include fibers regenerated from postconsumer waste (for example, up to about 90% fibers regenerated from postconsumer waste or even up to 100% fibers regenerated from postconsumer waste). The fibers may have or may provide improved thermal insulation properties. The fibers may have relatively low thermal conductivity. Such fibers may be useful for retaining heat or slowing the rate of heat transfer (e.g., to keep a user or wearer warm). The fibers may have or may provide high thermal conductivity, thereby increasing the rate of heat transfer. Such fibers may be useful for extracting heat from the surface of the source of moisture (e.g., to cool a user or wearer). The fibers may have geometries that are non-circular or non-cylindrical. The fibrous portion may include or contain engineered aerogel structures to impart additional thermal insulating benefits. The fibrous portion may include or be enriched with pyrolyzed organic bamboo additives.

[0062] The fibers, or at least a portion of the fibers, making up one or more fibrous portion and/or pad material may include a hydrophilic treatment, finish, or coating. The hydrophilic finish or coating may create or improve the capillary effect of drawing the moisture into the capillaries or channels formed by the fibers or improve absorption of the material by drawing the moisture away from the user. The fibers may be inherently hydrophilic. Hydrophilic fibers (e.g., inherently hydrophilic or with a hydrophilic treatment, finish, or coating), may be about 10 percent by weight of the fibers of the fibrous portion or greater, about 20 percent by weight or greater, about 40 percent by weight or greater, about 50 percent by weight or greater, about 60 percent by weight or greater. Hydrophilic fibers may be up to 100 percent by weight of the fibers of the fibrous portion.

[0063] For example, up to 100 percent of the staple fibers (e.g., polyester fibers) may be hydrophilic fibers. In an example where the fibers include about 70 percent by weight staple fibers and about 30 percent by weight bi-component fiber and/or binder, and all of the staple fibers are hydrophilic fibers, then the fibrous portion includes at least about 70 percent by weight hydrophilic fibers.

[0064] The fibers, or at least a portion of the fibers, may be super absorbing fibers (SAF). The SAF may be formed of a cellulose material or a synthetic polymeric material, for example. The SAF may be in a blend with other fibers. The SAF may be present in an amount of about 60% of the blend by weight or less, about 50% by weight or less, or about 40% by weight or less. The SAF may be present in an amount greater than 0%, about 1% by weight or greater, or about 5% by weight or greater. The SAF may pull moisture into the material cross-section, where it may evaporate.

[0065] One or more fibrous portion (or any other portion of the material) may include a plurality of bi-component fibers. The bi-component fibers may be a thermoplastic lower melt bicomponent fiber. The bi-component fibers may have a lower melting temperature than the other fibers within the mixture (e.g., a lower melting temperature than common or staple fibers). The bi- component fibers may be air laid or mechanically carded, lapped, and fused in space as a network so that the pad material or a portion thereof may have structure and body and can be handled, laminated, fabricated, installed as a cut or molded part, or the like to provide desired properties. The bi-component fibers may include a core material and a sheath material around the core material. The sheath material may have a lower melting point than the core material. The sheath material may have a melting point of about 90°C or greater, about 100 °C or greater, about 110°C or greater, or about 120 °C or greater. The sheath material may have a melting point of about 300°C or less, about 250°C or less, or about 200°C or less. The web of fibrous material may be formed, at least in part, by heating the material to a temperature to soften the sheath material of at least some of the bi-component fibers.

[0066] The bi-component fibers may be selected to provide the necessary attachment to other fibers in the fibrous portion at a node or connection point. The strength of the nodes or connection points may impact the resilience, reusability, washability, durability, cushioning, comfort, or a combination thereof to the wearer. The amount, denier, length, and/or type of bi- component fiber may be selected based on the desired connections between fibers.

[0067] The bi-component fiber may be present in the fibrous portion in an amount of about 100 percent by weight or less, about 80 percent by weight or less, about 60 percent by weight or less, about 50 percent by weight or less, about 40 percent by weight or less, about 30 percent by weight or less, about 25 percent by weight or less, or about 15 percent by weight or less. For example, the fibrous portion may include about 25 percent by weight to about 35 percent by weight (e.g., about 30 percent by weight) bi-component fiber. The fibrous portion may include about 65 percent by weight to about 75 percent by weight non-bi-component fiber (e.g., a polyester fiber). [0068] The bi-component fiber may have an average denier of about 0.5 denier or greater, about 1 denier or greater, about 1.5 denier or greater, or about 2 denier or greater. The bi- component fiber may have an average denier of about 10 denier or less, about 6 denier or less, or about 4 denier or less.

[0069] The average length of the bi-component fiber may be about 75 mm or less. The average length of the bi-component fiber may be about 10 mm or more, about 20 mm or more, about 30 mm or more, about 40 mm or more, or about 50 mm or more. The average length of the bi-component fiber may be similar to the length of the staple fibers (e.g., about 50 mm to about 75 mm).

[0070] The bi-component fiber may have a polyester core. For example, the core may be polyethylene terephthalate (PET); polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), or a combination thereof. The bi-component fiber may have a co-polyester sheath. For example, the sheath may be co-PET.

[0071] The fibrous portion (or any other portion of the pad material) may include a binder or binder fibers. The binder may include the bi-component fibers. The binder may be the bi- component fibers. The binder may exclude the bi-component fibers. Binder may be present in the fibrous portion in an amount of about 100 percent by weight or less, about 80 percent by weight or less, about 60 percent by weight or less, about 50 percent by weight or less, about 40 percent by weight or less, about 30 percent by weight or less, about 25 percent by weight or less, or about 15 percent by weight or less. The fibrous portion may be substantially free of binder. The fibrous portion may be entirely free of binder. While referred to herein as fibers, it is also contemplated that the binder could be generally powder-like, spherical, or any shape capable of being received within interstitial spaces between other fibers and capable of binding the fibrous portion together. The binder may have a softening and/or melting temperature of about 70 °C or greater, about 100 °C or greater, about 110 °C or greater, about 130 °C or greater, 180 °C or greater, about 200 °C or greater, about 225 °C or greater, about 230 °C or greater, or even about 250 °C or greater. For example, the binder may have a softening and/or melting temperature between about 70 °C and about 250 °C (with any range therein being contemplated). The fibers may be high-temperature thermoplastic materials. The fibers may include one or more of polyamideimide (PAI); high- performance polyamide (HPPA), such as Nylons; polyimide (PI); polyketone; polysulfone derivatives; polycyclohexane dimethyl-terephthalate (PCT); fluoropolymers; polyetherimide (PEI); polybenzimidazole (PBI); polyethylene terephthalate (PET); polybutylene terephthalate (PBT); polyphenylene sulfide; syndiotactic polystyrene; polyetherether ketone (PEEK); polyphenylene sulfide (PPS), polyether imide (PEI); and the like. The fibrous portion may include polyacrylate and/or epoxy (e.g., thermoset and/or thermoplastic type) fibers. The fibrous portion may include a multi-binder system. The fibrous portion may include one or more elastomeric fiber materials acting as a binder. The fibrous portion may include one or more sacrificial binder materials and/or binder materials having a lower melting temperature than other fibers within the portion.

[0072] The fibers forming the one or more fibrous layers may be formed into a nonwoven web using nonwoven processes including, for example, blending fibers, carding, lapping, air laying, mechanical formation, or a combination thereof. Through these processes, the fibers may be oriented in a generally vertical direction or near-vertical direction (e.g., in a direction generally perpendicular to the longitudinal axis of the fibrous layer). Fibers as used herein may refer to measurements of individual fibers, measurements of average direction of fibers (e.g., as visible in an enlarged photograph), or both. Direction of the fibers may be determined through the entire thickness of the material. Direction of the fibers may be determined through only a portion of the thickness of the material. For example, orientation of fibers or orientation of portions of segments between loops, may be considered at or near the surface adapted to contact a user. The fibers may be opened and blended using conventional processes. The resulting structure formed may be a lofted fibrous layer. The lofted fibrous layer may be engineered for optimum weight, thickness, physical attributes, thermal conductivity, insulation properties, moisture absorption, or a combination thereof.

[0073] One or more fibrous portions may be formed, at least in part, through a carding process. The carding process may separate tufts of material into individual fibers. During the carding process, the fibers may be aligned in substantially parallel orientation with each other and a carding machine may be used to produce the web. The fibers may extend generally in or generally parallel to the machine direction.

[0074] A carded web may undergo a lapping process to produce the fibrous portion. The carded web may be rotary lapped, cross-lapped or vertically lapped, to form a voluminous or lofted nonwoven material. The carded web may be vertically lapped according to processes such as “Struto” or “V-Lap”, for example. This construction provides a web with relative high structural integrity in the direction of the thickness of the fibrous layers, thereby minimizing the probability of the web falling apart during application, or in use, and/or providing compression resistance to the layered material. Carding and lapping processes may create nonwoven fibrous layers that have good compression resistance through the vertical cross-section (e.g., through the thickness of the pad material) and may enable the production of lower mass fibrous layers, especially with lofting to a higher thickness without adding significant amounts of fiber to the matrix. It is contemplated that a small amount of hollow conjugate fiber (i.e., in a small percentage) may improve lofting capability and resiliency to improve moisture absorption, physical integrity, or both. Such an arrangement also provides the ability to achieve a low density web with a relatively low bulk density.

[0075] The lapping process may create a looped, sinusoidal, or undulated appearance of the fibers when viewed from its cross-section prior to any compression operation. The loops may have generally curved or rounded portions (e.g., as opposed to sharp creases from a traditional pleating operation).

[0076] The frequency of the loops or undulations may be varied during the lapping process. For example, having an increase in loops or undulations per area may increase the density and/or stiffness of the portion or portions of the pad material. Reducing the loops or undulations per area may increase the flexibility of the portion or portions of the pad material and/or may decrease the density.

[0077] The ability to vary the loop or undulation frequency during the lapping process may allow for properties of the material to be varied or controlled. It is contemplated that the loop or undulation frequency may be varied throughout the material. During the lapping process, the loop frequency may be dynamically controlled and/or adjusted. The adjustment may be made during the lapping of a layer of the material. For example, certain portions of the fibrous portion or the fibrous absorbing material may have an increased frequency, while other portions of the fibrous portion or the fibrous absorbing material may have a frequency that is lower. The adjustment may be made during the lapping of different layers of the material. Different layers may be made to have different properties with different loop frequencies. For example, one portion may have a loop frequency that is greater than or less than another portion of the fibrous portion or fibrous absorbing material.

[0078] The frequency of loops may be about 5 loops per decimeter or greater, about 7 loops per decimeter or greater, or about 10 loops per decimeter or greater. The frequency may be over the entire fibrous portion. The frequency may be over only a portion of the fibrous portion. If the fibrous portion has a varying frequency, the average frequency for at least a portion of the fibrous portion may be about 5 loops per decimeter or greater, about 7 loops per decimeter or greater, or about 10 loops per decimeter or greater. The frequency of loops may be about 50 loops per decimeter or less, about 40 loops per decimeter or less, or about 35 loops per decimeter or less. If the fibrous portion has a varying frequency, the average frequency for at least a portion of the fibrous portion may be about 50 loops per decimeter or less, about 40 loops per decimeter or less, or about 35 loops per decimeter or less.

[0079] The distance between adjacent loops may be determined by the frequency of the loops. The distance between two adjacent loops may be about 0 mm (i.e. , no gap between loops) or greater, about 0.25 mm or greater, or about 0.5 mm or greater. The distance between two adjacent loops may be about 3 mm or less, about 2 mm or less, or about 1 mm or less. The distance may be measured from one crest to an adjacent crest. The distance may be measured from the closest points between the two loops. The distance may be measured from the farthest points between the two loops on opposing sides of the gap. The distance may be measured by calculating the average gap at multiple points between the two loops. The distance may be measured between one point and another point.

[0080] A loop may have an outer radius and an inner radius. The radii may be determined prior to any compression operations. The radii may be determined by the frequency of the loops. The outer radius of a loop may be about 1 mm or greater, about 2 mm or greater, or about 2.5 mm or greater. The outer radius of a loop may be about 5 mm or less, about 4 mm or less, or about 3.5 mm or less. For example, the outer radius of a loop may be about 2.75 mm or greater and about 3.25 mm or less (e.g., about 3 mm). The inner radius of a loop may be about 0.5 mm or greater, or about .75 mm or greater. The inner radius of a loop may be about 2 mm or less, or about 1.5 mm or less. For example, the inner radius of a loop may be about .75 mm or greater and about 1.25 mm or less (e.g., about 1 mm).

[0081] At least some of the loops within the fibrous portion may be compressed upon additional processing, adding of layers to the fibrous absorbing material, or both. This may cause the loops to flatten or otherwise deform at least partially. This may create a generally horizontal orientation of fibers that are generally parallel to an adjacent layer of material or opposing surface. The adjacent layer may be an outer layer of the fibrous absorbing material. This may also act to increase the surface area of the fibers and/or fibrous portion contacting the adjacent layer of material. This increased surface area may enhance the movement of moisture to the adjacent layer.

[0082] Between upper loops and lower loops may be a generally vertical portion of fibers. In referring to generally vertical fibers, this may include an average measurement of angles with individual fibers. This may include an average measurement of angles with a visible trend of fiber direction. This may include an average measurement of angles and/or individual fibers within a designated area of the material (e.g., at or near a surface, such as a surface of the material adapted to face the wearer or the source of moisture). [0083] The orientation may be determined based on superimposing a grid upon an image of the fibrous material, viewing the material from the side at its thickness. Each cell in the grid may be evaluated separately. The grid may include three or more rows and three or more columns. The grid and/or cells thereof may be square. The grid and/or cells thereof may be nonsquare. There may be the same number of rows and columns. There may be different numbers of rows and columns. For example, a grid could be superimposed on the photos of Figures 3-6. The more cells within the grid, the greater the accuracy of the calculation. For example, a 10 by 10 grid would produce 100 cells, where the angle of the average trend of visible fibers relative to the bottom of the cell, relative to the surface adapted to contact the wearer, relative to a top surface, relative to a bottom surface, relative to the longitudinal axis of the material or a combination thereof, would be calculated. A generally vertical orientation of the fibers in the cell may be at an angle between about 45 degrees and about 135 degrees, between about 60 degrees and about 120 degrees, between about 75 degrees and about 105 degrees.

[0084] The percentage of fibers of the fibrous portion, or the percentage of cells having a calculated angle of the average trend of visible fibers, in a generally vertical direction prior to any compression operations may be about 50% or greater, about 60% or greater, about 70% or greater, or about 75% or greater. The percentage of fibers of the fibrous portion in a generally vertical direction prior to any compression operations may be about 95% or less, about 90% or less, or about 85% or less. For example, the percentage of fibers in a generally vertical direction prior to any compression operations may be about 75% to about 85% (e.g., about 80%).

[0085] When viewing the fibrous material at its thickness, there may be one or more inflection points where the trend of fibers, laps, or segments between loops changes direction. Despite the change in direction, it is possible the fibers may still be considered generally vertical. For example, an angle of trending fibers or laps may be about 60 degrees until reaching an inflection point. The direction may change at the inflection point, where the angle of the new trend relative to the longitudinal axis of the material is about 120 degrees. Both 60 degrees and 120 degrees may be considered vertical where a generally vertical orientation of the fibers includes angles between about 45 degrees and about 135 degrees or between about 60 degrees and about 120 degrees.

[0086] In a material with a plurality of inflection points, if determining orientation via the grid method, to determine whether the fibers or trend of fibers are generally vertical, smaller and/or more cells may be necessary to more easily view, determine, and/or calculate the trend or average direction of the fibers within the cell. [0087] The orientation of fibers may be evaluated at or near the surface adapted to contact the wearer or the source of moisture.

[0088] The average angle of approach of the fibers, laps, loops, or the like to the surface may be calculated. The average angle of approach or incidence angle may be measured between halfway through the thickness and the surface (e.g., within 50% of the thickness) or less, within 25 percent of the thickness or less, within 15 percent of the thickness or less. For example, the angle may be measured by viewing fibers and/or laps between the surface and 10 mm or less away from the surface into the thickness of the material, about 7 mm or less, about 5 mm or less, or about 2 mm or less.

[0089] If calculating using the grid, one or more rows of cells closest to the surface adapted to contact the wearer or the source of moisture may be evaluated. The angle of approach of the fibers, laps, loops, or the like to the surface may be calculated within each cell of the grid. The percentage of cells with fibers considered to be generally vertical may be about 50% or greater, about 60% or greater, about 70% or greater, about 75% or greater, or about 100% or less.

[0090] A vertical portion may have a thickness or an average thickness of about 0.5 mm or greater, about 1 mm or greater, or about 2 mm or greater. A vertical portion may have a thickness or an average thickness of about 7 mm or less, about 6 mm or less, or about 5 mm or less. For example, the thickness of a vertical portion may be about 2.5 mm to about 4.5 mm (e.g., from about 3 mm to about 4 mm).

[0091] At or near the loops of the fibrous portion, the fibers may be oriented generally horizontally, where generally horizontal is measured within about ± 45 degrees from horizontal, with about ± 30, or within about ± 15, and where horizontal is generally parallel to the longitudinal axis of the fibrous portion, generally parallel to one or more facing layers, generally perpendicular to the thickness direction, or a combination thereof. The percentage of fibers of the fibrous portion in a generally horizontal direction may be about 5% or greater, about 10% or greater, or about 15% or greater. The percentage of fibers of the fibrous portion in a generally horizontal direction may be about 30% or less, about 27% or less, or about 25% or less. For example, the percentage of fibers in a generally horizontal direction may be about 18% or more to about 22% or less (e.g., about 20%).

[0092] The amount of fibers in a generally random orientation may be the remaining fibers that are not horizontal or vertical. The percentage of randomly oriented fibers in the fibrous portion may be about 0% or greater. The percentage of randomly oriented fibers in the fibrous portion may be about 10% or less, about 5% or less, or about 2% or less. [0093] In an exemplary fibrous portion, the carded web, with the fibers generally extending in the machine direction, may then undergo a lapping process, creating a series of loops, laps, or undulations (e.g., appearing as generally curved or rounded peaks and valleys when viewed from the side or a cross section). The loops (e.g., line extending across an entire peak or valley) may extend across the surface of the material generally perpendicularly to the longitudinal axis of the fibrous portion, generally perpendicularly to the longitudinal axis of the article of footwear extending from heel to toe, generally perpendicularly to the machine direction, or a combination thereof.

[0094] In another exemplary fibrous layer, it is contemplated that the loops (e.g., line extending across an entire peak or valley) may extend generally parallel to the longitudinal axis of the fibrous portion, generally parallel to the longitudinal axis of the article of footwear extending from heel to toe, or both.

[0095] The fibrous portion may be formed by an air laying process. This air laying process may be employed instead of carding and/or lapping. In an air laying process, fibers are dispersed into a fast moving air stream, and the fibers are then deposited from a suspended state onto a perforated screen to form a web. The deposition of the fibers may be performed by means of pressure or vacuum, for example. An air laid or mechanically formed web may be produced. The web may then be thermally bonded, air bonded, mechanically consolidated, the like, or combination thereof, to form a cohesive nonwoven fibrous layer. While air laying processes may provide a generally random orientation of fibers, there may be some fibers having an orientation that is generally in the vertical direction so that resiliency in the thickness direction of the material may be achieved.

[0096] During processing of the material, the fibrous layers may be compressed. Compression may occur during lamination, thermoforming in-situ, or the like. Compression may reduce thickness of the fibrous layers. The thickness may be reduced by 30% or more, about 40% or more, about 50% or more, or about 55% or more. The thickness may be reduced by about 80% or less, about 75% or less, about 67% or less, or about 60% or less. For example, a fibrous layer prior to compression may be about 15 mm to about 18 mm thick. After compression, the fibrous layer may be about 9 mm to about 10 mm. Upon compression, instead of a generally sinusoidal cross-section with generally straight segments between opposing loops, the segments between the loops may be generally C-shaped, S-shaped, Z-shaped, or otherwise curved, folded, or bent.

[0097] The pad material may be formed of a plurality of layers, including one or more wicking layers, one or more outer layers, one or more facing layers, one or more backing layers, one or more contact layers, one or more skin layers, and/or one or more fibrous layers or fibrous portions, in any combination and in any order. Some layers may serve multiple purposes (e.g., a layer may be a wicking layer, an outer layer, a facing layer, and/or a contact layer at the same time). While referred to as “layers,” it is contemplated that this includes discrete layers or portions within one or more materials. For example, a two layer material may include two discrete layers or a single material having two different portions. The pad material may include two or more fibrous layers. The pad material may include one or more lofted layers, one or more wicking layers, or both. A skin layer may be formed by melting a portion of the layer by applying heat in such a way that only a portion of the layer, such as the top surface, melts and then hardens to form a generally smooth surface. A scrim may be applied or secured to one or more fibrous layers. The pad material may include a plurality of layers, some or all of which serve different functions or provide different properties to the pad material. The ability to combine layers having different properties may allow the pad material to be customized based on the application. For example, the layers may be combined so that the layered material is a pad for an article of footwear that is moisture wicking, moisture transferring, insulative, cooling, has low drying times, or a combination thereof. The layers may be combined so that the pad material provides cushioning with high resilience.

[0098] The pad material, or the fibrous portion thereof, may have a fabric weight of about 100 grams per square meter (gsm) or greater, about 200 gsm or greater, about 300 gsm or greater, about 400 gsm or greater, about 500 gsm or greater, or about 600 gsm or greater. THe pad material, or the fibrous portion thereof, may have a fabric weight of about 2000 gsm or less, about 1600 gsm or less, about 1500 gsm or less, or about 1200 gsm or less. The weight may be selected based on the location within the article of footwear. For example, a pad material or fibrous portion located within an upper of the article of footwear may have a weight of about 200 gsm to about 500 gsm. In another example, a pad material or fibrous portion located at an insole may have a weight of about 600 gsm to about 1200 gsm.

[0099] The pad material may include one or more contact portions. A contact portion may be adapted to contact a wearer directly or indirectly (e.g., via contact with a wearer’s sock, bracing garment or bandage, or hosiery). A contact portion may be adapted to be positioned between the fibrous portion and an outer material of the article of footwear. A contact portion may attach, adhere, or secure the fibrous portion to another portion of the article of footwear, such as an outer material of the article of footwear, such that the pad material is positioned between the outer portion of the article of footwear and the wearer. In a pad material having two or more contact portions, the contact portions may be formed of the same material. The contact portions may be formed of different materials.

[00100] A contact portion may include one or more wicking layers. A wicking layer may be formed from a nonwoven material, a woven material, a knit material, a meltblown material (e.g., of thermoplastic polyurethane), or the like. One or more wicking layers may be made from Lycra, polyester, polyethylene terephthalate, or a combination thereof.

[00101] A contact portion may draw moisture in vapor form away from the source. For example, one or more contact portions may pull perspiration vapor away from a wearer’s foot before the perspiration becomes liquid sweat. A contact portion may assist in or facilitate direction of vapor out of the article of footwear (e.g., via one or more air flow channels).

[00102] A contact portion may have a generally flat or generally smooth surface. A contact portion may have a non-smooth surface. A contact portion may have a textured surface, such as a corduroy surface or surface having a plurality of channels, undulations, or areas of varying thickness. A contact portion may have a frictional surface, such that a wearer’s foot does not slide within the article of footwear while walking, running, or the like.

[00103] A coating may be applied to one or more portions or layers of the pad material. For example, a coating may be applied to form one or more surface layers on the fibrous portion. The coating may improve one or more characteristics of the pad material. For example, the surface layers may be anti-microbial, anti-fungal, have high infrared reflectance, moisture resistant, mildew resistant, or a combination thereof. The surface layers may be an extension of the fibrous portion or wicking layer. At least some of the surface layers may be metalized. For example, fibers along an outer surface of the fibrous layers or wicking layers may form the surface layers. Metallization processes can be performed by depositing metal atoms onto the fibers of the surface layers. As an example, metallization may be established by applying a layer of silver atoms to a surface layers or as a surface layer. Metalizing may be performed prior to the application of any additional layers to the fibrous layers.

[00104] The metallization may provide a desired reflectivity or emissivity. The surface layers may be about 50% IR reflective or more, about 65% IR reflective or more, or about 80% IR reflective or more. The surface layers may be about 100% IR reflective or less, about 99% IR reflective or less, or about 98% IR reflective or less. For example, the emissivity range may be about 0.01 or more or about 0.20 or less, or 99% to about 80% IR reflective, respectively. Emissivity may change over time as oil, dirt, degradation, and the like may impact the fibers in the application. [00105] Other coatings may be applied to the fibrous portion or another portion of the pad material to form the surface layers, metallized or not, to achieve desired properties. Hydrophilic coatings or treatments may be added. Oleophobic and/or hydrophobic treatments may be added. Flame retardants may be added. A corrosion resistant coating may be applied to the metalized fibers to reduce or protect the metal (e.g., aluminum) from oxidizing and/or losing reflectivity. IR reflective coatings not based on metallization technology may be added.

[00106] Anti-microbial or anti-fungal coatings may be applied. For example, silver powder or other antimicrobial nano-powders can be added into a portion of the fibrous layers to form the surface layers.

[00107] The pad material or portions thereof may be formed into a generally flat sheet. The pad material or parts thereof (e.g., as a sheet) may be capable of being rolled into a roll. The pad material may be a continuous material so that longer lengths can be employed in a single piece. The pad material (or one or more portions of the pad material) may be an engineered 3D structure. It is clear from these potential layers that there is great flexibility in creating a material that meets the specific needs of an end user, customer, installer, and the like.

[00108] The fibrous layers, the wicking layers, the surface layers, or a combination thereof may be directly attached to one another. One or more layers or portions may be attached to another by a laminating process. The one or more layers or portions may then be supplied as a roll or a sheet of the laminated product. The one or more layers, therefore, may be attached to each other prior to any additional shaping or molding steps. The one or more layers may include a thermoplastic component (e.g., binder or fibers) that melt and bond to an adjacent surface upon exposure to heat. One or more layers or portions may be attached to each other with an adhesive layer. The adhesive layer may be an adhesive. The adhesive may be a powder or may be applied in strips, sheets, or as a liquid or paste. The adhesive layer may extend along a surface of the fibrous layers, the wicking layers, the surface layers, or a combination thereof, to substantially cover the surface. The adhesive layer may be applied to a portion of the surface of the fibrous layers, the wicking layers, the surface layers, or a combination thereof. The adhesive layer may be applied in a pattern (e.g., dots of adhesive applied to the surface). The adhesive layer may be applied in a uniform thickness. The adhesive layer may have varying thickness. The adhesive layer may be a single layer (e.g., a single adhesive). The adhesive layer may be multiple layers (e.g., an adhesive layer and a thermoplastic fiber layer). The adhesive layer may be a single layer of blended materials (e.g., an adhesive and thermoplastic fibers are blended in a single layer).

[00109] The layers or portions may be directly attached to each other via other processes, such as by sewing, entanglement of fibers between layers, sealing, or other methods. The edges of the layers or portions may be sewn together. One or more layers may be sealed at the edges. For example, the outer layers (e.g., the wicking layers) may be sealed at the edges to encapsulate the interior layers, such as one or more fibrous portions. The layers may be heated and/or compressed to seal all of the layers together. For example, heated pinch edge sealing may bond the layers together. A double die system may be used, where the central portion of each die is insulated so as not to burn or melt the body of the material, and the edges of the dies are heated and pinched together such that the edges are sealed and the body of the material remains lofted. The thickness at this pinched edge may be about 3 mm or less, about 2 mm or less, or about 1 mm or less and greater than 0 mm. One or more layers or one or more edges may be ultrasonically sealed. The edge may be trimmed or cut after heating, compressing, pinching, sealing, the like, or combination thereof.

[00110] One of more of the portions of the pad material may have hydrophobic properties. One or more of the portions of the pad material may have hydrophilic properties. Entire layers may be hydrophobic or hydrophilic. A layer may have both hydrophobic and hydrophilic properties. For example, a layer may be formed from a mixture of hydrophobic fibers and hydrophilic fibers. The interfaces between layers may include one hydrophobic layer or portion abutting a hydrophilic layer or portion. The portion contacting the source of the moisture may be hydrophilic. Such layer may cause moisture to wick away from the skin and distribute the moisture over a larger area to quicken the wicking. Adjacent layers may, for example, be hydrophobic. This may assist in the drying of the material and/or resisting the uptake of moisture from the external environment. It is also possible that a hydrophobic layer or portions thereof may function to draw moisture away from a surface (e.g., a user’s skin) while absorbing little to no moisture, thereby acting to wick away the moisture. The hydrophobic layers or portions thereof may function to transfer moisture to another layer of the pad material. The hydrophilic layers or portions thereof may function to absorb moisture (e.g., from one or more hydrophobic layers or portions). Fibers within the layers may be hydrophobic. Fibers within the layers may be hydrophilic.

[00111] Fibers of one or more portions of the pad material, or one or more portions of the pad material, may exhibit antimicrobial properties. The fibers may be treated with an antimicrobial substance. For example, silver or copper may be used. Fibers may be coated with silver, copper, or a combination thereof. The antimicrobial substance may be otherwise deposited on the surface of the fibers (e.g., via sputtering, electrostatic deposition). The antimicrobial substance may be part of the fibers. For example, silver particles, copper particles, or both, may be within fibers of the one or more layers of the pad material. Fibers may be coated with or include chitosan. For example, fibers may be coated with a liquid chitosan formulation such as Tidal-Tex™ base formula from Tidal Vision Products, Inc., in Bellingham, Washington. Fibers may be coated with or be infused with one or more essential oils. Examples of essential oils include but are not limited to tea tree, eucalyptus, peppermint, cinnamon, clove, lemon, lemongrass, thyme, oregano, citronella, sage, or a combination thereof. Fibers may be coated with or include active enzymes. Fibers may be coated with one or more agents, such as Envira® products from PT Envira Indonesia, in East Java, Indonesia.

[00112] The pad material disclosed exhibits breathability, which allows for an increased drying time of the material and/or increased cooling of the surface of the source of the moisture. With the ability for air to permeate the material, this decreases the drying time, thereby also decreasing the formation of mold, mildew, and/or odors. The pad material, or one or more layers thereof, may exhibit a permeability at 100 Pa of about 600 liters per square meter per second (L/m ² /s) or greater, about 700 L/m ² /s or greater, or about 800 L/m ² /s or greater. The pad material, or one or more layers thereof, may exhibit a permeability of about 1500 L/m ² /s or less, about 1200 L/m ² /s or less, or about 1000 L/m ² /s or less. This is a significant improvement over other traditional materials. For example, a polyurethane memory foam at 1100 g/m ² at 15 mm thickness exhibits a permeability of about 500 L/m ² /s. An open cell polyurethane foam material at 600 g/m ² at 20 mm thickness exhibits a permeability of less than about 100 L/m ² /s. A two-layered foam formed of an ethylene vinyl acetate foam layer at 10 mm thickness and polyurethane foam layer 2 mm thickness at 1100 g/m ² total exhibits no permeability.

[00113] The pad material or one or more portions thereof (e.g., fibrous portion) may be formed to have a thickness and density selected according to the required physical, insulation, moisture absorption/resistance, and air permeability properties desired of the finished layers (and/or the pad material as a whole). The portions of the pad material may be any thickness depending on the application, location of installation, shape, fibers used, fiber geometry and/or orientation, lofting of the fibrous layers, or other factors. The density of the layers may depend, in part, on the specific gravity of any additives incorporated into the material comprising the layer (such as nonwoven material), and/or the proportion of the final material that the additives constitute. The pad material may have a varying density and/or thickness along one or more of its dimensions. Bulk density generally is a function of the specific gravity of the fibers and the porosity of the material produced from the fibers, which can be considered to represent the packing density of the fibers.

[00114] The pad material, or portions thereof, may be formed through one or more lamination techniques, or another technique capable of joining two or more layers together. The two or more layers or portions may then be supplied as a roll or a sheet of the laminated product. The two or more layers, therefore, may be attached to each other prior to any additional shaping or molding steps.

[00115] The fibrous portion, the pad material, or both, may be a thermoformable material, which indicates a material that may be formed with a broad range of densities and thicknesses and that contains a thermoplastic and/or thermoset binder. The thermoformable material may be heated and thermoformed into a specifically shaped thermoformed product. The pad material may have a varying thickness (and therefore a varied or non-planar profile) along the length of the material. Areas of lesser thickness may be adapted to provide controlled flexibility to the material, such as to provide an area with additional flexibility and elasticity, such as to form a stretchable compression article of clothing. The pad material may be shaped (e.g., by folding, bending, thermoforming, molding, and the like) to produce a shape generally matching a desired shape for a given application. The finished pad material may be fabricated into cut-to-print two-dimensional flat parts depending on the desired application. The pad material may be formed into any shape. For example, the pad material may be molded (e.g., into a three-dimensional shape) to generally match a desired shape. The finished pad material may be molded-to-print into a three-dimensional shape for a desired application.

[00116] The pad material may act to absorb moisture, such as perspiration. The pad may allow for evaporation of the moisture. Evaporation may occur while the article of footwear is being worn, when the article of footwear is not being worn, or both. The pad material may direct moisture toward areas of the material located at or near an air vent or near an area with air flow. For example, the pad material may direct moisture to the collar of the article of footwear or to an area of vent openings or mesh at or near the sole of the article of footwear. The pad material may direct moisture to an opening in the article of footwear, such as if the article of footwear is a clog (where the quarter is not present); a sandal (where openings are present, such as at the toes and/or heel); or a peep-toe shoe (where openings are present, such as at the toes). It is contemplated that at or near areas adjacent an air vent, the material may have a faster evaporation rate. It is possible that areas exposed to the greatest air flow may dry faster or may exhibit a higher rate of evaporation than areas not exposed to as much air flow. The material, in that location, may be drier than other portions of the material. The material may then pull more moisture toward the drier areas, thereby increasing and expediting evaporation.

[00117] Through and between any of the portions or layers of the pad material, moisture may travel in any direction. Moisture may move vertically in the thickness direction. Moisture may move in the length and/or width direction. Moisture may travel at any angle between vertical and horizontal, relative to the thickness direction. Moisture may travel at any angle between the length direction and the width direction relative to the longitudinal axis of the layered material. Moisture may travel to areas having less moisture present (e.g., areas at or near an area of air flow). Moisture may travel generally linearly. Moisture may travel in a non-linear direction or in multiple directions.

[00118] Moisture may travel across and/or along the fibers of one or more fibrous layers. Moisture may travel in the direction of the fibers. Moisture may travel in the thickness direction in areas between loops of the lapped structure. Moisture may travel in the generally longitudinal direction at areas of loops of the lapped structure. Moisture may travel across loops (e.g., from one loop to an adjacent loop via fibers extending between the two).

[00119] Air flow to the foot and/or air flow within the pad material may be increased or enhanced by one or more air flow channels in the pad material. Air flow may provide cooling to the wearer. Air flow may enhance evaporation of moisture. Air flow may assist in distributing any moisture or vapor within and outside of the article of footwear.

[00120] The pad material may have one or more air flow channels. An air flow channel may be part of or formed in an outermost portion of the pad material (e.g., a contact portion adapted to contact a foot or leg of a wearer, a contact portion adapted to contact another portion of the article of footwear such as an outer layer, or both). An air flow channel may be formed in or part of the fibrous portion of the pad material. An air flow channel may be formed in both a contact portion and a fibrous portion (e.g., via a localized compression operation performed on the pad material, such that the channel is formed in a contact portion and fibrous portion).

[00121] An air flow channel may extend across a surface of the pad material. An air flow channel may extend generally parallel to a surface of the pad material. An air flow channel may extend through the thickness of the pad material. An airflow channel may extend through a portion of the thickness of the pad material. An air flow channel may extend generally perpendicularly to a surface of the pad material. An air flow channel may be a portion of material removed from the pad material. An air flow channel may be formed by adding material to the pad material in certain places (e.g., by adding two or more ribs forming a channel therebetween). An air flow channel may be formed as a result of one or more processing steps. An air flow channel may be formed between two adjacent loops of a vertically lapped fibrous portion. An air flow channel may be formed via one or more localized compression operations. An air flow channel may be formed via one or more stitching operations. An air flow channel may be formed due to a material itself. For example, a textured contact surface (e.g., a corduroy pattern with raised cords or wales and a base fabric or material therebetween forming channels) may have channels formed therein. [00122] The air flow channels may be uniformly distributed across all or a portion of the pad material. The air flow channels may be located only in certain areas. One air flow channel may be generally parallel to another air flow channel. One air flow channel may be at an angle relative to another air flow channel. Two or more air flow channels may intersect. One or more air flow channels may be generally linear. One or more air flow channels may be generally non-linear (e.g., having one or more curves or angles).

[00123] In an article of footwear, one or more air flow channels may be positioned such that hot air from within the article of footwear is able to vent or escape out of the article of footwear. As heat from within the article of footwear rises, the one or more air flow channels may facilitate travel of the heat from the shoe through the collar of the article of footwear. For example, in a boot one or more air flow channels may be generally parallel to the axis extending from the wearer’s knee to the wearer’s ankle. Heat may rise through the shaft of the boot out of the collar. An article of footwear may include one or more ventilation holes or openings or one or more permeable portions (e.g., one or more mesh portions). One or more air flow channels may be positioned such that air is directed via the channel to the ventilation holes or openings or one or more permeable portions. Such air flow channel may permit heat generated from within the article of footwear to escape, permit circulation of external air within the article of footwear, or both, to provide cooling to the wearer, evaporation of moisture within the article of footwear, or both.

[00124] Variations in topography, which may form one or more air flow channels, of one or more layers or portions may be due to one or more operations performed upon the material or due to the material itself. Variations in topography may result in variations of thickness through the pad material or one or more portions thereof. For example, variations in topography may be formed by compression, stitching, or features of the material itself. Variations in topography may be formed via one or more shaping, thermoforming, or molding operations. These variations in topography may provide increased surface area exposed to air flow. For example, channels may be formed via compression, stitching, or textured material. Channels may be formed during one or more shaping operations, such as thermoforming to create a three-dimensional structure. Such channels may permit air flow between the article of footwear and the pad material. Such channels may permit air flow between the wearer and the article of footwear. Increased air flow may provide cooling effects, increased evaporation of moisture, or both. Stitching, localized compression, or texture of the material may allow for tunability of the material to provide desired properties, such as flexibility, fiber orientation, direction of moisture travel, density, air flow, and the like.

[00125] Air may cycle through the pad material during periods of compression and release of the material. As a load is applied and the pad compresses, air is forced out of the material. When the load is released and the pad material returns to an uncompressed or less compressed state, air may be pulled back into the pad material. Air may fill the interstitial spaces in the pad material. This cyclic or periodic load and release may create a pumping effect where air is forced or squeezed out of the pad material and then returns to the pad material. Air may be pulled back into the structure (e.g., via a vacuum effect) as the pad material returns to an uncompressed or less compressed state. This pumping action may increase the air flow within the material. This pumping action may provide a cooling effect to the wearer. As humid air or vapor is pushed out of the material, less humid air may cycle in when the pad material returns to an uncompressed or less compressed state. This may help to exchange warmer and/or more humid air for cooler and/or less humid air as the periodic load cycle continues.

[00126] There may be a desired directionality to the air flow. It is possible that air or vapor may preferentially exit the article of footwear at or around the collar or at or around one or more openings or vents in the article of footwear.

[00127] One or more layers (or the layered material in its entirety) may undergo one or more compression operations. Compression may be areas of localized compression, such that the entirety of the material is not compressed. Compression may be areas of localized compression such that certain areas are compressed more than others. For example, areas of localized compression may be in lines across at least a portion of the surface of the pad material or one or more layers or portions thereof. Localized compression may be via application of heat, pressure, or both. One or more layers or portions may be compressed during the compression operation. This may provide indentations within one or more of the layers to form channels, grooves, or other depressions. Localized compression may secure one or more layers or portions together (e.g., via application of heat and pressure, causing one or more layers to melt and/or activate and adhere to an adjacent layer). Areas of localized compression may extend across at least a portion of the surface of one or more layers or portions. For example, localized compression may be one or more, two or more, or a plurality of lines extending from one edge of the pad material to another edge. The areas of localized compression, such as lines, may begin and/or terminate at distance from the edge so it does not extend the entirety of the length or width of the surface of the layer or surface of the pad material. Lines formed via localized compression may be generally parallel to an axis of the article of footwear, generally parallel to an axis extending from a wearer’s heel to toes, generally parallel to an axis extending from a wearer’s knee to the wearer’s foot, or a combination thereof. Lines formed via localized compression may be generally perpendicular to an axis of the article of footwear, generally perpendicular to an axis extending from a wearer’s heel to toes, generally perpendicular to an axis extending from a wearer’s knee to the wearer’s foot, or a combination thereof. Lines formed via localized compression may be generally parallel to the direction of loops of the fibrous portion. Lines formed via localized compression may be generally perpendicular to the direction of loops of the fibrous portion. Lines formed via localized compression may be at an angle between parallel and perpendicular with the direction of loops of the fibrous portion. Lines formed via localized compression may be generally parallel to each other. Lines formed via localized compression may be an angle between parallel and perpendicular to each other or to another axis of the material. One or more lines formed via localized compression may be at an angle (i.e., nonparallel) relative to another line formed via localized compression. Lines formed via localized compression may intersect (e.g., forming diamonds, triangles, squares, or other polygonal shapes). Other shapes are also contemplated via localized compression, such as a zig zag pattern, dashes, spots, or the like. The number and configuration of areas of localized compression may be selected to tune the performance of the material. The configuration of areas of localized compression may be selected to provide a desired flexibility to the material in certain areas. The areas of localized compression may be generally evenly distributed over the area of the layer or layers. The areas of localized compression may be unevenly distributed, such that certain areas have more areas of localized compression. This may act to increase the density at certain areas of the pad material, increase air flow at certain areas of the pad material, impact flexibility at certain areas of the pad material, or a combination thereof.

[00128] Stitching may be performed instead of or in addition to localized compression.

Stitching may have the same or similar functions as would providing localized compression. Stitching may act to secure two or more layers or portions together. The stitching may extend through one or more of the layers of the pad material. Stitching may extend through the entirety of the pad material. Stitching may extend partially through the pad material. Stitching may be visible on one or both outermost surfaces of the pad material. For example, stitching may be in lines across at least a portion of the surface of the pad material or one or more layers thereof. Stitching may also act to compress one or more layers or portions in the areas of the stitching. The stitches within one or more of the layers may form channels, grooves, or other depressions. Stitching may extend across at least a portion of the surface of one or more layers. For example, stitching may form one or more, two or more, or a plurality of lines extending from one edge of the pad material or portion thereof to another edge. The number and configuration of stitches or lines formed via stitching may be selected to tune the performance of the material. The configuration of stitches may be selected to provide a desired flexibility to the material in certain areas. The stitches may be generally evenly distributed over the area of the layer or layers. The stitches may be unevenly distributed, such that certain areas have more areas of stitching than others. This may act to increase the density at certain areas of the pad material, increase air flow at certain areas of the pad material, impact flexibility at certain areas of the pad material, or a combination thereof. The stitching and/or lines may begin and/or terminate at distance from the edge so it does not extend the entirety of the length or width of the surface of the layer or does not extend all the way to the edge of the material. Lines formed via stitching may be generally parallel to the longitudinal axis of the body of the wearer, the leg of the wearer, the foot of the wearer, or a combination thereof. Lines formed via stitching may be generally parallel to an axis of the article of footwear, generally parallel to an axis extending from a wearer’s heel to toes, generally parallel to an axis extending from a wearer’s knee to the wearer’s foot, or a combination thereof. Lines formed via stitching may be generally perpendicular to an axis of the article of footwear, generally perpendicular to an axis extending from a wearer’s heel to toes, generally perpendicular to an axis extending from a wearer’s knee to the wearer’s foot, or a combination thereof. Lines formed via stitching may be generally parallel to the direction of loops of the fibrous layer. Lines formed via stitching may be generally perpendicular to the direction of loops of the fibrous layer. Lines formed via stitching may be at an angle between parallel and perpendicular with the direction of loops of the fibrous layer. Lines formed via stitching may be generally parallel to each other. Lines formed via stitching may be an angle between parallel and perpendicular to the longitudinal axis. One or more lines formed stitching may be at an angle (i.e., nonparallel) relative to another line formed via stitching. Lines formed via stitching may intersect (e.g., forming diamonds, triangles, squares, or other polygonal shapes). Other shapes are also contemplated via stitching, such as a zig zag pattern, curved patterns, dashes, spots, or the like.

[00129] The pad material may have one or more otherwise textured surfaces (e.g., a plurality of ribs, cords, or wales), raised surfaces, or voids in or across the material. The texture may create channels or undulations in a surface of the material. The texture may provide projections as opposed to or in addition to indentations. The direction of the texture, ribs, cords, wales, or the like may extend in any direction that provides air flow or in any direction as described herein pertaining to localized compression or stitching. The direction of texture, ribs, cords, wales, or the like may extend generally parallel to the direction of loops of the fibrous portion (where the direction of loops is parallel to a line extending across an entire peak or valley or a crest or trough of a loop), generally perpendicular to the direction of loops of the fibrous portion, or any direction therebetween. The texture, ribs, cords, wales, or the like may extend through the entirety of the thickness of the pad material. The texture, ribs, cords, wales, or the like may extend only partially though the thickness of the pad material. The texture, ribs, cords, wales, or the like may only be present on or in a single layer of the material. The texture, ribs, cords, wales, or the like may be generally evenly distributed across the entire surface of the layer or layers. The texture, ribs, cords, wales, or the like may be concentrated in certain areas or may have a non-even distribution. The distribution may increase air flow at certain areas of the material, impact flexibility at certain areas of the layered material, or a combination thereof.

[00130] The pad material may exhibit improved compressive strength (e.g., as compared to a polyurethane foam). As the pad material is compressed, the compressive strength may increase. Upon performance of a compression force deflection test under ASTM D3574-3-C, the pad material may be capable of withstanding loads of about 10 kPa or greater, about 15 kPa or greater, about 20 kPa or greater, about 23 kPa or greater, about 25 kPa or greater, or about 27 kPa or greater. The pad material may gently deform at the outset of an application of load (e.g., having a displacement of about 2 mm or greater, or about 3 mm or greater), providing a soft touch. The pad material may then rapidly increase in strength, such that as displacement increases, the load also increases.

[00131] The pad material may provide cushioning while also providing moisture wicking, evaporation, thermal insulation, or the like. The pad material, or portions thereof, may exhibit resilience. Resilience may be at least in part due to the orientation of the fibers, geometry of the fibers, denier of the fibers, composition of the fibers, the like, or a combination thereof. Resilience may be measured using a standardized compression force deflection or indentation force deflection test (e.g., ASTM D3574). The desired resilience may depend upon the application within which the layered material is used. The pad material may have a resilience suitable for its intended purpose.

[00132] Compression set may be a measure of a material’s permanent deformation remaining after removal of a force applied to it. The recovery is a measure of the material’s return to its condition prior to compression.

[00133] The pad material may take a compression set to allow the material to conform to the wearer’s foot, ankle, leg, or a combination thereof. The compression set may allow for the article of footwear to more quickly break in, such that the article of footwear is more comfortable to the wearer as it conforms to the foot, ankle, leg, or the like.

[00134] The compression set may be measured via one or more tests. For example, the pad material may be compressed for a period of hours (e.g., about 4 hours or more, about 5 hours or more, about 6 hours or more). The compression source may be removed. Measurements (e.g., of the thickness of the material at the areas where compression are applied) are taken after predetermined shorter periods (e.g., 30 seconds or more, 1 minute or more, 2 minutes or more, 5 minutes or more). Measurements are taken after predetermined longer periods (e.g., about 1 hour or more, about 10 hours or more, about 24 hours or more). The amount of recovery at the predetermined measurement times allows for the compression set to be calculated.

[00135] The pad material may continue to heal or recover the longer the period after removal of the compression, but due to the compression set, the pad material may retain some deformation as a result of the compression. Therefore, the pad material may take a form of at least a portion of a wearer’s foot, particularly in areas where increased pressure occur during wearing of the article of footwear. For example, where the ball of the foot, heel, or ankle press into the pad material during wearing of the article of footwear, a form of that part of the body or indentation may be formed in the pad material.

[00136] T urning now to the figures, Figure 1 illustrates an exemplary article of footwear 10, shown as a boot. It is contemplated that other articles of footwear may omit certain portions shown in Figure 1. The elements shown are intended to be exemplary. In general, the article of footwear 10 may include an upper 11 , the part of the article of footwear that covers the foot, and a sole 30, the part of the article of footwear that is located below the wearer’s foot.

[00137] The upper 11 of the exemplary article of footwear 10 includes a vamp 12. The vamp covers the foot from a toe 14 to a top edge of the article of footwear or the tongue 16 (if the article of footwear has a tongue). The exemplary article of footwear 10 includes a quarter 18, which covers the rear portion of the foot, such as the heel 20. The quarter 18 extends from the heel 20 to the collar 24 of the article of footwear, where the collar is the edge where the foot of a wearer is inserted to put on the footwear. The article of footwear 10 may include a shaft 22 that extends the article of footwear upward on the wearer’s leg (e.g., toward or past the ankle and/or toward or past the knee).

[00138] Figure 2 illustrates a side view, or a view of the thickness or cross-section, of an exemplary pad material 40. The exemplary pad material 40 includes a fibrous material 42, illustrated as a carded and lapped material. The fibrous material 42 as shown is in an uncompressed state, though it is contemplated that a final pad or insert may undergo one or more compression operations or one or more operations that result in a compressed carded and lapped fibrous material. It is contemplated that a final pad or insert may undergo one or more localized compression operations, such that only portions of the pad material are compressed (e.g., forming one or more air flow channels).

[00139] The lapping procedure produces a structure with a series of first loops 44 and generally opposing second loops 46. When fibers 48 forming the carded and lapped fibrous material 42 are carded, the fibers generally follow the machine direction. Upon lapping, the fibers 48 are seen to follow the generally undulating shape, where the fibers 48 at the first loops 44 and generally opposing second loops 46 may curve, and the general direction of the fibers between the loops are in a generally vertical orientation (or extending in a direction generally perpendicular to the longitudinal axis L _A of the material. In Figure 2, the first loops 44 (as well as the second loops 46) run generally perpendicular to the machine direction and/or generally perpendicular to the longitudinal axis L _A of the material. The direction of the loops is into the page.

[00140] Figure 2 shows an optional first contact portion 50 and an optional second contact portion 52. A pad material of the present teachings may be free of one or both contact portions. One contact portion may act to contact the wearer, such as the wearer’s foot, ankle, sock, hosiery, or the like. One or more contact portions may serve to protect the carded and lapped fibrous material. One or more contact portions may secure the carded and lapped fibrous material 42 within the article of footwear (e.g., by attaching the pad material to the interior of the article of footwear via stitching, adhesive, or other fastening methods).

[00141] Figures 3, 4, 5, and 6 are enlarged photos of fibrous materials 42 with a first contact portion 50, adapted to be situated toward the wearer, and a second contact portion 52 on the opposing surface, sandwiching the fibrous material. The measurement of thickness of each sample is also provided in the photos, with each horizontal rectangular segment on the ruler indicating a millimeter. The fibrous materials are prepared using polyester staple fibers and bicomponent fibers.

[00142] Figure 3 shows a fibrous material 42 having generally vertical laps or generally vertical undulations. Put another way, the segments between the loops are generally vertical, extending from one loop to an opposing loop. The lines with arrows illustrate an average direction of the laps or undulations through the thickness of the material. The circles show inflection points 49, where the average direction changes. The angle of the laps or undulations approaching the first contact portion 50 (e.g., between the inflection point at the surface and the next inflection point) is measured using software. As calculated, the angle is about 104 degrees relative to the surface of the first contact portion 50, which illustrates a generally vertical orientation (e.g., generally vertically oriented fibers) within the meaning of the term as described herein.

[00143] Figure 4 provides a comparative fibrous material having generally horizontal laps or generally horizontal undulations. Put another way, the segments between the loops are generally horizontal, extending from one loop to an opposing loop. The lines with the arrows illustrate an average direction of the laps or undulations when viewing the thickness of the material. The question mark denotes a lack of inflection points or average direction changes. The laps are generally parallel to the first contact portion 50, so the angle is 180 degrees. [00144] Figure 5 shows a fibrous material 42 having laps or undulations at an angle from the first contact portion 50. Put another way, the segments between the loops are generally at an angle between horizontal and vertical, extending from one loop to an opposing loop. The lines with the arrows illustrate an average direction of the laps or undulations through the thickness of the material. The question mark denotes a lack of inflection points or average direction changes. As calculated, the average angle of the laps or undulations is under 135 degrees relative to the surface of the first contact portion 50. This may be considered a generally vertical orientation (e.g., generally vertically oriented fibers) within the meaning of the term as described herein.

[00145] Figure 6 shows a fibrous material 42 having laps or undulations that are compressed toward the second contact portion 52. Put another way, the segments between the loops have generally vertical portions and portions closer to horizontal, as the segment extends from one loop to an opposing loop. This is an example of a material having a variable density through the thickness of the material. The lines with arrows illustrate an average direction of the laps or undulations through the thickness of the material. Inflection points 49 show where the average direction changes. As calculated, the angle of the fibers or laps approaching the first contact portion 50 is about 124 degrees relative to the surface of the first contact portion. The angle of fibers or laps toward the second contact portion 52 is generally closer to horizontal or generally parallel to the surface of the second contact portion. Due to the orientation of laps or fibers, the material may have a greater density toward the second contact portion 52 than the first contact portion 50. The fibrous material 46 of Figure 6 may be considered a generally vertical orientation (e.g., generally vertically oriented fibers) within the meaning of the term as described herein.

[00146] Figure 7 is a top view of an exemplary article of footwear 10 looking down through the collar 24 to an insole 32. Within the interior of the article of footwear 10 is a pad material 40. The pad material 40 is shown to have a plurality of air flow channels 54. The air flow channels allow for heat within the article of footwear to rise out of the article of footwear; permit venting; increase air flow within the article of footwear to provide cooling, evaporation of moisture, or both; or a combination thereof.

[00147] The frequency and position of the air flow channels may vary, and the frequency shown in Figure 7 may be exaggerated. Air flow channels may be spaced generally evenly in an area. Air flow channels may be located only at certain locations within the article of footwear (e.g., areas where increased air flow and/or venting may be needed). The air flow channels may be created by a gap between the pad material and the wearer. For example, the air flow channels may be created where an area of decreased thickness of the pad does not contact or makes less contact with the foot, ankle, and/or leg within the article of footwear.

[00148] Figure 8 is a top view of an exemplary insole 32 formed by or including a pad material 40. Upon positioning within an article of footwear and applying pressure (e.g., via wearing, standing, walking, running, or a combination thereof), the pad material takes a compression set. When the pressure is removed from the insole 32 (e.g., upon removal of the article of footwear), the pad material 40 begins to recover. The pad material does not completely recover, thereby leaving at least a partial form 34 of the foot. The outline of the foot may be exaggerated for purposes of illustration. It is contemplated that areas of the pad material that undergo increased pressure (e.g., at areas of the heel and/or ball of the foot) may experience increased compression as compared with an area of the insole corresponding to the arch of the foot.

[00149] When the pad material is located in a place other than the insole, the pad material may still have a compression set, allowing the pad material to generally take on the shape of the foot, ankle, or leg where the pad material is situated on the wearer. In an area that may undergo increased pressure, such as at the ankle, the pad material may experience increased compression as compared with another area of the pad corresponding to an area of the foot or leg that does not project outwardly like an ankle bone.

[00150] Figures 9 and 10 are exemplary insoles 32 formed by or including a pad material 40. The pad material 40 includes areas of air flow channels 54. Figure 9 shows the air flow channels 54 generally parallel to the longitudinal axis of the article of footwear. Figure 10 shows the air flow channels 54 generally perpendicular to the longitudinal axis of the article of footwear. It is contemplated that the air flow channels are located any angle between those shown in the figures.

[00151] The airflow channels may have an increased frequency as compared to the figures throughout the entire insole or in portions of the insole. The air flow channels may have a decreased frequency as compared to the figures throughout the entire insole or in portions of the insole. While shown as extending across the entire length of the insole (Fig. 9) or across the entire width of the insole (Fig. 10), it is contemplated that air flow channels may extend only partially in a particular direction. The air flow channels are shown to extend to the edge of the insole. It is contemplated that one or more air flow channels may terminate before reaching the edge. Air flow channels may correspond, for example, to areas of increased ventilation within the material of the article of footwear. For example, one or more air flow channels may be positioned at or near a vent or opening in the article of footwear or a mesh panel within the article of footwear. [00152] ILLUSTRATIVE EXAMPLES

[00153] Figures 11 A and 11 B illustrate an illustrative comparison between commonly used polyurethane foam and the carded and lapped fibrous material as described herein in performing a Compression Force Deflection Test according to ASTM D3574-03-C. Figure 11A illustrates the performance of polyurethane foam. The graph shows that the foam cells rapidly collapse. Figure 11 B illustrates the performance of the carded and lapped fibrous material as described herein. At the area on the graph with the arrow marked “1” the material gently deforms, leading to a “soft touch”. At the area on the graph with the arrow marked “2” the material rapidly increases in strength. Therefore, the carded and lapped material as described compresses in a unique way and absorbs energy. Foam bottoms out, while the compressive strength of the carded and lapped material as described herein increases as the material is compressed.

[00154] In another example, samples are prepared for conducting various tests. Each sample has fibrous material sandwiched between facing layers. The facing layers are the same material in each sample and are a permeable wicking fabric. Samples are prepared having different orientations of fibers or different orientations of laps or segments between loops. These orientations are as follows:

[00155] Samples having a generally vertical orientation of fibers or generally vertical orientation of segments between loops (identified in the graphs as “Fully Vertical Pleat”), such as that shown in Figure 2;

[00156] Samples having a compressed vertical orientation of fibers or compressed generally vertical orientation of segments between loops (identified in the graphs as “Compressed Vertical Pleat”), such as that shown in Figure 6;

[00157] Samples having a generally horizontal orientation of fibers or generally horizontal orientation of segments between loops (identified in the graphs as “Horizontal Pleat”), such as that shown in Figure 4.

[00158] Each sample type is prepared with a low weight fibrous material (about 400 gsm) and a high weight fibrous material (about 600 gsm). Each sample has the same bi-component to staple fiber ratio and fiber denier.

[00159] BREATHABILITY

[00160] Breathability of the samples is tested using ASTM D737. The compression factor is defined as percent compression of original thickness. Data are collected at compression factors of 0% (no compression), 50%, and 75% for all three sample types (Fully Vertical Pleat, Compressed Vertical Pleat, and Horizontal Pleat). Results of the testing are shown in Figure 12. [00161] As shown, the Fully Vertical Pleats have the highest breathability. Horizontal Pleats have the lowest breathability of the samples. Compressed Vertical Pleats have a breathability between Fully Vertical Pleats and Horizontal Pleats. Breathability increases as the segments between loops, laps, or pleats become more vertical. A reduction in breathability is proportional to the compression factor, regardless of the sample type. Comparing results for the samples at the highest compression level (75%), the originally Fully Vertical Pleats sample has the highest breathability.

[00162] Breathability of the samples is higher without the facing material. The type of material for the facing material influences the final breathability of the composite. There is contact resistance between the facing material and the fibrous structure between for air flow.

[00163] WICKING PERFORMANCE

[00164] In testing wicking performance, samples (types: Fully Vertical Pleat, Compressed Vertical Pleat, and Horizontal Pleat samples) are 2 inch by 2 inch squares. Five of each of the three sample types are tested. Fibers in the fibrous material of the samples include hydrophilic treated fibers, and the permeable wicking fabric sandwiches the fibrous material. 30 mL of colored water is put into a 4 inch diameter petri dish. The samples are placed in the petri dish with water for 15 seconds and the moisture wicking uptake is measured in grams. The results of the testing are shown in Figure 13, where the y-axis is grams of water absorbed into the 2 inch by 2 inch sample with a facing on both sides of the fibrous material. The Student’s t-test in Figure 13 shows the results are statistically different between the Fully Vertical Pleat, Compressed Vertical Pleat and Horizontal Pleat samples.

[00165] The moisture wicking uptake of the Fully Vertical Pleats is shown to be the highest. The moisture wicking uptake of the Horizontal Pleats is shown to be the lowest. The moisture wicking uptake of the Compressed Vertical Pleats is between the other two sample types. The results indicate that the orientation of the segments between loops, or at least portions thereof, have an influence on the ability of the material to move moisture away from the body.

[00166] In observing the direction of moisture travel due to the dye in the water in the petri dish, the moisture is shown to move in the direction of the fibers or webbing.

[00167] Testing samples without hydrophilic fibers shows little to no tendency to absorb moisture into the structure.

[00168] DRYING PERFORMANCE

[00169] In testing drying performance, samples (types: Fully Vertical Pleat, Compressed Vertical Pleat, and Horizontal Pleat samples) are 4 inch by 4 inch squares. The samples are placed in a 4 inch by 4 inch by 0.75 inch polystyrene tray. A sample holder keeps the edges of the sample from being exposed. 15 grams of moisture are introduced to the sample, and a fan is positioned 2 feet from the surface of the sample. The results of the testing are shown in Figure 14.

[00170] The A-surface fabric is seen to dry faster in the Fully Vertical Pleat sample compared with the Horizontal Pleat sample. Moisture is observed to move in the pleat direction. In the Fully Vertical Pleat sample, the moisture moves toward the opposite side. The A-surface, or the surface adapted to contact the wearer, of the Fully Vertical Pleat sample is dry to the touch faster than the Horizontal Pleat sample. The orientation of the pleats has an influence in drawing moisture away from the body and giving the wearer a feeling of dryness, even if the entirety of the structure has not completely dried yet.

[00171] COMPRESSION FORCE DEFLECTION

[00172] Compression force deflection of the samples are tested in accordance with ASTM D3574 Test C. Results of the testing are shown in Figure 15. L indicates the low weight fibrous material (about 400 gsm) and H indicates the high weight fibrous material (about 600 gsm). Ten samples are tested for the three sample types (types: Fully Vertical Pleat, Compressed Vertical Pleat, and Horizontal Pleat samples), with three repeats each.

[00173] The results show the force required to compress the structure is greatest for the Fully Vertical Pleats samples and least for the Horizontal Pleats samples, with Compressed Vertical Pleats samples therebetween.

[00174] Any of the materials described herein may be combined with other materials described herein (e.g., in the same layer or in different layers of the layered material). The layers may be formed from different materials. Some layers, or all of the layers, may be formed from the same materials, or may include common materials or fibers. The type of materials forming the layers, order of the layers, number of layers, positioning of layers, thickness of layers, or a combination thereof, may be chosen based on the desired properties of each material (e.g., wicking properties, cooling properties, insulative properties, and the like), the desired air flow resistive properties of the material as a whole, the desired weight, density and/or thickness of the material, the desired flexibility of the material (or locations of controlled flexibility), or a combination thereof. The layers may be selected to provide varying orientations of fibers.

[00175] Parts by weight as used herein refers to 100 parts by weight of the composition specifically referred to. Any numerical values recited in the above application include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , 30 to 32, etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001 , 0.001 , 0.01 , or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value, and the highest value enumerated are to be expressly stated in this application in a similar manner. Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of “about” or “approximately” in connection with a range applies to both ends of the range. Thus, “about 20 to 30” is intended to cover “about 20 to about 30”, inclusive of at least the specified endpoints. The term “consisting essentially of” to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms “comprising” or “including” to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps. Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of “a” or “one” to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

Element List