U.S. patent application number 14/932702 was filed with the patent office on 2016-06-16 for nonwoven material, method of making same, and articles incorporating the nonwoven material.
The applicant listed for this patent is NIKE, Inc.. Invention is credited to Chris Breithaupt, Christina M. Wood.
Application Number | 20160168774 14/932702 |
Document ID | / |
Family ID | 56110603 |
Filed Date | 2016-06-16 |
United States Patent
Application |
20160168774 |
Kind Code |
A1 |
Breithaupt; Chris ; et
al. |
June 16, 2016 |
Nonwoven Material, Method Of Making Same, And Articles
Incorporating The Nonwoven Material
Abstract
A method for making a nonwoven material includes dispensing
fiber particles onto a substrate. The substrate may be shaped or
flat. A separate substance may be utilized to enhance the adhesion
of the fiber particles onto the substrate. The substrate may be
charged to enhance the adhesion of the fiber particles onto the
substrate. The articles resulting from this process have the same
contours as the substrate as the fiber particles are matted and
cured on the substrate prior to removing the nonwoven fabric from
the substrate. The resultant articles may be monofabric articles,
including only the fiber particles and a binder.
Inventors: |
Breithaupt; Chris; (Newberg,
OR) ; Wood; Christina M.; (Beaverton, OR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Family ID: |
56110603 |
Appl. No.: |
14/932702 |
Filed: |
November 4, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62092517 |
Dec 16, 2014 |
|
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Current U.S.
Class: |
36/50.1 ;
156/62.2; 36/45; 428/138; 442/381 |
Current CPC
Class: |
D04H 1/76 20130101; A43B
23/042 20130101; D04H 1/645 20130101; D04H 1/593 20130101; A43B
23/0225 20130101; A43D 25/183 20130101; A43B 7/00 20130101; A43B
7/125 20130101; D10B 2501/043 20130101; A43B 3/00 20130101; B29D
35/00 20130101; D04H 1/70 20130101; A43D 3/02 20130101 |
International
Class: |
D04H 1/645 20060101
D04H001/645; A43B 23/04 20060101 A43B023/04; A43C 5/00 20060101
A43C005/00; D04H 1/593 20060101 D04H001/593; A43B 23/02 20060101
A43B023/02 |
Claims
1. A method of making a nonwoven article, the method comprising:
preparing a substrate to receive fiber particles; depositing a
first plurality of fiber particles onto the substrate; applying an
adhesive to the plurality of fiber particles; depositing a second
plurality of fiber particles onto the substrate; matting the first
plurality of fiber particles and the second plurality of fiber
particles together to form a matted ply of a resultant nonwoven
article; curing the resultant nonwoven article; and removing the
resultant nonwoven article from the substrate.
2. The method according to claim 1, wherein the substrate is
configured to produce an article having curvature along at least
two axes.
3. The method according to claim 2, wherein the substrate is a last
for an article of footwear.
4. The method according to claim 1, wherein the substrate is
substantially flat to produce a sheet of fabric.
5. The method according to claim 1 further comprising the steps of
applying a second adhesive to the matted ply; depositing a third
plurality of fiber particles onto the matted ply; and matting the
third plurality of fiber particles together to form a second matted
ply of the resultant nonwoven article.
6. The method according to claim 5 further comprising the step of
applying a mask to a portion of the matted ply prior to depositing
at least one of the second adhesive and the third plurality of
fiber particles onto the matted ply.
7. The method according to claim 1 further comprising the step of
applying a mask to a portion of the substrate prior to depositing
the plurality of fiber particles onto the substrate.
8. The method according to claim 1, wherein the step of preparing
the substrate includes applying to the substrate a substance
designed to capture the fiber particles.
9. The method of claim 1, wherein the step of preparing the last
includes applying a charge to the substrate.
10. The method according to claim 1, wherein depositing the first
plurality of fiber particles to the substrate includes blowing the
first plurality of fiber particles onto the substrate.
11. The method according to claim 1, wherein applying the adhesive
includes spraying the adhesive onto the fiber particles.
12. The method according to claim 1, wherein matting the fiber
particles includes a mechanical compressing of the first plurality
of fiber particles and second plurality of fiber particles.
13. The method according to claim 12, wherein the mechanical
compressing includes using a roller to entangle the first plurality
of fiber particles and the second plurality of fiber particles.
14. A method of making a nonwoven upper, the method comprising:
preparing a last to receive a plurality of fiber particles;
depositing the plurality of fiber particles onto the last in the
shape of an upper, including a throat opening; applying an adhesive
to the plurality of fiber particles; matting the fiber particles to
form a matted layer of the upper; curing the adhesive; and removing
the resultant upper from the last.
15. The method according to claim 14, wherein the step of preparing
the last includes applying to the last a substance designed to
capture the plurality of fiber particles.
16. The method according to claim 15, wherein the substance is
applied to the last to form an outline of the throat opening of the
upper.
17. The method according to claim 15, wherein the substance
facilitates removing the upper from the last.
18. The method according to claim 17, wherein the substance is
petroleum jelly.
19. The method according to claim 17, wherein the substance is
silicone.
20. The method according to claim 17, wherein the step of preparing
the last includes applying a release film to the last.
21. The method according to claim 14, wherein the step of preparing
the last includes applying a charge to the last.
22. The method according to claim 21, wherein the last has a
negative charge when the charge is applied to the last and each
fiber in the plurality of fiber particles has a positive
charge.
23. The method according to claim 14 further comprising removing a
completed upper from the last after neutralizing the charge to the
last.
24. The method according to claim 14 further comprising the step of
incorporating the resultant upper into an article of footwear.
25. The method according to claim 24 further comprising associating
the resultant upper with a sole.
26. The method according to claim 24 further comprising finishing
the throat opening with at least one of a tongue and a securing
system.
27. A method of making a nonwoven fabric, the method comprising:
preparing a substantially flat substrate to receive a plurality of
fiber particles; depositing the plurality of fiber particles onto
the substantially flat substrate; applying an adhesive to the
plurality of fiber particles; matting the fiber particles to form a
matted layer of the nonwoven fabric; curing the adhesive; and
removing the resultant nonwoven fabric from the substantially flat
substrate.
28. The method according to claim 27, wherein the step of preparing
the substantially flat substrate includes applying to the
substantially flat substrate a substance designed to capture the
plurality of fiber particles.
29. The method according to claim 28, wherein the substance
facilitates removing the upper from the substantially flat
substrate.
30. The method according to claim 28, wherein the substance is one
of petroleum jelly and silicone.
31. The method according to claim 28, wherein the step of preparing
the substantially flat substrate includes applying a release film
to the substantially flat substrate.
32. The method according to claim 27, wherein the step of preparing
the substantially flat substrate includes applying a charge to the
substantially flat substrate.
33. The method according to claim 32, wherein the substantially
flat substrate has a negative charge when the charge is applied to
the substantially flat substrate and each fiber in the plurality of
fiber particles has a positive charge.
34. The method according to claim 27, wherein removing the
resultant fabric from the substantially flat substrate occurs after
neutralizing the charge to the substantially flat substrate.
35. The method according to claim 27 further comprising
incorporating the nonwoven fabric into an article.
36. The method according to claim 35, wherein incorporating the
nonwoven fabric into an article includes cutting the nonwoven
fabric into a pattern.
37. The method according to claim 35, wherein the article is an
article of apparel.
38. An article incorporating a nonwoven fabric, the article
comprising: a first layer incorporating a first plurality of matted
fiber particles and an adhesive, wherein each fiber in the first
plurality of matted fiber particles is a monofilament, and where
all of the fibers in the first plurality of matted fiber particles
is the same monofilament; and a second layer incorporating a second
plurality of matted fiber particles and the adhesive, wherein each
fiber in the second plurality of matted fiber particles is a
monofilament, and where all of the fibers in the second plurality
of matted fiber particles is the same monofilament.
39. The article according to claim 38, wherein the fabric has
curvature along at least two axes.
40. The article according to claim 39, wherein the article is an
upper of an article of footwear.
41. The article according to claim 40, wherein the upper is
seamless.
42. The article according to claim 41, wherein the upper is
associated with a sole.
43. The article according to claim 41, wherein the upper includes a
throat opening.
44. The article according to claim 41, wherein the upper includes a
second material.
45. The article according to claim 44, wherein the second material
is a polymer layer applied to at least one of the toe region and
the heel region.
46. The article according to claim 44, wherein the second material
is a reinforcing layer associated with the throat opening.
47. The article according to claim 46, wherein a first part of a
securing system is formed in the reinforcing layer.
48. The article according to claim 47, wherein the first part of
the securing system includes eyelets configured to receive a
lace.
49. The article according to claim 38, wherein the article is an
article of apparel.
50. The article according to claim 49, wherein the nonwoven fabric
is associated with a second fabric to form the article of
apparel.
51. The article according to claim 38, wherein the first layer
includes a gap devoid of matted fiber particles, and the second
layer spans the gap so that the nonwoven fabric is continuous.
52. The article according to claim 50, wherein the gap is provided
to alter at least one performance characteristic of the nonwoven
fabric proximate the gap.
53. The article according to claim 51, wherein the at least one
performance characteristic includes at least one of breathability,
stiffness, flexibility, and permeability.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Patent Application No. 62/092,517,
entitled "NONWOVEN MATERIAL AND METHOD OF MAKING SAME AND ARTICLES
INCORPORATING THE NONWOVEN MATERIAL", and filed on Dec. 16, 2014,
which application is hereby incorporated by reference.
BACKGROUND
[0002] The present invention relates generally to nonwoven
materials, methods of making nonwoven materials, and articles made
from nonwoven materials. In particular, the present invention
relates to a breathable nonwoven material, methods of making the
nonwoven material, and articles incorporating the nonwoven
material.
[0003] Fabrics may be incorporated into a variety of products for
both personal and industrial purposes. Nonwoven fabrics may be used
in various products, and nonwoven fabrics may be manufactured for
incorporation into a particular type of article. Breathable
nonwoven fabrics may be desirable for articles of footwear and
articles of apparel. Certain types of conventional nonwoven
materials made with a backing material may not be sufficiently
breathable for incorporation into articles of footwear and articles
of apparel, while other types of conventional nonwoven material
made without a backing material may not be sufficiently durable for
incorporation into articles of footwear and articles of
apparel.
SUMMARY
[0004] A nonwoven fabric may form an article, a component of an
article, or form a material that can be used to form an article or
a component of an article. A method of making the nonwoven fabric
includes depositing a plurality of fiber particles onto a
substrate. The fiber particles may be relatively long compared to
the industry standard. The substrate may have any shape, including
a flat surface, a curved surface, or a three-dimensional surface.
The shape of the substrate is imparted to the resultant fabric, so
the resultant fabric can be formed into the shape of the desired
article or a component of the desired article in addition to a
sheet of fabric from which components of the desired article may be
cut.
[0005] The substrate may be prepared to accept the fiber particles,
such as by spreading a gelatinous substance on the surface of the
substrate to which the fiber particles may temporarily adhere or by
charging the substrate with an electromagnetic charge. The fiber
particles are then deposited onto the substrate using any method
known in the art, such as by blowing the fiber particles onto the
substrate. An adhesive is applied to the fiber particles prior to
matting the fiber particles into a nonwoven fabric layer.
[0006] This process of depositing fiber particles, applying
adhesive, and matting the fiber particles may be repeated until a
desired number of layers or a desired thickness of the resultant
nonwoven fabric is achieved. Optionally, some layers may include a
mask to prevent fiber particles from accumulating in selected areas
to manipulate the thickness, flexibility, breathability, and other
properties of the nonwoven fabric in those selected areas. The
adhesive is then cured, and the resultant nonwoven fabric is
removed from the substrate and optionally sent for additional
processing. Nonwoven articles made using this method include
articles of apparel and articles of footwear.
[0007] In one aspect, the invention provides a method of making a
nonwoven article, the method comprising the steps of: preparing a
substrate to receive a plurality of fiber particles, depositing the
plurality of fiber particles onto the substrate, applying an
adhesive to the plurality of fiber particles, depositing a second
plurality of fiber particles onto the adhesive and the first
plurality of fiber particles, matting the fiber particles to form a
matted layer, and removing the resultant nonwoven article from the
substrate.
[0008] In one aspect, the invention provides a method of making a
nonwoven upper, the method comprising the steps of preparing a last
to receive a plurality of fiber particles, depositing the plurality
of fiber particles onto the last in the shape of an upper,
including a throat opening, applying an adhesive to the plurality
of fiber particles, depositing a second plurality of fiber
particles onto the adhesive and the first plurality of fiber
particles, matting the fiber particles to form a matted layer of
the upper; curing the adhesive; and removing the resultant upper
from the last.
[0009] In one aspect, the invention provides a method of making a
nonwoven fabric, the method comprising the steps of preparing a
substantially flat substrate to receive a plurality of fiber
particles, depositing the plurality of fiber particles onto the
substantially flat substrate, applying an adhesive to the plurality
of fiber particles, depositing a second plurality of fiber
particles onto the adhesive and the first plurality of fiber
particles, matting the fiber particles to form a matted layer of
the nonwoven fabric, curing the adhesive, and removing the
resultant nonwoven fabric from the last.
[0010] In one aspect the invention provides an article
incorporating a nonwoven fabric. The article includes a first layer
incorporating a first plurality of matted fiber particles and an
adhesive, wherein each fiber in the first plurality of matted fiber
particles is a monofilament, and where all of the fibers in the
first plurality of matted fiber particles is the same monofilament.
The article also includes a second layer incorporating a second
plurality of matted fiber particles and the adhesive, wherein each
fiber in the second plurality of matted fiber particles is a
monofilament, and where all of the fibers in the second plurality
of matted fiber particles is the same monofilament.
[0011] Other systems, methods, features and advantages of the
invention will be, or will become, apparent to one of ordinary
skill in the art upon examination of the following figures and
detailed description. It is intended that all such additional
systems, methods, features and advantages be included within this
description and this summary, be within the scope of the invention,
and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention can be better understood with reference to the
following drawings and description. The components in the figures
are not necessarily to scale, emphasis instead being placed upon
illustrating the principles of the invention. Moreover, in the
figures, like reference numerals designate corresponding parts
throughout the different views.
[0013] FIG. 1 is a perspective view of an embodiment of an article
of footwear having a nonwoven upper;
[0014] FIG. 2 is a perspective, exploded view of the embodiment of
the article of footwear having a nonwoven upper shown in FIG.
1;
[0015] FIG. 3 is a perspective view of an embodiment of a nonwoven
upper;
[0016] FIG. 4 is a flowchart of an embodiment of a method of making
a nonwoven upper;
[0017] FIG. 5 shows a last for use in the embodiment of a method of
making a nonwoven upper;
[0018] FIG. 6 shows the last of FIG. 5 being prepared to receive a
first layer of fiber particles;
[0019] FIG. 7 shows an embodiment of the depositing of the first
layer of fiber particles onto the last;
[0020] FIG. 8 shows an embodiment of applying an adhesive to the
first layer of fiber particles;
[0021] FIG. 9 shows an embodiment of applying a second layer of
fiber particles onto the first layer of fiber particles and
adhesive;
[0022] FIG. 10 shows an embodiment of mechanically matting the
first and second layers of fiber particles to form a first ply of
nonwoven material;
[0023] FIG. 11 shows an embodiment of applying an adhesive to the
third layer of fiber particles, using a mask to inhibit the
application of adhesive in a selected location;
[0024] FIG. 12 shows an embodiment of depositing a third layer of
fiber particles onto the last and the first ply of nonwoven
material, using a mask to inhibit the deposition of fiber particles
in a selected location;
[0025] FIG. 13 shows an embodiment of mechanically matting the
third layer of fiber particles to form a second ply of nonwoven
material and curing the nonwoven material;
[0026] FIG. 14 shows an embodiment of removing the completed
seamless nonwoven upper from the last;
[0027] FIG. 15 shows an embodiment of a nonwoven upper with void
areas due to the masking;
[0028] FIG. 16 shows a perspective view of an embodiment of a flat
substrate;
[0029] FIG. 17 shows an embodiment of preparing the flat substrate
to receive fiber particles;
[0030] FIG. 18 shows an embodiment of the depositing of a fourth
layer of fiber particles onto the flat substrate;
[0031] FIG. 19 shows an embodiment of applying an adhesive to the
fourth layer of fiber particles;
[0032] FIG. 20 shows an embodiment of applying a fifth layer of
fiber particles onto the fourth layer and the adhesive binder;
[0033] FIG. 21 shows an embodiment of mechanically matting the
fourth and fifth layers of fiber particles to form a first ply of
nonwoven material;
[0034] FIG. 22 shows an embodiment of applying an adhesive to the
first ply of nonwoven material;
[0035] FIG. 23 shows an embodiment of depositing a sixth layer of
fiber particles onto the first ply of nonwoven material and the
applied adhesive;
[0036] FIG. 24 shows an embodiment of matting the sixth layer of
fiber particles to form a second ply of nonwoven material
interconnected with the first ply of nonwoven material;
[0037] FIG. 25 shows an embodiment of curing the nonwoven material
in a convection oven;
[0038] FIG. 26 shows an embodiment of removing the resultant
nonwoven fabric from the substrate;
[0039] FIG. 27 shows an embodiment of a resultant nonwoven
fabric;
[0040] FIG. 28 shows a charged last for use in the embodiment of a
method of making a seamless nonwoven upper;
[0041] FIG. 29 shows an embodiment of the depositing of a seventh
layer of fiber particles onto the charged last;
[0042] FIG. 30 shows an embodiment of applying an adhesive to the
seventh layer of fiber particles;
[0043] FIG. 31 shows an embodiment of applying an eighth layer of
fiber particles onto the seventh layer of fiber particles and the
charged last;
[0044] FIG. 32 shows an embodiment of mechanically matting the
seventh and eighth layers of fiber particles to form a ply of
nonwoven material;
[0045] FIG. 33 shows an embodiment of applying an adhesive to the
ply of nonwoven material;
[0046] FIG. 34 shows an embodiment of applying a ninth layer of
fiber particles onto the ply of nonwoven material and the adhesive
binder;
[0047] FIG. 35 shows an embodiment of mechanically matting the
ninth layer of fiber particles to form a second ply of nonwoven
material;
[0048] FIG. 36 shows an embodiment of removing the completed
seamless nonwoven upper from the uncharged last;
[0049] FIG. 37 shows a perspective view of an embodiment of a
seamless nonwoven upper;
[0050] FIG. 38 shows a perspective view of an embodiment of a
charged flat substrate;
[0051] FIG. 39 shows an embodiment of the depositing of a tenth
layer of fiber particles onto the charged substrate;
[0052] FIG. 40 shows an embodiment of applying an adhesive to the
tenth layer of fiber particles;
[0053] FIG. 41 shows an embodiment of depositing an eleventh layer
of fiber particles onto the charged substrate, tenth layer of fiber
particles, and adhesive binder;
[0054] FIG. 42 shows an embodiment of mechanically matting the
tenth and eleventh layers of fiber particles to form a ply of
nonwoven material;
[0055] FIG. 43 shows an embodiment of applying an adhesive to the
ply of nonwoven material;
[0056] FIG. 44 shows an embodiment of depositing a twelfth layer of
fiber particles onto the first ply of nonwoven material and the
adhesive binder;
[0057] FIG. 45 shows an embodiment of mechanically matting the
twelfth layer of fiber particles to form a second layer of nonwoven
material and curing the nonwoven material;
[0058] FIG. 46 shows an embodiment of removing the completed
seamless nonwoven fabric from the uncharged substrate;
[0059] FIG. 47 shows an embodiment of an article of apparel being
made from a nonwoven material on a body last; and
[0060] FIG. 48 shows an embodiment of an article of apparel and its
pattern on a nonwoven material.
DETAILED DESCRIPTION
[0061] A variety of products are at least partially formed from
fabrics. As examples, articles of apparel (e.g., shirts, pants,
socks, jackets, undergarments, footwear), containers (e.g.,
backpacks, bags), and upholstery for furniture (e.g., chairs,
couches, car seats) are often formed from various fabric elements
that are joined through stitching or adhesive bonding. Fabrics may
also be utilized in bed coverings (e.g., sheets, blankets), table
coverings, towels, flags, tents, sails, and parachutes. Fabrics
utilized for industrial purposes are commonly referred to as
technical fabrics and may include structures for automotive and
aerospace applications, filter materials, medical fabrics (e.g.
bandages, swabs, implants), and industrial apparel that protects or
insulates against heat and radiation.
[0062] Although some products are formed from one type of fabric,
many products may also be formed from two or more types of fabrics
in order to impart different properties to different areas. As an
example, shoulder and elbow areas of a shirt may be formed from a
fabric that imparts durability (e.g., abrasion-resistance) and
stretch-resistance, whereas other areas may be formed from a fabric
that imparts breathability, comfort, stretch, and
moisture-absorption. As another example, an upper for an article of
footwear may have a structure that includes numerous layers formed
from various types of fabrics and other materials (e.g., polymer
foam, leather, synthetic leather), and some of the layers may also
have areas formed from different types of fabrics to impart
different properties. As yet another example, straps of a backpack
may be formed from non-stretch fabric elements, lower areas of a
backpack may be formed from durable and water-resistant fabric
elements, and a remainder of the backpack may be formed from
comfortable and compliant fabric elements. Accordingly, many
products may incorporate various types of fabrics in order to
impart different properties to different portions of the
products.
[0063] In order to impart the different properties to different
areas of a product, fabric elements or components formed from the
materials may be cut to desired shapes and then joined together,
usually with stitching or adhesive bonding. As the number and types
of fabric elements incorporated into a product increases, the time
and expense associated with transporting, stocking, cutting, and
joining the fabric elements may also increase. Waste material from
cutting and stitching processes also accumulates to a greater
degree as the number and types of fabric elements incorporated into
a product increases. Moreover, products with a greater number of
fabric elements and other materials may be more difficult to
recycle than products formed from few elements and materials. By
decreasing the number of elements and materials utilized in a
product, therefore, waste may be decreased while increasing the
manufacturing efficiency and recyclability.
[0064] Fabrics may be defined as any manufacture from fibers,
filaments, or yarns having a generally two-dimensional structure
(i.e., a length and a width that are substantially greater than a
thickness). In general, fabrics may be classified as
mechanically-manipulated fabrics or non-woven fabrics.
Mechanically-manipulated fabrics are often formed by weaving or
interlooping (e.g., knitting) a yarn or a plurality of yarns,
usually through a mechanical process involving looms or knitting
machines. Non-woven fabrics are webs or mats of filaments that are
bonded, fused, interlocked, or otherwise joined. Felt and nonwoven
material are common examples of non-woven fabrics.
[0065] Flocking, generally, is the process of depositing many small
fiber particles, called fiber particles, onto a surface or backing
layer. The fiber particles affix onto the surface. However,
flocking includes retaining the surface or backing layer as part of
the resultant article. The technique described below for making
nonwoven material is inspired by conventional flocking techniques,
but no backing layer remains in the resultant nonwoven material;
the fiber particles and binder are matted to produce a flexible
fabric. The resultant nonwoven material may have enhanced
breathability as compared to other types of woven or nonwoven
materials because the process of depositing fiber particles and
matting those particles together allows for large pores or air gaps
between the fiber particles. This breathability may be desirable
for articles of footwear and articles of apparel.
[0066] FIGS. 1 and 2 show an embodiment of one type of article of
footwear 100 incorporating a nonwoven material. Nonwoven upper 101
is a breathable seamless upper. For the purposes of this
disclosure, a seamless upper means that the upper lacks overlapping
edges or portions that are joined together by any conventional
method, such as stitching, welding, or with adhesives. A seamless
upper may be joined to another component, such as a sole 124 and
other finishing or decorative elements, such as an eyestay
reinforcing element 130, a first protective portion or toe counter
125 disposed on a toe of nonwoven fabric upper 101, a second
protective portion or heel counter 126 disposed on a heel of
nonwoven fabric upper 101. In the embodiment shown in FIG. 2,
finishing element 130 includes a tongue 135 and a portion 132
configured to accommodate a fastening system 133 (shown in FIG. 1).
Fastening system 133 may include eyelets 132 and a lace 134. In
other embodiments, nonwoven fabric upper 101 may include additional
components or nonwoven fabric upper 101 may eliminate one or more
of these described components.
[0067] As shown in FIGS. 2 and 3, nonwoven fabric upper 101 may be
made from a nonwoven material. The nonwoven material may be shaped
with curvature along one or more axes of nonwoven fabric upper 101
so that the nonwoven material is produced in the shape of nonwoven
fabric upper 101. As shown in FIG. 3, nonwoven fabric upper 101
includes curvature along each of a longitudinal axis 170 that
extends in a heel-to-toe direction, a transverse axis 172 that
extends in a medial-to-lateral direction, and a vertical axis 174
that extends in through nonwoven fabric upper 101 in a direction
that is substantially orthogonal to longitudinal axis 170 and
transverse axis 172.
[0068] In the embodiment shown in FIG. 2, nonwoven fabric upper 101
includes a throat opening 112, where the throat opening is defined
by a heel edge 113, a medial edge 114, and a lateral edge 115. In
the embodiment shown in FIG. 2, nonwoven fabric upper 101 also
includes an optional lower opening 116 defined by a medial edge 118
and a lateral edge 119. Lower opening 116 is disposed opposite to
throat opening 112. When nonwoven fabric upper 101 is associated
with an upper surface 122 of sole 120 to produce article of
footwear 100, sole 120 closes and seals lower opening 116. In other
embodiments, no lower opening 116 is provided; nonwoven fabric
upper 101 may include a solid portion of material connecting medial
edge 118 to lateral edge 119 across the bottom of nonwoven fabric
upper 101. In such embodiments, sole 120 is affixed to this solid
portion of material. These components of article of footwear 100
may be attached to each other using any method known in the art,
such as with adhesives, stitching, and/or welding.
[0069] The material for a nonwoven article may be made according to
the method shown in FIG. 4. By utilizing the method shown in the
flow diagram of FIG. 4, the nonwoven material may be made so that
the entire thickness of the nonwoven material is made from fiber
particles and binder. No additional backing or substrate needs to
be incorporated into the final material, though a substrate may be
used during the method to support the uncured layers of fiber
particles and binder. Further, in some embodiments of the method, a
substrate shaped in all three dimensions may be used so that the
nonwoven material may be manufactured in the shape of the article
to avoid the need for additional processing steps or to limit the
number of additional processing steps. Conventional methods for
making articles such as an article of footwear generally include
multiple preparation and cuttings steps to shape the article and to
form multiple seams to hold the shape. The article may then be sent
for additional finishing work, such as associating a sole with an
upper or adding other finishing elements or components to the
article. One embodiment of the method of FIG. 4 is shown in FIGS.
5-13, and the method is described below with reference to FIGS.
4-13.
[0070] The method described in FIG. 4 for making the nonwoven
material occurs on a substrate. In some embodiments, the method of
FIG. 4 allows for a shaped nonwoven article to be made on the
shaped substrate. In some embodiments, the substrate may be a last
for an article of footwear or a body last. In other embodiments,
the method of FIG. 4 allows for a substantially flat portion of
nonwoven material to be made on a substantially flat substrate.
When a flat substrate is used, the resultant nonwoven material may
then be finished into a flat article or cut and/or shaped to form a
shaped article.
[0071] Generally, the method described in FIG. 4 begins by
preparing a substrate to receive fiber particles in a first step
200. The substrate may be any type of surface capable of supporting
fiber particles and binder. In some embodiments, the substrate may
be a non-porous surface. In some embodiments, the substrate may be
made from thermoplastic materials, such as various types of known
polymers, thermoset materials, such as rubber or various types of
known polymers, ceramic materials, metals, composite materials, or
combinations thereof.
[0072] The resultant nonwoven fabric will take on the shape of the
substrate. In some embodiments, the substrate may be a
substantially flat surface so that the resultant nonwoven fabric is
also substantially flat. In some embodiments, the substrate may
include a surface shaped with curvature along at least two axes so
that the resultant nonwoven fabric is formed with the same
curvature. In some embodiments, the substrate may include multiple
shaped and/or curved surfaces so that the resultant nonwoven fabric
is formed into a shaped, three-dimensional article.
[0073] FIG. 5 shows an embodiment of a substrate 300 used in an
embodiment of a method of making a nonwoven upper 301 (shown in
FIGS. 13 and 14). In the embodiment shown in FIG. 5, substrate 300
is a last for an article of footwear. Substrate 300 may be
supported on a manufacturing floor, preparation table, or otherwise
in a manufacturing facility by a base 310. Base 310 may be any type
of structure capable of supporting and stabilizing substrate 300,
such as a weighted plate. In some embodiments, a pole 312 may be
associated with base 310 so that substrate 300 may be positioned at
a predetermined height above base 310. In some embodiments, pole
312 may position substrate 300 so that substrate 300 is positioned
at a comfortable working height for a user standing or sitting on
the manufacturing floor. In other embodiments, pole 312 may
position substrate 300 so that all sides of substrate 300 are
accessible to the manufacturing process. In some embodiments,
substrate 300 may include provisions for associating with pole 312.
For example, in one embodiment substrate 300 may include a recess
or hole configured to receive a free end of pole 312. The free end
of pole 312 may be inserted into substrate 300 and fitted there by
an interference fit or with threading. In other embodiments, pole
312 may be an integral extension of substrate 300.
[0074] Substrate 300 may be any type of last known in the art. In
some embodiments, substrate 300 may be a solid, rigid material but
in other embodiments may be made of any substrate material
discussed above. In other embodiments, substrate 300 may be an
inflatable last. Substrate 300 may be a last configured for any
type of foot in terms of size or shape, such as shapes and sizes
for adult males, adult females, and children.
[0075] Substrate 300 may be a material to which fiber particles may
not adhere without an additional adhesive or other substance to
which the fiber particles may temporarily adhere. The fiber
particles may be any types of fiber particle known in the art, but
are, in general, small pieces of cut fiber. In some embodiments,
the fiber particles may be natural or synthetic fibers, yarns, or
threads. In some embodiments, the fiber particles may be wool,
cotton, Nylon, Polyester, Rayon, Kevlar, or combinations of these
materials. In some embodiments, only one type of fiber particle is
used in the manufacture of the nonwoven material. In other
embodiments, different types of fiber particle may be used in the
manufacture of the nonwoven material.
[0076] Fiber particles are generally small cut pieces of fiber.
While the fiber particles may have any denier known in the art, in
some embodiments, the denier may be less than 100. In some
embodiments, the denier of the fiber particles may be less than
about 75. In some embodiments, the denier of the fiber particles
may be less than about 50. In some embodiments, the denier of the
fiber particles may be less than about 20. In some embodiments, the
fiber particles have a length of 1 mm or less. In other
embodiments, however, the fiber particles may be longer than 1 mm.
In some embodiments, the fiber particles may be 1.5 mm or less in
length. In some embodiments, the fiber particles may be at least 2
mm in length. In some embodiments, the fiber particles may be
between 0.25 mm and 5 mm in length. In some embodiments, the fiber
particles may be between 0.5 mm and 4 mm in length. In some
embodiments, the fiber particles may be about 2 mm in length. Fiber
particles having a length of 2 mm or greater may produce articles
that have enhanced durability over articles produced with fiber
particles having a length of less than 2 mm. Fiber particles having
a length of less than 2 mm may produce articles with less porosity
than articles produced with fibers having a length of 2 mm or
greater.
[0077] In some embodiments, all of the fiber particles used to make
a single nonwoven fabric may have substantially the same length. In
other embodiments, the fiber particles used to make a single
nonwoven fabric may have different lengths. In one embodiment, the
fiber particles are a mix of lengths between about 0.5 mm and about
4 mm. In one embodiment, the fiber particles are a mix of lengths
between about 0.5 mm and about 4 mm with a denier of less than
20.
[0078] In order to receive the fiber particles and hold the fiber
particles in position on the surface of substrate 300, substrate
300 may be prepared with a substance to which the fiber particles
may temporarily adhere. In the embodiment shown in FIG. 6,
substrate 300 is prepared by spreading a substance 320 onto the
surface of substrate 300. Substance 320 may be any type of
substance to which the fiber particles may adhere and may be
cleaned off of substrate 300 and the resultant article when the
article is removed from substrate 300. In some embodiments,
substance 320 may be a gelatinous substance such as silicone or
petroleum jelly. In other embodiments, substance 320 may be a
release film, such as polyurethane film.
[0079] Substance 320 may be applied onto the surface of substrate
300 using any method known in the art. In one embodiment, such as
the embodiment shown in FIG. 6, substance 320 is dispensed from a
container 324 and spreads onto surface 330 of substrate 300, with
or without additional mechanical manipulation such as with a brush.
A mask or masking agent such as mask 309 may be placed onto
substrate 300 prior to the application of substance 320 onto
substrate 300. In some embodiments, such as the embodiment shown in
FIG. 6, mask 309 may be used to provide a shape to the edges of
substance 320 so that the resultant nonwoven material has edges
with a specific contour. For example, mask 309 may be provided on
substrate 300 so that a resultant nonwoven upper 301 (shown in FIG.
16) has a throat opening 302 (shown in FIG. 16) without a
subsequent cutting step, as an edge 303 of throat opening 302 may
be adequately finished without any subsequent cutting or trimming
steps.
[0080] Mask 309 may be any type of material capable of blocking the
application of substance 320 to a selected or predetermined area of
substrate 300. In some embodiments, mask 309 may be a flexible
sheet, screen, or film so that mask 309 may be wrapped around or
otherwise fitted to substrate 300. For example, mask 309 may be a
sheet or film of thermoset material, such as rubber, a
thermoplastic material, such as polyurethane, paper, a fabric, or a
metal. In other embodiments, mask 309 may be a hard or relatively
rigid piece of material that is formed to fit onto substrate 300 in
the desired configuration. For example, mask 309 may be cardboard,
a molded thermoplastic or thermoset material, metal, glass,
composite material, ceramic, or any other kind of material. Mask
309 may be positioned proximate to substrate 300 or affixed to
substrate 300.
[0081] In other embodiments, first step 200 may include other ways
to prepare substrate 300 to receive the fiber particles. For
example, in the electrostatic embodiments discussed below with
respect to FIGS. 30-50, first step 200 may be achieved by applying
a charge to the substrate.
[0082] A second step 210 of the method shown in FIG. 4 includes
dispensing or depositing a plurality of the fiber particles onto
the substrate. FIG. 7 shows an embodiment of second step 210. In
the embodiment shown in FIG. 7, substrate 300 has been prepared
with substance 320. A dispenser 342 is associated with a reservoir
340 containing a plurality of fiber particles 341, which may be any
type of fiber particle as discussed above. Reservoir 340 may be any
container capable of holding a desired quantity of fiber particle
341 and communicating that fiber particle to dispenser 342.
Dispenser 342 is configured to dispense fiber particles 341 onto
substance 320. Dispenser 342 may be any type of dispenser capable
of propelling fiber particles 341 from reservoir 340 onto substance
320. Dispenser 342 may be manual or automated.
[0083] In the embodiment shown in FIG. 7, dispenser 342 is a blower
or other type of pneumatic device equipped with a nozzle 343.
Dispenser 342 may be any type of blower known in the art. Dispenser
342 is configured to draw fiber particles 341 from reservoir 340
and expel the fiber particles through nozzle 343 towards substance
320 and substrate 300. Once expelled, the fiber particles become
ambient fiber particles 346. Ambient fiber particles 346 are
carried along streams of flowing air 344 propelled from dispenser
342. Ambient fiber particles 346 move towards substance 342 until
the ambient fiber particles 346 alight on to substance 320. Once
ambient fiber particles 346 come into contact with substance 320,
the fiber particles become embedded fiber particles 350. In some
embodiments, embedded fiber particles 350 are positioned within
substance 320 so that embedded fiber particles 350 are
substantially normal to the surface of substrate 300. In other
embodiments, embedded fiber particles 350 are embedded at other
angles with respect to the surface of substrate 300. In some
embodiments, embedded fiber particles 350 are positioned at random
angles with respect to the surface of substrate 350.
[0084] Dispenser 342 and substrate 300 may move relative to one
another to ensure that the entire surface of substrate 300 is
exposed to ambient fiber particles 346. In one embodiment,
dispenser 342 may move around a stationary substrate 300. In
another embodiment, substrate 300 may move and rotate relative to a
stationary dispenser 342. In some embodiments, more than one
dispenser 342 may be positioned at various locations around
substrate 300.
[0085] In some embodiments, dispenser 342 may be configured to
dispense fiber particles 341 until ambient fiber particles 346 no
longer adhere to substance 320. In some embodiments, the duration
of dispensing may be controlled by one or more sensors positioned
proximate substrate 300 that may send a signal to dispenser 342 to
cease dispensing fiber particles. In some embodiments, the duration
of dispensing may be determined by an operator visually inspecting
substrate 300 and ambient fiber particles 346. Excess ambient fiber
particles 346 may be removed from the proximity of substrate 300 by
additional blowing air or a vacuum.
[0086] A third step 220 of the method shown in FIG. 4 includes
applying an adhesive to the embedded fiber particles. The applied
adhesive enhances the matting of the fiber particles in subsequent
manufacturing steps and enhances the ability of each layer of the
matted fiber particles to accept an additional layer of fiber
particles. The adhesive may be any type of adhesive known in the
art. In some embodiments, the adhesive may be an aerosolized
adhesive configured to spray small droplets of adhesive onto the
embedded fiber particles. In some embodiments, the adhesive may be
a liquid adhesive that may be brushed or rolled onto the embedded
fiber particles or into which the substrate and embedded fibers may
be dipped. In some embodiments, the adhesive may be water based. In
other embodiments, the adhesive may be polyvinyl acetate based. In
other embodiments, the adhesive may be rubber based. In some
embodiments, the adhesive may be LocTite.RTM. spray adhesive or
liquid adhesive, 3M.RTM. spray or liquid adhesives, KIWO.RTM. fiber
particles adhesive, and/or spray or liquid Plasti Dip.RTM..
[0087] FIG. 8 shows an embodiment of third step 220. In the
embodiment shown in FIG. 8, a sprayer 360 is configured to apply an
adhesive 362 onto embedded fiber particles 350. Sprayer 360 may be
any kind of spray device known in the art capable of aerosolizing
and propelling adhesive 362 towards embedded fiber particles 350.
In some embodiments, sprayer 360 may be a trigger-type intermittent
sprayer, such as a manual spray bottle or handheld spray unit. In
some embodiments, sprayer 360 may be a compressor-driven continuous
sprayer, such as a power sprayer. In some embodiments, sprayer 360
may be a manually operated sprayer. In other embodiments, such as
the embodiment shown in FIG. 8, sprayer 360 may be automated. In
some embodiments, sprayer 360 may include a nozzle 364 is
configured to expel aerosolized adhesive 362. In some embodiments,
sprayer 360 may be a robot programmed to operate and manipulate the
position of nozzle 364. The general operation of a robotic arm is
well known in the art. Sprayer 360 may in some embodiments be an
articulated robotic arm connected to a controller, such as a
processor with associated memory, and a power source such as a
battery or a connection to a power grid via a power cord such as
cord 825. In some embodiments, nozzle 364 may be associated with a
source of adhesive, such as source 820. In some embodiments, a
feeder tube 821 may establish a fluid connection between adhesive
source 820 and nozzle 364. In some embodiments, feeder tube 821 may
be exposed, such as in the embodiment shown in FIG. 8. In other
embodiments, feeder tube 821 may be integrated into sprayer 360 and
may be threaded through sprayer 360 to connect source 820 to nozzle
364.
[0088] Sprayer 360 may include multiple members and joints so that
the height and/or orientation of nozzle 364 may be manipulated.
While sprayer 360 may include any number of members and joint, in
some embodiments such as the embodiment shown in FIG. 8, sprayer
360 may include a base 806, a first member 807, a second member
809, a third member 811, and a grip 805. A first joint 801 may
connect third member 811 and second member 809. A second joint 802
may connect second member 809 and first member 807. A third joint
803 may connect first member 807 and base 806. Each member such as
base 806, first member 807, second member 809, third member 811,
and grip 805, may be any type of member known in the art, such as
solid rods, hollow tubes, flat bars, and combinations of these
types of members. Each joint such as first joint 801, second joint
802, and third joint 803 may be any type of joint known in the art,
such as hinge joints and rotary joints. Each joint may be
independently moved by controller. Moving the joints to push the
members apart may control the height of sprayer 360. Each joint may
be configured to allow the attached member to move, pivot, swivel,
rotate, or otherwise move with respect to each other.
[0089] Sprayer 360 and substrate 300 may move relative to one
another to ensure that adhesive 362 is applied to the entire
surface of substrate 300. In one embodiment, sprayer 360 may move
around a stationary substrate 300. For example, in the embodiment
shown in FIG. 8, sprayer 360 may be mounted onto a track 810 that
encircles, surrounds, or partially surrounds substrate 300. A
connector 815 may be attached to base 806 and slidably positioned
within track 810. Connector 815 may be actuated by the controller
and the power source using known techniques to translate connector
815, and, by extension, sprayer 360, along track 810. In this
manner, sprayer 360 may move to multiple positions around substrate
300. Further, base 360 may be configured to rotate with respect to
connector 815 to allow nozzle 364 to face substrate 300 regardless
of the position of sprayer 360 on track 810. In another embodiment,
substrate 300 may move and rotate relative to a stationary sprayer
360. In some embodiments, more than one sprayer 360 may be
positioned at various locations around substrate 300. The operation
of robotic arms for manufacturing
[0090] In some embodiments, a large amount of adhesive may be
applied to embedded fiber particles 350, such as when a dip-type
adhesive is used. In other embodiments, such as shown in the
enlarged view in FIG. 8, a relatively light coating of adhesive is
applied to embedded fiber particles 350. The enlarged view in FIG.
8 shows adhesive droplets 366 dispersed within embedded fiber
particles 350. Adhesive droplets 366 may be adhered to an
individual fiber particle 346 or adhesive droplets 366 may be
adhered to multiple embedded fiber particles 350. Adhesive droplets
366 remain uncured at this point in the manufacturing process.
[0091] A fourth step 225 of the method shown in FIG. 4 includes
dispensing a second layer of fiber particles onto the first layer
of fiber particles, the adhesive binder, and the last/substrate. In
most respects, fourth step 225 is a repetition of second step 210.
FIG. 9 shows an embodiment of fourth step 225, in which dispenser
342 deposits an additional plurality of fiber particles onto
embedded fiber particles 350. Dispenser 342 may be manually
operated or automated using factory or other robotic mechanisms
like an articulated robotic arm. Adhesive particles 366 assist in
capturing second embedded fibers 355 and holding second embedded
fibers 355 to embedded fibers 350.
[0092] A fifth step 230 of the method shown in FIG. 4 includes
matting the fiber particles. Matting the fiber particles causes the
individual fibers to bend, intertwine, and adhere to each other.
This matting process transforms the individual fiber particles into
a continuous if porous layer of fabric. In some embodiments, fifth
step 230 involves mechanically manipulating embedded fiber
particles 350 and second embedded fiber particles 355 by rubbing,
grinding, rolling, compressing, or otherwise moving the embedded
fiber particles to entangle the embedded fiber particles together.
In other embodiments, fifth step 230 may involve a vacuum matting
process in which the substrate in positioned in a vacuum chamber to
compress the embedded fibers when a vacuum is applied. In other
embodiments, fifth step 230 may involve a manual matting process in
which an operator or technician uses his or her hands to entangle
the embedded fiber particles together.
[0093] FIG. 10 shows an embodiment of fifth step 230 in which a
roller 370 is passed over embedded fiber particles 350 and second
embedded fiber particles 355. Roller 370 may be any type of roller
known in the art, such as a roller on a robotic arm, as shown in
FIG. 10, or a manually-manipulated roller. Roller 370 may have a
smooth surface or a textured surface. A textured surface, such as
with projections, may assist in the matting and entangling of the
fiber particles. The movement of a robotic arm may be guided by a
controller such as a processor, a computer, or a handheld mobile
device that send movement signals to the roller 370. Roller 370
compresses and entangles embedded fiber particles 350 and second
embedded fiber particles 355 together to form a first ply 375 of
nonwoven fabric. As shown in the enlarged portion of FIG. 10,
individual fiber particles 346 become entangled at connection
points 376. The matting process leaves relatively large pores 378
in first ply 375. Large pores 378 may contribute to the
breathability of the resultant nonwoven fabric upper 301 (shown in
FIG. 16).
[0094] Robotic arm 1060 may include multiple members and joints so
that the height and/or orientation of roller 370 may be
manipulated. While robotic arm 1060 may include any number of
members and joint, in some embodiments such as the embodiment shown
in FIG. 10, robotic arm 1060 may include a base 1006, a first
member 1007, a second member 1009, a third member 1011, and a grip
1005. A first joint 1001 may connect third member 1011 and second
member 1009. A second joint 1002 may connect second member 1009 and
first member 1007. A third joint 1003 may connect first member 1007
and base 1006. Each member such as base 1006, first member 1007,
second member 1009, third member 1011, and grip 1005, may be any
type of member known in the art, such as solid rods, hollow tubes,
flat bars, and combinations of these types of members. Grip 1005
may be a clamp or similar mechanism. In some embodiments, roller
370 may include a handle 379 configured to be securely and
optionally removably or interchangeably held by grip 1005. Each
joint such as first joint 1001, second joint 1002, and third joint
1003 may be any type of joint known in the art, such as hinge
joints and rotary joints. Each joint may be independently moved by
controller. Moving the joints to push the members apart may control
the height of robotic arm 1060. Each joint may be configured to
allow the attached member to move, pivot, swivel, rotate, or
otherwise move with respect to each other.
[0095] Robotic arm 1060 and embedded fiber particles 350 on
substrate 300 may move relative to one another to ensure that
roller 370 may contact all of the embedded fiber particles 350 on
the surface of substrate 300. In one embodiment, robotic arm 1060
may move around a stationary substrate 300. For example, in the
embodiment shown in FIG. 10, robotic arm 1060 may be mounted onto a
track 1010 that encircles, surrounds, or partially surrounds
substrate 300. A connector 1015 may be attached to base 1006 and
slidably positioned within track 1010. Connector 1015 may be
actuated by the controller and the power source using known
techniques to translate connector 1015, and, by extension, robotic
arm 1060, along track 1010. In this manner, robotic arm 1060 may
move to multiple positions around substrate 300. Further, base 360
may be configured to rotate with respect to connector 1015 to allow
roller 370 to face substrate 300 regardless of the position of
robotic arm 1060 on track 1010. In another embodiment, substrate
300 may move and rotate relative to a stationary robotic arm 1060.
In some embodiments, more than one robotic arm 1060 may be
positioned at various locations around substrate 300.
[0096] An optional sixth step 240 of the method shown in FIG. 4 may
be performed. Sixth step 240 involves repeating third step 220
through sixth step 240 to build up additional plies of nonwoven
fabric. Sixth step 240 may be repeated as many times as desired
until the desired number of layers are formed. In some embodiments,
the resultant nonwoven fabric material or article may include one
to twenty layers. In some embodiments, resultant nonwoven fabric
may include two to ten layers.
[0097] The thickness of each ply depends on the type of fiber
particles used. In some embodiments, the thickness of each ply may
be 0.5 mm or less. In some embodiments, the thickness of each ply
may range from about 0.1 mm to about 0.4 mm. In some embodiments,
the thickness of each ply may range from about 0.1 mm to about 0.15
mm. In some embodiments, the thickness of each ply may be about
0.138 mm. The overall thickness of the resultant matted fiber
fabric is the aggregate of the thickness of the individual plies.
In some embodiments, the thickness of the resultant nonwoven fabric
may be less than 1 mm. In some embodiments, the thickness of the
resultant nonwoven fabric may be between 0.5 mm and 5 mm. In some
embodiments, the thickness of the resultant nonwoven fabric may be
between 1 mm and 3 mm. In some embodiments, the thickness of the
resultant nonwoven fabric may be greater than 5 mm. In one
embodiment, the resultant nonwoven fabric includes 10 plies with an
overall thickness of about 1.38 mm.
[0098] In some embodiments, when forming the first ply or
additional plies of the nonwoven fabric, one or more areas of the
substrate or an existing ply of fabric may be masked so that the
next ply is not formed or built up in that selected area. Leaving
selected areas devoid of additional fiber particles in any given
ply or plies may tailor the properties of the resultant fabric ply.
For example, in areas devoid of additional fiber particles in a
selected region or area of a ply, the thickness of the overall
fabric is reduced. In those areas devoid of additional fiber
particles, breathability and flexibility may be increased over
areas in which the thickness is greater due to the additional
material present in completed areas. In those areas which include
complete plies and greater thickness, durability, stability, and
support may be increased. Creating areas of different thickness in
the nonwoven fabric permits a designer to create performance zones
to tailor an article for a specific purpose, such as building a
thick zone in a heel region to create a stiff heel cup or a
building a relatively thin zone proximate a toe box to create a
flexible region.
[0099] FIGS. 11-13 show an embodiment of forming a second ply of
nonwoven fabric on top of first ply 375 of nonwoven fabric 301.
Additionally, a mask 385 may be employed to prevent additional
fiber particles and binder from accumulating proximate mask 385.
Mask 385 may be any type of mask discussed above, such as a film,
screen, paper, or cardboard. In the embodiment shown in FIGS.
11-13, mask 385 is positioned centrally along a side of substrate
300. This kind of mask creates a zone with increased flexibility
and breathability compared to the rest of nonwoven fabric upper
301. In other embodiments, mask 385 may be positioned in different
locations. In some embodiments, more than one mask may be used. In
some embodiments, some plies may be masked in first locations while
in other plies, the mask may be positioned in different locations.
A person of ordinary skill in the art will understand how to use a
mask or masks to manipulate the properties of the resultant
nonwoven fabric.
[0100] As shown in FIG. 11, after mask 385 has been placed on first
ply 375 in the selected location, third step 220 of the method
shown in FIG. 4 is essentially repeated. In the embodiment shown in
FIG. 11, sprayer 360 is configured to apply an adhesive 362 onto
first ply 375. Sprayer 360 and substrate 300 may again move
relative to one another to ensure that adhesive 362 is applied to
the entirety of first ply 375. In one embodiment, sprayer 360 may
move around a stationary substrate 300. In another embodiment,
substrate 300 may move and rotate relative to a stationary sprayer
360. In some embodiments, more than one sprayer 360 may be
positioned at various locations around substrate 300. Mask 385
prevents/inhibits adhesive from being applied underneath mask 385
on first ply 375. As shown, first ply 375 may include pile from
unmated or loosely matted fibers.
[0101] As in the embodiment shown in FIG. 8, sprayer 360 may be
automated as an articulated robot as shown in FIG. 8. In some
embodiments, such as the embodiment shown in FIG. 11, a second
sprayer 1160 may be provided so that the spraying step may be
achieved more quickly. Coverage of first ply 375 may also be
enhanced with multiple sprayers. Second sprayer 1160 may be similar
or identical to sprayer 1160.
[0102] In some embodiments, second sprayer 1160 may include a
secondary nozzle 1164 is configured to expel aerosolized secondary
adhesive 1162. In some embodiments, second sprayer 1160 may be a
robot programmed to operate and manipulate the position of
secondary nozzle 1164. The general operation of a robotic arm is
well known in the art. Second sprayer 1160 may in some embodiments
be an articulated robotic arm connected to a controller, such as a
processor with associated memory, and a power source such as a
battery or a connection to a power grid via a power cord such as
secondary cord 1125. In some embodiments, secondary nozzle 1164 may
be associated with a source of adhesive, such as secondary source
1120. In some embodiments, a secondary feeder tube 1121 may
establish a fluid connection between secondary source 1120 and
secondary nozzle 1164. In some embodiments, secondary feeder tube
1121 may be exposed, such as in the embodiment shown in FIG. 11. In
other embodiments, secondary feeder tube 1121 may be integrated
into second sprayer 1160 and may be threaded through second sprayer
1160 to connect secondary source 1120 to secondary nozzle 1164.
[0103] Second sprayer 1160 may include multiple members and joints
so that the height and/or orientation of secondary nozzle 1164 may
be manipulated. While second sprayer 1160 may include any number of
members and joint, in some embodiments such as the embodiment shown
in FIG. 11, second sprayer 1160 may include a secondary base 1106,
a secondary first member 1107, a secondary second member 1109, a
secondary third member 1111, and a secondary grip 1105. A secondary
first joint 1101 may connect secondary third member 1111 and
secondary second member 1109. A secondary second joint 1102 may
connect secondary second member 1109 and secondary first member
1107. A secondary third joint 1103 may connect secondary first
member 1107 and secondary base 1106. Each member such as secondary
base 1106, secondary first member 1107, secondary second member
1109, secondary third member 1111, and secondary grip 1105, may be
any type of member known in the art, such as solid rods, hollow
tubes, flat bars, and combinations of these types of members. Each
joint such as secondary first joint 1101, secondary second joint
1102, and secondary third joint 1103 may be any type of joint known
in the art, such as hinge joints and rotary joints. Each joint may
be independently moved by controller. Moving the joints to push the
members apart may control the height of second sprayer 1160. Each
joint may be configured to allow the attached member to move,
pivot, swivel, rotate, or otherwise move with respect to each
other.
[0104] Second sprayer 1160 and substrate 300 may move relative to
one another to ensure that secondary adhesive 1162 is applied to
the entire surface of substrate 300. In one embodiment, second
sprayer 1160 may move around a stationary substrate 300. For
example, in the embodiment shown in FIG. 11, second sprayer 1160
may be mounted onto a secondary track 1110 that encircles,
surrounds, or partially surrounds substrate 300. A secondary
connector 1115 may be attached to secondary base 1106 and slidably
positioned within secondary track 1110. Secondary connector 1115
may be actuated by the controller and the power source using known
techniques to translate secondary connector 1115, and, by
extension, second sprayer 1160, along secondary track 1110. In this
manner, second sprayer 1160 may move to multiple positions around
substrate 300. Further, secondary base 1160 may be configured to
rotate with respect to secondary connector 1115 to allow secondary
nozzle 1164 to face substrate 300 regardless of the position of
second sprayer 1160 on secondary track 1110. In another embodiment,
substrate 300 may move and rotate relative to a stationary second
sprayer 1160. In some embodiments, more than one second sprayer
1160 may be positioned at various locations around substrate
300.
[0105] In some embodiments, a relatively light coating of adhesive
may be applied to first ply 375. The enlarged view in FIG. 11 shows
second set of adhesive droplets 386 dispersed within first ply 375.
Second set of adhesive droplets 386 also remain uncured at this
point in the manufacturing process.
[0106] FIG. 12 shows an embodiment of repeating fourth step 225 in
which a third layer of particles is deposited onto the last. Third
embedded fiber particles 380 are deposited onto last 300 and into
first ply 375 by dispenser 342 in the manner described above with
respect to second embedded fiber particles 355. Second set of
adhesive droplets 386 assist in retaining third embedded fiber
particles 380 in position.
[0107] FIG. 13 shows an embodiment of repeating fifth step 230 in
which roller 370 is passed over first ply 375. As discussed above
with respect to FIG. 10, roller 370 may be any type of roller known
in the art, such as a roller on a robotic arm or a
manually-manipulated roller. A controller such as a processor, a
computer, or a handheld mobile device that sends signals to the
roller 370 may guide the movement of a robotic arm. Roller 370
compresses and entangles second embedded fiber particles 380
together and to first ply 375 to form a second layer 390 of
nonwoven fabric. In other embodiments, repeating fifth step 230 may
involve other methods of matting first ply 375, such as vacuum
entanglement or manual entanglement.
[0108] Third step 220 through fifth step 230 may be repeated in
this manner until the desired number of layers and/or thickness of
the nonwoven material is achieved. Once the desired number of
layers is laid down, a seventh step 245 in the method shown in FIG.
4 may be performed: the adhesive may be cured to finish the
nonwoven material. Depending upon the type of adhesive, curing may
be achieved by exposing the layers to heat, convection, and/or the
flow of ambient temperature air over the layers. As shown in FIG.
13, heated air 397 may be applied to the nonwoven fabric to cure
the adhesive. In some embodiments, the adhesive may be cured at
temperatures less than 100 degrees C., less than 120 degrees C.,
and less than 200 degrees C. In some embodiments, the adhesive may
be cured at temperatures between 100 degrees C. and 150 degrees C.,
between 110 degrees C. and 130 degrees C., or between 115 degrees
C. and 125 degrees C. Heat 397 may be applied using any method
known in the art, such as a convection blow heater such as heater
398 or an oven (not shown). The heat and/or convection air flow may
be applied for any duration. The duration may be influenced by such
factors as the type of adhesive, the type of fiber particles, and
the thickness of the nonwoven fabric. In some embodiments, the
duration of cure may be less than a minute or for longer than a
minute.
[0109] In some embodiments, such as the embodiment shown in FIG.
13, heater 398 may be mounted on a heater articulated robotic arm
1360. Heater articulated robotic arm 1360 may be similar to the
articulated robotic arms shown and discussed above with respect to
FIGS. 8, 10, and 11. In some embodiments, heater articulated
robotic arm 1360 may include multiple members such as base 1306,
heater first member 1307, and heater second member 1309. In some
embodiments, heater articulated robotic arm 1360 may include
multiple joints connecting the members to each other, such as first
heater joint 1301, second heater joint 1302, and third heater joint
1303. As noted above, members 1306, 1307, and 1309 may be any type
of member known in the art. Similarly, joints 1301, 1302, and 1303
may be any type of joint known in the art. Heater articulated
robotic arm 1360 may be controlled by a processor with a memory
programmed to manipulate articulated robotic arm as is known in the
art. Heater articulated robotic arm 1360 may be powered by a power
source such as a battery or a connection to a power grid by a
heater cord 1314.
[0110] Robotic arm 1360 and substrate 300 may move relative to one
another to ensure that roller 370 may contact the entire surface of
substrate 300. In one embodiment, robotic arm 1360 may move around
a stationary substrate 300. For example, in the embodiment shown in
FIG. 13, robotic arm 1360 may be mounted onto a heater track 1310
that encircles, surrounds, or partially surrounds substrate 300. A
heater connector 1315 may be attached to base 1306 and slidably
positioned within track 1310. Connector 1315 may be actuated by the
controller and the power source using known techniques to translate
connector 1315, and, by extension, robotic arm 1360, along track
1310. In this manner, robotic arm 1360 may move to multiple
positions around substrate 300. Further, base 1360 may be
configured to rotate with respect to connector 1315 to allow nozzle
364 to face substrate 300 regardless of the position of robotic arm
1360 on track 1310. In another embodiment, substrate 300 may move
and rotate relative to a stationary robotic arm 1360. In some
embodiments, more than one robotic arm 1360 may be positioned at
various locations around substrate 300.
[0111] Once the adhesive is cured, the nonwoven fabric is
completed. At this point, an eighth step 250 in the method shown in
FIG. 4 may be performed. Eighth step 250 includes removing the
nonwoven fabric from the substrate. Because the layers of the
nonwoven fabric were built up and cured directly on the surface of
the substrate, the nonwoven fabric will have the same contours as
the substrate.
[0112] FIG. 14 shows an embodiment of eighth step 250. Nonwoven
fabric 301 has conformed to the shape of the last-shaped substrate
300. In this embodiment, nonwoven fabric 301 is a seamless nonwoven
upper. Nonwoven fabric upper 301 includes a throat opening 312 that
allows nonwoven fabric upper 301 to be pulled off of substrate 300
as shown in FIG. 14. Substance 320 may facilitate the removal of
nonwoven fabric upper 301. In addition to making substrate 300 able
to receive fiber particles, substance 320 may lubricate the surface
of substrate 300 so that nonwoven fabric upper 301 slips more
easily off of substrate 300.
[0113] FIG. 15 shows the completed nonwoven fabric upper 301.
[0114] Nonwoven fabric upper 301 is seamless, having been made by
building up layers on last substrate 300 so that nonwoven fabric
upper 301 was made in the shape of an upper. No additional cutting
or shaping may be required to use nonwoven fabric upper 301 in an
article of footwear. A breathable region 395 of nonwoven fabric
upper 301 was formed using the masking technique shown above. A
void 396 was formed in matted layer 390. Within void 396, the no
fiber particles accumulated, so matted layer 390 is discontinuous.
The discontinuity is not reflected in adjacent matted layer 375.
Therefore, nonwoven fabric upper 301 is continuous through
breathable region 395, but the density of the nonwoven fabric is
reduced in breathable region 395. This lower density leads to
greater breathability, increased flexibility, and reduced stiffness
in breathable region 395 compared to the rest of nonwoven fabric
upper 301. This type of zonal manipulation of the properties of
nonwoven fabric upper 301 can be located in different positions in
other embodiments of nonwoven fabric upper 301, in multiple
positions in other embodiments of nonwoven fabric upper 301, or
eliminated entirely is some embodiments of nonwoven fabric upper
301 for an upper having uniform properties throughout.
[0115] In some embodiments, nonwoven fabric upper 301 may be made
using only one type of fiber particles to produce a monofiber upper
nonwoven fabric--a fabric containing only one type of fiber and a
binder (the adhesive). For example, nonwoven fabric upper 301 may
be a mono-polymer upper, composed of a single type of polymeric
fiber particle and an adhesive binder. In other embodiments,
multiple types of fiber particle and/or multiple types of binder
may be used in any given matted layer or in adjacent matted
layers.
[0116] An optional ninth step 260 of the method of FIG. 4 includes
additional finishing steps for the nonwoven material. Depending
upon the final article for which the nonwoven material is intended,
no additional finishing steps may be necessary. In some
embodiments, an additional finishing step may be washing or
otherwise laundering the nonwoven material to remove any remnants
of the substance used to coat the substrate. In other embodiments,
such as the article shown in FIGS. 1 and 2, components such as a
sole, a tongue, or an eyestay reinforcement may be associated with
the nonwoven fabric to complete an article like an article of
footwear. In other embodiments, such as when making an article of
apparel, the additional finishing steps may include cutting the
nonwoven fabric and joining the cut pieces to each other or to
other pieces of fabric to make another article, like an article of
apparel. An embodiment of these types of finishing steps is
discussed below with respect to FIGS. 47 and 48.
[0117] FIGS. 16-25 show another embodiment of the method generally
set forth in FIG. 4. In this embodiment, a substantially flat
substrate is provided to make a substantially flat nonwoven
material.
[0118] Generally, the method described in FIG. 4 begins by
preparing a substrate to receive fiber particles in first step 200.
The substrate 400 may be any type of surface capable of supporting
fiber particles and binder and may be any type of substrate
described above capable of being formed as a flat surface or having
a flat surface. FIG. 16 shows an embodiment of a flat substrate 400
used in an embodiment of a method of making a nonwoven upper. In
the embodiment shown in FIG. 16, flat substrate 400 is a
substantially flat surface like a table configured to make a
substantially flat nonwoven fabric.
[0119] Flat substrate 400 may be supported on a manufacturing floor
or otherwise a manufacturing facility by a second base 410. Second
base 410 may be any type of structure capable of supporting and
stabilizing flat substrate 400, such as a weighted plate. In some
embodiments, a first leg 412 and a second leg 413 may be associated
with second base 410 so that flat substrate 400 may be positioned
at a predetermined height above second base 410. In some
embodiments, first leg 412 and second leg 413 may elevate flat
substrate 400 so that flat substrate 400 is positioned at a
comfortable working height for a user standing or sitting on the
manufacturing floor. In other embodiments, first leg 412 and second
leg 413 may position flat substrate 400 so that all sides of flat
substrate 400 are accessible to the manufacturing process. In some
embodiments, flat substrate 400 may include provisions for
associating with first leg 412 and second leg 413. For example, in
one embodiment flat substrate 400 may include a recess or hole
configured to receive free ends of first leg 412 and second leg
413. The free end of first leg 412 and second leg 413 may be
inserted into flat substrate 400 and fitted there by an
interference fit or with threading. In other embodiments, first leg
412 and second leg 413 may be an extension of flat substrate
400.
[0120] In some embodiments, flat substrate 400 may be a solid,
rigid material. Flat substrate 400 may be a table configured for
any size of nonwoven fabric in terms of size or shape.
[0121] Like substrate 300 discussed above, flat substrate 400 is
generally a material to which fiber particles may not adhere
without an additional adhesive or other substance to which the
fiber particles may adhere. The fiber particles may be any types of
fiber particle discussed above. The fiber particles may have any
length or denier discussed above. In order to receive the fiber
particles and hold the fiber particles in position on the surface
of flat substrate 400, flat substrate 400 may be prepared with a
substance to which the fiber particles may temporarily adhere. In
the embodiment shown in FIG. 16, flat substrate 400 is prepared by
spreading a second substance 420 onto the surface of flat substrate
400. Second substance 420 may be any type of substance to which the
fiber particles may adhere and may be cleaned off of flat substrate
400. In some embodiments, second substance 420 may be a gelatinous
substance such as silicone or petroleum jelly. In other
embodiments, second substance 420 may be a release film, such as
polyurethane film.
[0122] Second substance 420 may be applied onto the surface of flat
substrate 400 using any method known in the art. In one embodiment,
such as the embodiment shown in FIG. 17, second substance 420 is
dispensed from a second container 421 and spreads onto surface 417,
with or without additional mechanical manipulation such as with a
brush 419. Brush 419 may be automated, such as with a robotic arm
like the robotic arm shown above with respect to, for example,
FIGS. 10 and 13. In this embodiment, no mask such as mask 309 is
provided. In other embodiments, a mask like mask 309 may be
provided to establish edges of the resultant nonwoven fabric.
[0123] Second step 210 of the method shown in FIG. 4 includes
dispensing the fiber particles onto the substrate. FIG. 18 shows an
embodiment of second step 210. In the embodiment shown in FIG. 18,
flat substrate 400 has been prepared with second substance 420. A
second dispenser 442 is associated with a second reservoir 440
containing a plurality of second fiber particle 441, which may be
any type of fiber particle as discussed above. Second reservoir 440
may be any container capable of holding a desired quantity of
second fiber particle 441 and communicating that fiber particle to
second dispenser 442. Second dispenser 442 is configured to
dispense second fiber particles 441 onto second substance 420.
Second dispenser 442 may be any type of dispenser capable of
propelling second fiber particle 441 from second reservoir 440 onto
second substance 420.
[0124] In the embodiment shown in FIG. 18, second dispenser 442 is
a blower or other type of pneumatic device equipped with a second
nozzle 443. Second dispenser 442 may be any type of blower known in
the art. Second dispenser 442 is configured to draw second fiber
particle 441 from reservoir 440 and expel the fiber particles
through second nozzle 443 towards second substance 420 and flat
substrate 400. Once expelled, the fiber particles become second
ambient fiber particles 446. Second ambient fiber particles 446 are
carried along streams of second air flow 444 propelled from second
dispenser 442. Second ambient fiber particles 446 move towards
substance 420 until ambient fiber particles 446 alight upon second
substance 420. Once in contact with and adhered to second substance
420, the fiber particles become fourth embedded fiber particles
450. In some embodiments, fourth embedded fiber particles 450 are
positioned within second substance 420 so that fourth embedded
fiber particles 450 are substantially normal to the surface of flat
substrate 400. In other embodiments, fourth embedded fiber
particles 450 are embedded at other angles with respect to the
surface of flat substrate 400. In some embodiments, fourth embedded
fiber particles 450 are positioned at random angles with respect to
the surface of substrate 400.
[0125] Second dispenser 442 and flat substrate 400 may move
relative to one another to ensure that the entire surface of flat
substrate 400 is exposed to second ambient fiber particles 446. In
one embodiment, second dispenser 442 may move around a stationary
flat substrate 400. In another embodiment, flat substrate 400 may
move and rotate relative to a stationary second dispenser 442. In
some embodiments, more than one second dispenser 442 may be
positioned at various locations around flat substrate 400.
[0126] Second dispenser 442 is configured to dispense second fiber
particle 441 until second ambient fiber particles 446 no longer
adhere to second substance 420. In some embodiments, the duration
of dispensing may be sensed by one or more sensors positioned
proximate flat substrate 400. In some embodiments, the duration of
dispensing may be determined by an operator visually inspecting
flat substrate 400 and second ambient fiber particles 446. Excess
second ambient fiber particles 446 may be removed from the
proximity of flat substrate 400 by additional blowing air or a
vacuum.
[0127] Third step 220 of the method shown in FIG. 4 includes
applying an adhesive to the embedded fiber particles, which is
achieved in substantially the same manner as the embodiment of
third step 220 shown in FIG. 8. The types and application styles
for the adhesive are also the same.
[0128] FIG. 19 shows an embodiment of third step 220. In the
embodiment shown in FIG. 19, a second nozzle 464 is configured to
apply a second adhesive 462 onto fourth embedded fiber particles
450. Second nozzle 464 may be any kind of spray device known in the
art capable of aerosolizing and propelling second adhesive 462
towards fourth embedded fiber particles 450. In some embodiments,
second nozzle 464 may be a trigger-type intermittent sprayer, such
as a manual spray bottle. In some embodiments, second nozzle 464
may be a compressor-driven continuous sprayer, such as a power
sprayer. In other embodiments, an articulated robotic arm such as
sprayer 360 shown in FIG. 8 may be used. In another embodiment,
such as the embodiment shown in FIG. 19, a factory line mechanism
may be used to support and control second nozzle 464.
[0129] In some embodiments, the factory line mechanism may include
a factory track 1910 disposed on a ceiling or otherwise suspended
above flat substrate 400. A base 1906 is attached to factory track
1910 so that base 1906 may translate along track 1910 using known
techniques such as servo motors and rollers or wheels. A controller
such as a processor with associated memory containing a program for
manipulating base 1906 and/or nozzle 464 may be linked wirelessly
or via wireline to base 1906 or any other part of the factory line
mechanism. The factory line mechanism may include any number of
members and joints to allow nozzle 464 to move over the entire
surface of flat substrate 400. In the embodiment shown in FIG. 19,
a first factory joint 1901 may attach base 1906 to a first factory
member 1907. A second factory joint 1903 may attach first factory
member 1907 to a second factory member 1909. A third factory joint
1902 may attach second factory member to factory grip 1905. Each
joint may be any type of joint known in the art, such as hinge
joints and rotary joints. Each joint may be independently moved by
a controller. Moving the joints to push the members apart may
control the height of sprayer 460. Each joint may be configured to
allow the attached member to move, pivot, swivel, rotate, or
otherwise move with respect to each other.
[0130] Second sprayer 460 and flat substrate 400 may move relative
to one another to ensure that second adhesive 462 is applied to the
entire surface of flat substrate 400. In one embodiment, second
sprayer 460 may move around a stationary flat substrate 400. In
another embodiment, flat substrate 400 may move and rotate relative
to a stationary second sprayer 460. In some embodiments, more than
one second sprayer 460 may be positioned at various locations
around flat substrate 400.
[0131] In some embodiments, a large amount of adhesive may be
applied to fourth embedded fiber particles 450, such as when a
dip-type adhesive is used. In other embodiments, such as shown in
the enlarged view in FIG. 8, a relatively light coating of adhesive
is applied to fourth embedded fiber particles 450. The enlarged
view in FIG. 19 shows third adhesive droplets 466 dispersed within
fourth embedded fiber particles 450. Third adhesive droplets 466
may be adhered to an individual fiber particle 446 or third
adhesive droplets 466 may be adhered to multiple fourth embedded
fiber particles 450. Third adhesive droplets 466 remain uncured at
this point in the manufacturing process.
[0132] Fourth step 225 of the method shown in FIG. 4 includes
depositing another layer of fiber particles onto fourth embedded
fiber particles 450 and third adhesive droplets 466. FIG. 20 shows
an embodiment of fourth step 225 for a flat substrate 400. Fifth
embedded fiber particles 455 are deposited onto substrate 400 and
into fourth embedded fiber particles 450 by dispenser 442. Uncured
third adhesive droplets 466 assist in holding fifth embedded fiber
particles 455 in position.
[0133] Fifth step 230 of the method shown in FIG. 4 includes
matting the fiber particles. In this embodiment, fifth step 230 may
be achieved as discussed above. FIG. 21 shows an embodiment of
fifth step 230 in which a second roller 470 is passed over fourth
embedded fiber particles 450 and fifth embedded fiber particles
455. Second roller 470 may be any type of roller known in the art,
such as a roller on a robotic arm or a manually-manipulated roller.
The movement of a robotic arm may be guided by a controller such as
a processor, a computer, or a handheld mobile device that send
movement signals to the second roller 470. Second roller 470
compresses and entangles fourth embedded fiber particles 450
together to form an initial ply 475 of nonwoven fabric. Other
features of the matting process are similar to those described
above with respect to FIG. 9.
[0134] Like roller 370, second roller 470 may be automated. Second
roller 470 may be controlled by a roller robotic arm 2160, which
may be similar to the robotic arm discussed above with respect to
roller 370. The movement of a robotic arm may be guided by a
controller such as a processor, a computer, or a handheld mobile
device that send movement signals to the roller 470. Robotic arm
2160 may include multiple members and joints so that the height
and/or orientation of roller 470 may be manipulated. While robotic
arm 2160 may include any number of members and joint, in some
embodiments such as the embodiment shown in FIG. 21, robotic arm
2160 may include a base 2106, a first member 2107, a second member
2109, a third member 2111, and a grip 2105. A first joint 2101 may
connect third member 2111 and second member 2109. A second joint
2102 may connect second member 2109 and first member 2107. A third
joint 2103 may connect first member 2107 and base 2106. Each member
such as base 2106, first member 2107, second member 2109, third
member 2111, and grip 2105, may be any type of member known in the
art, such as solid rods, hollow tubes, flat bars, and combinations
of these types of members. Grip 2105 may be a clamp or similar
mechanism. In some embodiments, roller 470 may include a handle 479
configured to be securely and, optionally, removably held by grip
2105. Each joint such as first joint 2101, second joint 2102, and
third joint 2103 may be any type of joint known in the art, such as
hinge joints and rotary joints. Each joint may be independently
moved by controller. Moving the joints to push the members apart
may control the height of robotic arm 2160. Each joint may be
configured to allow the attached member to move, pivot, swivel,
rotate, or otherwise move with respect to each other.
[0135] Robotic arm 2160 and substrate 400 may move relative to one
another to ensure that roller 470 may contact the entire surface of
substrate 400. In one embodiment, robotic arm 2160 may move around
a stationary substrate 400. For example, in the embodiment shown in
FIG. 21, robotic arm 2160 may be mounted onto a track 2110 that
encircles, surrounds, or partially surrounds substrate 400. A
connector 2115 may be attached to base 2106 and slidably positioned
within track 2110. Connector 2115 may be actuated by the controller
and the power source using known techniques to translate connector
2115, and, by extension, robotic arm 2160, along track 2110. In
this manner, robotic arm 2160 may move to multiple positions around
substrate 400. Further, base 2106 may be configured to rotate with
respect to track 2110 to allow roller 470 to face substrate 400
regardless of the position of robotic arm 2160 on track 2110. In
another embodiment, substrate 400 may move and rotate relative to a
stationary robotic arm 2160. In some embodiments, more than one
robotic arm 2160 may be positioned at various locations around
substrate 400.
[0136] As with the embodiments discussed above, an optional sixth
step 240 of the method shown in FIG. 4 involves repeating third
step 220 through fifth step 230 to build up additional plies of
nonwoven fabric. Sixth step 240 may be repeated until the desired
number of plies is formed. The number and thicknesses of the layers
are the same as those discussed above.
[0137] FIGS. 22-24 show an embodiment of forming a second ply of
nonwoven fabric on top of initial ply 475 of second nonwoven fabric
401. As shown in FIG. 22, third step 220 of the method shown in
FIG. 4 is essentially repeated. In the embodiment shown in FIG. 22,
a second sprayer 460 is configured to apply a second adhesive 462
onto initial ply 475. Second sprayer 460 may be any kind of spray
device known in the art capable of aerosolizing and propelling
second adhesive 462 towards initial ply 475. In some embodiments,
second sprayer 460 may be a trigger-type intermittent sprayer, such
as a manual spray bottle with a third nozzle 464. In some
embodiments, second sprayer 460 may be a compressor-driven
continuous sprayer, such as a power sprayer.
[0138] Second sprayer 460 and flat substrate 400 may move relative
to one another to ensure that second adhesive 462 is applied to the
entirety of initial ply 475, which may or may not include a pile
from unmated or poorly matted fibers and uncured adhesive. In one
embodiment, second sprayer 460 may move around a stationary flat
substrate 400. In another embodiment, flat substrate 400 may move
and rotate relative to a stationary second sprayer 460. In some
embodiments, more than one second sprayer 460 may be positioned at
various locations around flat substrate 400.
[0139] FIG. 23 shows an embodiment of repeating fourth step 225 in
which another layer of fiber particles is deposited onto substrate
400, similar to the process discussed above with respect to FIG.
20. Sixth embedded fiber particles 480, once deposited by dispenser
442, may be held in position by the geometry of sixth embedded
fiber particles 480 and uncured adhesive droplets 486.
[0140] FIG. 24 shows an embodiment of repeating fifth step 230 in
which second roller 470 is passed over sixth embedded fiber
particles 480 to mat the embedded fiber particles together into a
fourth ply 490 and to initial ply 475. As discussed above with
respect to FIG. 9, second roller 470 may be any type of roller
known in the art, such as a roller on a robotic arm or a
manually-manipulated roller. A controller such as a processor, a
computer, or a handheld mobile device that sends signals to the
second roller 470 may guide the movement of a robotic arm. Second
roller 470 compresses and entangles sixth embedded fiber particles
480 together to form a fourth ply 490 of nonwoven fabric. In other
embodiments, repeating fifth step 230 may involve other methods of
matting sixth embedded fiber particles 480, such as vacuum
entanglement or manual entanglement.
[0141] The movement of a robotic arm may be guided by a controller
such as a processor, a computer, or a handheld mobile device that
send movement signals to the roller 470. The robotic arm may
include multiple members and joints so that the height and/or
orientation of roller 470 may be manipulated. While the robotic arm
may include any number of members and joint, in some embodiments
such as the embodiment shown in FIG. 24, the robotic arm may
include a base 2406, a first member 2407, a second member 2409, a
third member 2411, and a grip 2405. A first joint 2401 may connect
third member 2411 and second member 2409. A second joint 2402 may
connect second member 2409 and first member 2407. A third joint
2403 may connect first member 2407 and base 2406. Each member such
as base 2406, first member 2407, second member 2409, third member
2411, and grip 2405, may be any type of member known in the art,
such as solid rods, hollow tubes, flat bars, and combinations of
these types of members. Grip 2405 may be a clamp or similar
mechanism. In some embodiments, roller 470 may include a handle 479
configured to be securely and optionally removably held by grip
2405. Each joint such as first joint 2401, second joint 2402, and
third joint 2403 may be any type of joint known in the art, such as
hinge joints and rotary joints. Each joint may be independently
moved by controller. Moving the joints to push the members apart
may control the height of the robotic arm. Each joint may be
configured to allow the attached member to move, pivot, swivel,
rotate, or otherwise move with respect to each other.
[0142] The robotic arm and substrate 400 may move relative to one
another to ensure that roller 470 may contact the entire surface of
substrate 400. In one embodiment, the robotic arm may move around a
stationary substrate 400. For example, in the embodiment shown in
FIG. 24, the robotic arm may be mounted onto a track 2424 that
encircles, surrounds, or partially surrounds substrate 400. A
connector may be attached to base 2406 and slidably positioned
within track 2424. The connector may be actuated by the controller
and the power source using known techniques to translate the
connector, and, by extension, the robotic arm, along track 2424. In
this manner, the robotic arm may move to multiple positions around
substrate 400. Further, base 2406 may be configured to rotate with
respect to track 2410 to allow roller 470 to face substrate 400
regardless of the position of the robotic arm on track 2424. In
another embodiment, substrate 400 may move and rotate relative to a
stationary the robotic arm. In some embodiments, more than one the
robotic arm may be positioned at various locations around substrate
400.
[0143] Third step 220 through fifth step 230 may be repeated in
this manner until the desired number of plies or material thickness
is achieved. Once the desired number of plies is laid down, a
seventh step 245 in the method shown in FIG. 4 may be performed:
the adhesive may be cured. Depending upon the type of adhesive,
curing may be achieved by exposing the layers to heat, convection,
and/or the flow of ambient temperature air over the layers. FIG. 25
shows an embodiment of curing utilizing an oven 495. Oven 495 may
be any type of oven known in the art, such as a convection oven or
an industrial oven configured to receive a conveyor belt. As shown,
oven 495 is a convection oven configured so that uncured fabric 401
may be passed into oven 495 where uncured fabric 401 is exposed to
heat 498 and air flow 497 at a temperature and for a duration
sufficient to cure adhesive particles 486. In one embodiment, where
the adhesive is LocTite spray adhesive, the adhesive is cured with
heat applied at about 120 degrees Celsius for about one minute.
Cured fabric 402 then exits oven 495.
[0144] Once the adhesive is cured, the nonwoven fabric is
completed. At this point, an eighth step 250 in the method shown in
FIG. 4 may be performed. Eighth step 250 includes removing the
nonwoven fabric from the substrate. Because the layers of the
nonwoven fabric were built up and cured directly on the surface of
the substrate, the nonwoven fabric will have the same contours as
the substrate.
[0145] FIG. 26 shows an embodiment of eighth step 250. Second
nonwoven fabric 402 has conformed to the shape of the substantially
flat substrate 400. In this embodiment, second nonwoven fabric 402
is a two-ply seamless nonwoven sheet of fabric as shown in FIG. 27.
Second nonwoven fabric 402 may be pulled off of substantially flat
substrate 400 as shown in FIG. 26. Second substance 420 may
facilitate the removal of second nonwoven fabric 402. In addition
to making substantially flat substrate 400 able to receive fiber
particles, second substance 420 may lubricate the surface of
substantially flat substrate 402 so that second nonwoven fabric 402
slips more easily off of substantially flat substrate 400.
[0146] An optional ninth step 260 of the method of FIG. 4 includes
additional finishing steps for the nonwoven material. Depending
upon the final article for which the nonwoven material is intended,
no additional finishing steps may be necessary. In some
embodiments, an additional finishing step may be washing or
otherwise laundering the nonwoven material to remove any remnants
of the substance used to coat the substrate. In other embodiments,
additional components may be associated with the nonwoven fabric to
complete an article like an article of footwear or an article of
apparel. In other embodiments, such as when making an article of
apparel, the additional finishing steps may include cutting the
nonwoven fabric and joining the cut pieces to each other or to
other pieces of fabric to make another article, like an article of
apparel. An embodiment of these types of finishing steps is
discussed below with respect to FIGS. 47 and 48.
[0147] FIGS. 28-37 show another embodiment of the method generally
set forth in FIG. 4. In this embodiment, a shaped substrate--a
last--is provided to make a seamless nonwoven upper.
[0148] FIG. 28 shows an embodiment of a shaped substrate 500 used
in an embodiment of a method of making a nonwoven upper. In the
embodiment shown in FIG. 28, shaped substrate 500 is a last
configured to make a nonwoven fabric having the shape of an upper,
similar to last 300 described above. Shaped substrate 500 may be
supported on a manufacturing floor or otherwise a manufacturing
facility by a third base 510. Third base 510 may be any type of
structure capable of supporting and stabilizing shaped substrate
500, such as a weighted plate. In some embodiments, a pole 512 may
be associated with third base 510 so that shaped substrate 500 may
be positioned at a predetermined height above third base 510. In
some embodiments, pole 512 may elevate shaped substrate 500 so that
shaped substrate 500 is positioned at a comfortable working height
for a user standing or sitting on the manufacturing floor. In other
embodiments, pole 512 may position shaped substrate 500 so that all
sides of shaped substrate 500 are accessible to the manufacturing
process. In some embodiments, shaped substrate 500 may include
provisions for associating with pole 512. For example, in one
embodiment shaped substrate 500 may include a recess or hole
configured to receive a free end of pole 512. The free end of pole
512 may be inserted into shaped substrate 500 and fitted there by
an interference fit or with threading. In other embodiments, pole
512 may be an extension of shaped substrate 500.
[0149] In some embodiments, shaped substrate 500 may be a solid,
rigid material. Shaped substrate 500 may be last for making an
article of footwear, similar to substrate 300 described above.
[0150] Like substrate 300 discussed above, shaped substrate 500 is
generally a material to which fiber particles may not adhere
without an additional adhesive or other substance to which the
fiber particles may adhere. The fiber particles may be any types of
fiber particle discussed above. The fiber particles may have any
length or denier discussed above. In order to receive the fiber
particles and hold the fiber particles in position on the surface
of shaped substrate 500, shaped substrate 500 may be prepared with
a substance to which the fiber particles may temporarily adhere. In
the embodiment shown in FIG. 28, shaped substrate 500 is prepared
by applying an electromagnetic charge or field to shaped substrate
500. The electromagnetic charge may be provided using any method of
charging an object known in the art. In some embodiments, the
charge may be produced by turning on a switch 514 that controls the
flow of power from a power source to shaped substrate 500. The
power source may be any type of power source known in the art, such
as a wall outlet connected to the local power grid, a battery, or a
generator. In some embodiments, shaped substrate 500 may include
circuitry that produces a charge when switch 514 is in the ON
position. In other embodiments, current from the power source may
simply flow through shaped substrate 500 so that the
electromagnetic field of the current produces the charge. In other
embodiments, shaped substrate 500 may include a magnet that spins
when switch 514 is in the ON position to generate the magnetic
field. In some embodiments, shaped substrate 500 may be positioned
within a chamber that imparts a charge to the surface of shaped
substrate 500.
[0151] In other electrostatic embodiments, substrate 500 may have a
positive charge or remain neutral or uncharged. In those
embodiments, the fiber particles will have an opposite charge to
the substrate or be charged when the substrate is uncharged. The
substrate attracts and holds onto the fiber particles due to
electrostatic attraction.
[0152] Once shaped substrate 500 has been charged, the method of
making the nonwoven fabric occurs in a substantially similar manner
to the embodiments described above.
[0153] Second step 210 of the method shown in FIG. 4 includes
dispensing the fiber particles onto the substrate. FIG. 29 shows an
embodiment of second step 210. In the embodiment shown in FIG. 29,
shaped substrate 500 has been prepared with a negative charge. A
third dispenser 542 is associated with a third reservoir 540
containing a plurality of third fiber particles 541, which may be
any type of fiber particle as discussed above. Third reservoir 540
may be any container capable of holding a desired quantity of third
fiber particle 541 and communicating that fiber particle to third
dispenser 542. Third dispenser 542 is configured to dispense second
fiber particles 441 onto shaped substrate 500. Third dispenser 542
may be any type of dispenser capable of propelling third fiber
particle 541 from third reservoir 540 onto shaped substrate
500.
[0154] In the embodiment shown in FIG. 29, third dispenser 542 is a
blower or other type of pneumatic device equipped with a third
nozzle 543. Third dispenser 542 may be automated, such as by using
a robot arm such as the robotic arms described above. Third
dispenser 542 may be any type of blower known in the art. Third
dispenser 542 is configured to draw a plurality of third fiber
particles 541 from third reservoir 540 and expel the plurality of
fiber particles through third nozzle 543 towards shaped substrate
500. Once expelled, the fiber particles become third ambient fiber
particles 546. Third ambient fiber particles 546 are carried along
streams of third air flow 544 propelled from third dispenser 542.
Third ambient fiber particles 546 have a positive charge in this
embodiment.
[0155] Third ambient fiber particles 546 move towards shaped
substrate 500 until third ambient fiber particles 546 stick to
shaped substrate 500. Once stuck onto the charged surface of shaped
substrate 500, the fiber particles become attached fiber particles
550. In some embodiments, attached fiber particles 550 are
positioned on shaped substrate 500 so that attached fiber particles
550 are substantially normal to the surface of shaped substrate
500. In other embodiments, attached fiber particles 550 are
positioned at other angles with respect to the surface of shaped
substrate 500. In some embodiments, attached fiber particles 550
are positioned at random angles with respect to the surface of
shaped substrate 500.
[0156] Third dispenser 542 and shaped substrate 500 may move
relative to one another to ensure that the entire surface of shaped
substrate 500 is exposed to third ambient fiber particles 546. In
one embodiment, third dispenser 542 may move around a stationary
shaped substrate 500. In another embodiment, shaped substrate 500
may move and rotate relative to a stationary third dispenser 542.
In some embodiments, more than one third dispenser 542 may be
positioned at various locations around shaped substrate 500.
[0157] Third dispenser 542 is configured to dispense third fiber
particle 541 until third ambient fiber particles 546 no longer
adhere to substrate 500. In some embodiments, the duration of
dispensing may be sensed by one or more sensors positioned
proximate shaped substrate 500. In some embodiments, the duration
of dispensing may be determined by an operator visually inspecting
shaped substrate 500 and third ambient fiber particles 546. Excess
third ambient fiber particles 546 may be removed from the proximity
of shaped substrate 500 by additional blowing air or a vacuum.
[0158] Third step 220 of the method shown in FIG. 4 includes
applying an adhesive to the embedded fiber particles, which is
achieved in substantially the same manner as the embodiment of
third step 220 shown in FIG. 8. The types and application styles
for the adhesive are also the same.
[0159] FIG. 30 shows an embodiment of third step 220. In the
embodiment shown in FIG. 30, a third sprayer 3060 is configured to
apply a third adhesive 562 onto attached fiber particles 550. Third
sprayer 3060 may be any kind of spray device known in the art
capable of aerosolizing and propelling third adhesive 562 towards
attached fiber particles 550. In some embodiments, third sprayer
3060 may be a trigger-type intermittent sprayer, such as a manual
spray bottle. In some embodiments, third sprayer 3060 may be a
compressor-driven continuous sprayer, such as a power sprayer.
[0160] In some embodiments, such as the embodiment shown in FIG.
30, third sprayer 3060 may be a factory line mechanism. In some
embodiments, the factory line mechanism may include a factory track
3010 disposed on a ceiling or otherwise suspended above charged
substrate 500. A base 3006 may be attached to factory track 3010 so
that base 3006 may translate along track 3010 using known
techniques such as servo motors and rollers or wheels. A controller
such as a processor with associated memory containing a program for
manipulating base 3006 and/or nozzle 564 may be linked wirelessly
or via wireline to base 3006 or any other part of the factory line
mechanism. A spray reservoir may be in fluid communication with
nozzle 564 through track 3010, such as with a tube embedded within
track 3010 or a channel formed in track 3010. In other embodiments,
a feeder line may be provided to link nozzle 564 to a spray
reservoir.
[0161] Third sprayer 3060 may include any number of members and
joints to allow nozzle 564 to move over the entire surface of
substrate 500. In the embodiment shown in FIG. 30, a first factory
joint 3001 may attach base 3006 directly to an articulated grip
3005 that holds nozzle 564, and, in some embodiments, feeds the
spray to nozzle 564. Articulated grip 3005 may include a number of
members and joints. A first grip joint 3002 may attach first grip
member 3007 to a second grip member 3009. A second factory joint
3003 may attach third grip member 3011 to fourth grip member 3013.
Each joint may be any type of joint known in the art, such as hinge
joints and rotary joints. Each joint may be independently moved by
a controller. Each joint may be configured to allow the attached
member to move, pivot, swivel, rotate, or otherwise move with
respect to each other. By translating along track 3010 and by
moving the joints, the entire surface of substrate 500 may be
exposed to spray 562.
[0162] Third sprayer 560 and shaped substrate 500 may move relative
to one another to ensure that third adhesive 562 is applied to the
entire surface of shaped substrate 500. In one embodiment, third
sprayer 560 may move around a stationary shaped substrate 500. In
another embodiment, shaped substrate 500 may move and rotate
relative to a stationary third sprayer 560. In some embodiments,
more than one third sprayer 560 may be positioned at various
locations around shaped substrate 500.
[0163] In some embodiments, a large amount of adhesive may be
applied to attached fiber particles 550, such as when a dip-type
adhesive is used. In other embodiments, such as shown in the
enlarged view in FIG. 30, a relatively light coating of adhesive is
applied to attached fiber particles 550. The enlarged view in FIG.
30 shows fifth adhesive droplets 566 dispersed within attached
fiber particles 550. Fifth adhesive droplets 566 may be adhered to
an individual fiber particle 546 or fifth adhesive droplets 566 may
be adhered to multiple attached fiber particles 550. Fifth adhesive
droplets 566 remain uncured at this point in the manufacturing
process.
[0164] Fourth step 225 of the method shown in FIG. 4 includes
applying a second layer of fiber particles onto attached fiber
particles 550 and fifth adhesive droplets 566. FIG. 31 shows an
embodiment of a layer of second attached fiber particles 555 being
deposited onto last 500, attached fiber particles 550, and fifth
adhesive droplets 566. The electrostatic charge, the geometry of
attached fiber particles 550, and fifth adhesive droplets 566 hold
second attached fiber particles 555 in position on last 500.
[0165] Fifth step 230 of the method shown in FIG. 4 includes
matting the fiber particles. In this embodiment, fifth step 230 may
be achieved as discussed above. FIG. 32 shows an embodiment of
fifth step 230 in which a third roller 570 is passed over attached
fiber particles 550 and second attached fiber particles 555. Third
roller 570 may be any type of roller known in the art, such as a
roller on a robotic arm or a manually-manipulated roller. The
movement of a robotic arm may be guided by a controller such as a
processor, a computer, or a handheld mobile device that send
movement signals to the third roller 570. Third roller 570
compresses and entangles attached fiber particles 550 and second
attached fiber particles 555 together to form a base ply 575 of
nonwoven fabric.
[0166] Third roller 570 may be automated, such as by employing a
robotic arm like articulated robotic arm 3260. The movement of
articulated robotic arm 3260 may be guided by a controller such as
a processor, a computer, or a handheld mobile device that send
movement signals to the roller 570. Articulated robotic arm 3260
may include multiple members and joints so that the height and/or
orientation of roller 570 may be manipulated. While articulated
robotic arm 3260 may include any number of members and joint, in
some embodiments such as the embodiment shown in FIG. 32,
articulated robotic arm 3260 may include a base 3206, a first
member 3207, a second member 3209, a third member 3211, and a grip
3205. A first joint 3201 may connect third member 3211 and second
member 3209. A second joint 3202 may connect second member 3209 and
first member 3207. A third joint 3203 may connect first member 3207
and base 3206. Each member such as base 3206, first member 3207,
second member 3209, third member 3211, and grip 3205, may be any
type of member known in the art, such as solid rods, hollow tubes,
flat bars, and combinations of these types of members. Grip 3205
may be a clamp or similar mechanism. In some embodiments, third
roller 570 may include a handle 579 configured to be securely and
optionally removably or interchangeably supported by grip 3205.
Each joint such as first joint 3201, second joint 3202, and third
joint 3203 may be any type of joint known in the art, such as hinge
joints and rotary joints. Each joint may be independently moved by
controller. Moving the joints to push the members apart may control
the height of the robotic arm. Each joint may be configured to
allow the attached member to move, pivot, swivel, rotate, or
otherwise move with respect to each other so that roller 570 may
have access to the entirety of substrate 500 an any particles on
substrate 500.
[0167] The robotic arm and substrate 500 may move relative to one
another to ensure that roller 570 may contact the entire surface of
substrate 500. In one embodiment, the robotic arm may move around a
stationary substrate 500. For example, in the embodiment shown in
FIG. 32, the robotic arm may be mounted onto a track that
encircles, surrounds, or partially surrounds substrate 500. A
connector may be attached to base 3206 and slidably positioned
within the track. The connector may be actuated by the controller
and the power source using known techniques to translate the
connector, and, by extension, the robotic arm, along the track. In
this manner, the robotic arm may move to multiple positions around
substrate 500. Further, base 3206 may be configured to rotate with
respect to track 3210 to allow roller 570 to face substrate 500
regardless of the position of the robotic arm on the track. In
another embodiment, substrate 500 may move and rotate relative to a
stationary the robotic arm. In some embodiments, more than one the
robotic arm may be positioned at various locations around substrate
500.
[0168] As with the embodiments discussed above, an optional sixth
step 240 of the method shown in FIG. 4 involves repeating third
step 220 through fifth step 240 to build up additional plies of
nonwoven fabric. Sixth step 240 may be repeated as many times as
desired until the desired number of plies is formed. The number and
thicknesses of the layers are the same as those discussed
above.
[0169] FIGS. 33-35 show an embodiment of forming a second ply of
nonwoven fabric on top of base ply 575 of third nonwoven fabric
501. As shown in FIG. 33, third step 220 of the method shown in
FIG. 4 is essentially repeated, using any of the adhesive
application techniques shown and/or discussed above. FIG. 33 shows
sprayer 3364, which may be any type of sprayer discussed above.
Sprayer 3364 applies sixth adhesive droplets 586 to base ply 575.
In FIG. 33, sprayer 3364 is incorporated into a robotic arm similar
to the robotic arms discussed above. Multiple members such as base
3306, first member 3307, and second member 3309 are connected
together by joints such as first joint 3301, second joint 3302, and
third joint 3303. A feeder line 3321 connected to a spray reservoir
3320 may feed sprayer 3364 so that spray 3362 may be propelled
towards substrate 500. The operation of sprayer 3364 may be the
same or similar to any automated sprayer discussed above, such as
by changing height or position and controlling the amount and
duration of spray.
[0170] Sprayer 3364 and substrate 500 may move with respect to each
other so that the entirety of substrate 500 may exposed to spray
3362. In some embodiments, such as those discussed above, sprayer
3364 may move around substrate 500. However, in the embodiment
shown in FIG. 33, substrate 500 may be configured to spin. For
example, a motor and gearbox 3310 may be attached to platform 510
and powered by a battery or a powerline 3311 controlled by switch
514. When switch 514 is in the ON position, gearbox 3310 may cause
substrate 500 to spin using known techniques. Between the rotating
of substrate 500 and the ability of sprayer 3364 to change height
and other spatial positions, sprayer 3364 may be able to expose the
entirety of rotating substrate 500 to spray 3362.
[0171] Fourth step 225 of the method shown in FIG. 4 is also
repeated, using any technique for fourth step 225 discussed above.
FIG. 34 shows an embodiment of fourth step 225. Dispensers 542
deposit charged fiber particles 546 onto last 500, base ply 575,
and sixth adhesive droplets 586 until third attached fiber
particles 580 attach to base ply 575. Sixth adhesive droplets 586
assist in maintaining third attached fiber particles 580 in
position. As noted above, charged fiber particles 546 are dispensed
until no additional fiber particles adhere to last 500 and/or a
visual inspection of last 500 shows the desired level of
coverage.
[0172] FIG. 35 shows an embodiment of repeating fifth step 230 in
which third roller 570 is passed over third attached fiber
particles 580 to mat and interconnect third attached fiber
particles 580. As discussed above with respect to FIG. 10, third
roller 570 may be any type of roller known in the art, such as a
roller on a robotic arm 3560 or a manually-manipulated roller. A
controller such as a processor, a computer, or a handheld mobile
device that sends signals to the third roller 570 may guide the
movement of a robotic arm. The movement of a robotic arm may be
guided by a controller such as a processor, a computer, or a
handheld mobile device that send movement signals to the roller
570. The robotic arm may include multiple members and joints so
that the height and/or orientation of roller 570 may be
manipulated. While the robotic arm may include any number of
members and joint, in some embodiments such as the embodiment shown
in FIG. 35, the robotic arm may include a base 3506, a first member
3507, a second member 3509, a third member 3511, and a grip 3505. A
first joint 3501 may connect third member 3511 and second member
3509. A second joint 3502 may connect second member 3509 and first
member 3507. A third joint 3503 may connect first member 3507 and
base 3506. Each member such as base 3506, first member 3507, second
member 3509, third member 3511, and grip 3505, may be any type of
member known in the art, such as solid rods, hollow tubes, flat
bars, and combinations of these types of members. Grip 3505 may be
a clamp or similar mechanism. In some embodiments, roller 570 may
include a handle 579 configured to be securely and optionally
removably held by grip 3505. Each joint such as first joint 3501,
second joint 3502, and third joint 3503 may be any type of joint
known in the art, such as hinge joints and rotary joints. Each
joint may be independently moved by controller. Moving the joints
to push the members apart may control the height of the robotic
arm. Each joint may be configured to allow the attached member to
move, pivot, swivel, rotate, or otherwise move with respect to each
other.
[0173] The robotic arm and substrate 500 may move relative to one
another to ensure that roller 570 may contact the entire surface of
substrate 500. Similar to the embodiment shown in FIG. 33,
substrate 500 may be configured to rotate or spin to expose the
entirety of substrate to roller 570.
[0174] Third roller 570 compresses and entangles third attached
fiber particles 580 together to form an additional ply 590 of
nonwoven fabric. Additionally, third roller 570 also entangles
third attached fiber particles 580 to the fibers of base ply 575.
In other embodiments, repeating fifth step 230 may involve other
methods of matting third attached fiber particles 580, such as
vacuum entanglement or manual entanglement.
[0175] Third step 220 through fifth step 230 may be repeated in
this manner until the desired number of layers is achieved. Once
the desired number of plies is laid down, seventh step 245 in the
method shown in FIG. 4 may be performed: the adhesive may be cured.
Depending upon the type of adhesive, curing may be achieved by
exposing the layers to heat, convection, and/or the flow of ambient
temperature air over the layers. In the embodiment shown in FIG.
35, a curing device 3565 mounted on a track 3566 propels heated air
3564 towards substrate 500 at a desired temperature and for a
desired duration. Curing device 3565 may be a factory line
mechanism as discussed above, having a base 3561 slidably mounted
to track 3566. An articulated joint 3562 may connect base 3561 to
body 3563. A controller and power source may feed information and
power through track 3566 or through other lines connected to curing
device 3565. In one embodiment, where the adhesive is LocTite spray
adhesive, the adhesive is cured with heat applied at about 120
degrees Celsius for about one minute. Any of the adhesive curing
methods, including temperature and duration, discussed above may be
used in this embodiment.
[0176] Once the adhesive is cured, the nonwoven fabric is
completed. At this point, an eighth step 250 in the method shown in
FIG. 4 may be performed. Eighth step 250 includes removing the
nonwoven fabric from the substrate. Because the layers of the
nonwoven fabric were built up and cured directly on the surface of
the substrate, the nonwoven fabric will have the same contours as
the substrate.
[0177] FIG. 36 shows an embodiment of eighth step 250. Third
nonwoven fabric 501 has conformed to the shape of the substantially
shaped substrate 500. In this embodiment, third nonwoven fabric 501
is a seamless nonwoven upper. Third nonwoven fabric 501 includes a
throat opening 520 that allows third nonwoven fabric 501 to be
pulled off of shaped substrate 500 as shown in FIG. 36. Switch 514
has been turned to the OFF position, which removes or neutralizes
the charge on shaped substrate 500. Neutralizing the charge on
shaped substrate 500 allows third nonwoven fabric 501 to slip more
easily off of shaped substrate 500. In another embodiment, the
charge on shaped substrate 500 may even switch polarity for this
step, so that shaped substrate 500 and third nonwoven fabric 501
may have the same polarity and will repel each other for easy
removal of the third nonwoven fabric 501 from shaped substrate
500.
[0178] An optional ninth step 260 of the method of FIG. 4 includes
additional finishing steps for the nonwoven material, which in this
embodiment is a seamless nonwoven upper 501 as shown in FIG. 37.
Depending upon the final article for which the nonwoven material is
intended, no additional finishing steps may be necessary. In some
embodiments, an additional finishing step may be washing or
otherwise laundering the nonwoven material to remove any remnants
of the substance used to coat the substrate. In other embodiments,
additional components may be associated with the nonwoven fabric to
complete an article like an article of footwear or an article of
apparel. In other embodiments, such as when making an article of
apparel, the additional finishing steps may include cutting the
nonwoven fabric and joining the cut pieces to each other or to
other pieces of fabric to make another article, like an article of
apparel. For example a ragged edge such as throat opening edge 512
may be finished with cutting, sealing, or additional material
adhered, welded or sewn into position for a more durable and
aesthetically pleasing article. In another example, bottom opening
516 may be closed and/or sealed with a sole.
[0179] FIGS. 38-46 show another embodiment of the method generally
set forth in FIG. 4. In this embodiment, a charged, substantially
flat substrate is provided to make a substantially flat nonwoven
material. This method is similar to the method described above with
respect to FIGS. 28-37, though the intention is to produce a flat
sheet of material as opposed to a shaped, three-dimensional
article. Only the shapes of the substrate and the resultant article
differ from the embodiment shown and discussed above with respect
to FIGS. 28-37.
[0180] The resultant nonwoven fabric will take on the shape of the
substrate. FIG. 38 shows an embodiment of a substantially flat
charged substrate 600 used in an embodiment of a method of making a
flat sheet of nonwoven material or fabric. In the embodiment shown
in FIG. 38, substantially flat charged substrate 600 is a
substantially flat surface like a table configured to make a
substantially flat nonwoven fabric. Substantially flat charged
substrate 600 may be supported on a manufacturing floor or
otherwise a manufacturing facility by a fourth base 610. Fourth
base 610 may be any type of structure capable of supporting and
stabilizing substantially flat charged substrate 600, such as a
weighted plate. In some embodiments, a leg 612 may be associated
with fourth base 610 so that substantially flat charged substrate
600 may be positioned at a predetermined height above fourth base
610. In some embodiments, leg 612 may elevate substantially flat
charged substrate 600 so that substantially flat charged substrate
600 is positioned at a comfortable working height for a user
standing or sitting on the manufacturing floor. In other
embodiments, leg 612 may position substantially flat charged
substrate 600 so that all sides of substantially flat charged
substrate 600 are accessible to the manufacturing process. In some
embodiments, substantially flat charged substrate 600 may include
provisions for associating with leg 612. For example, in one
embodiment substantially flat charged substrate 600 may include a
recess or hole configured to receive a free end of leg 612. The
free end of leg 612 may be inserted into substantially flat charged
substrate 600 and fitted there by an interference fit or with
threading. In other embodiments, leg 612 may be an extension of
substantially flat charged substrate 600.
[0181] In some embodiments, substantially flat charged substrate
600 may be a solid, rigid material. Substantially flat charged
substrate 600 may have a substantially flat surface, similar to
substantially flat substrate 400 described above.
[0182] Like substantially flat substrate 400 discussed above,
substantially flat charged substrate 600 may be a material to which
fiber particles may not adhere without a charge. In other
embodiments, flat substrate 600 may have no charge while the fiber
particles are charged. The fiber particles may be any types of
fiber particle discussed above. The fiber particles may have any
length or denier discussed above. In this embodiment, substantially
flat charged substrate 600 is prepared by applying an
electromagnetic charge or field to substantially flat charged
substrate 600 so that the fiber particles may attach to charged
substrate 600 electrostatically. The electromagnetic charge may be
provided using any method of charging an object known in the art.
In some embodiments, the charge may be produced by turning on a
second switch 614 that controls the flow of power from a power
source to substantially flat charged substrate 600. The power
source may be any type of power source known in the art, such as a
wall outlet connected to the local power grid, a battery, or a
generator. In some embodiments, substantially flat charged
substrate 600 may include circuitry that produces a charge when
second switch 614 is in the ON position. In other embodiments,
current from the power source may simply flow through substantially
flat charged substrate 600 so that the electromagnetic field of the
current produces the charge. In other embodiments, substantially
flat charged substrate 600 may include a magnet that spins when
second switch 614 is in the ON position to generate the magnetic
field.
[0183] Once substantially flat charged substrate 600 has been
charged, the method of making the nonwoven fabric occurs in a
substantially similar manner to the embodiments described
above.
[0184] Second step 210 of the method shown in FIG. 4 includes
dispensing the fiber particles onto the substrate. FIG. 39 shows an
embodiment of second step 210. In the embodiment shown in FIG. 39,
substantially flat charged substrate 600 has been prepared with a
negative charge. A fourth dispenser 642 is associated with a fourth
reservoir 640 containing a plurality of fourth fiber particles 641,
which may be any type of fiber particle as discussed above. Fourth
reservoir 640 may be any container capable of holding a desired
quantity of fourth fiber particles 641 and communicating that fiber
particle to fourth dispenser 642. Fourth dispenser 642 is
configured to dispense fourth fiber particles 641 onto
substantially flat charged substrate 600. Fourth dispenser 642 may
be any type of dispenser capable of propelling fourth fiber
particles 641 from fourth reservoir 640 onto substantially flat
charged substrate 600.
[0185] In the embodiment shown in FIG. 39, fourth dispenser 642 is
a blower or other type of pneumatic device equipped with a fourth
nozzle 643. Fourth dispenser 642 may be any type of blower known in
the art. Fourth dispenser 642 is configured to draw fourth fiber
particles 641 from fourth reservoir 640 and expel the fiber
particles through fourth nozzle 643 towards substantially flat
charged substrate 600. Once expelled, the fiber particles become
fourth ambient fiber particles 646. Fourth ambient fiber particles
646 are carried along streams of fourth air flow 644 propelled from
fourth dispenser 642. Fourth ambient fibers 646 also carry a
positive charge, which is the opposite electromagnetic state as
that of substantially flat charged substrate. Fourth ambient fiber
particles 646 are drawn towards substantially flat charged
substrate 600 due in part to the electromagnetic attraction until
fourth ambient fiber particles 646 stick to substantially flat
charged substrate 600 due to the electromagnetic attraction. Once
positioned onto the charged surface of substantially flat charged
substrate 600, the fiber particles become fifth attached fiber
particles 650. In some embodiments, fifth attached fiber particles
650 are positioned on substantially flat charged substrate 600 so
that fifth attached fiber particles 650 are substantially normal to
the surface of substantially flat charged substrate 600. In other
embodiments, fifth attached fiber particles 650 are attached at
other angles with respect to the surface of substantially flat
charged substrate 600. In some embodiments, fifth attached fiber
particles 650 are positioned at random angles with respect to the
surface of substantially flat charged substrate 600.
[0186] Fourth dispenser 642 and substantially flat charged
substrate 600 may move relative to one another to ensure that the
entire surface of substantially flat charged substrate 600 is
exposed to fourth ambient fiber particles 646. In one embodiment,
fourth dispenser 642 may move around a stationary substantially
flat charged substrate 600. In another embodiment, substantially
flat charged substrate 600 may move and rotate relative to a
stationary fourth dispenser 642. In some embodiments, more than one
fourth dispenser 642 may be positioned at various locations around
substantially flat charged substrate 600.
[0187] Fourth dispenser 642 is configured to dispense fourth fiber
particles 641 until fourth ambient fiber particles 646 no longer
adhere to substantially flat charged substrate 600. In some
embodiments, the duration of dispensing may be sensed by one or
more sensors positioned proximate substantially flat charged
substrate 600. In some embodiments, the duration of dispensing may
be determined by an operator visually inspecting substantially flat
charged substrate 600 and fourth ambient fiber particles 646.
Excess fourth ambient fiber particles 646 may be removed from the
proximity of substantially flat charged substrate 600 by additional
blowing air or a vacuum.
[0188] Third step 220 of the method shown in FIG. 4 includes
applying an adhesive to the embedded fiber particles, which is
achieved in substantially the same manner as the embodiment of
third step 220 shown in FIG. 8. The types and application styles
for the adhesive are also the same.
[0189] FIG. 40 shows an embodiment of third step 220. In the
embodiment shown in FIG. 40, a fourth sprayer 4360 is configured to
apply a fourth adhesive 662 onto fifth attached fiber particles
650. Fourth sprayer 4360 may be any kind of spray device known in
the art capable of aerosolizing and propelling fourth adhesive 662
towards fifth attached fiber particles 650. In some embodiments,
fourth sprayer 4360 may be a trigger-type intermittent sprayer,
such as a manual spray bottle. In some embodiments, fourth sprayer
4360 may be a compressor-driven continuous sprayer, such as a power
sprayer.
[0190] In some embodiments, fourth sprayer 4360 may be a factory
line mechanism 626 that may include a factory track 660 disposed on
a ceiling or otherwise suspended above flat substrate 600. A base
621 may be attached to factory track 660 so that base 621 may
translate along track 660 using known techniques such as servo
motors and rollers or wheels. A controller such as a processor with
associated memory containing a program for manipulating base 621
and/or nozzle 664 may be linked wirelessly or via wireline to base
621 or any other part of the factory line mechanism. The factory
line mechanism may include any number of members and joints to
allow nozzle 664 to move over the entire surface of flat substrate
600. In the embodiment shown in FIG. 40, a first factory joint 624
may attach base 621 to a first factory member 623. A second factory
joint 622 may attach first factory member 623 to a second factory
member 625 that support nozzle 664. Each joint may be any type of
joint known in the art, such as hinge joints and rotary joints.
Each joint may be independently moved by a controller. Moving the
joints to push the members apart may control the height of sprayer
360. Each joint may be configured to allow the attached member to
move, pivot, swivel, rotate, or otherwise move with respect to each
other.
[0191] Fourth sprayer 4360 and substantially flat charged substrate
600 may move relative to one another to ensure that fourth adhesive
662 is applied to the entire surface of substantially flat charged
substrate 600. In one embodiment, fourth sprayer 4360 may move
around a stationary substantially flat charged substrate 600. In
another embodiment, substantially flat charged substrate 600 may
move and rotate relative to a stationary fourth sprayer 4360. In
some embodiments, more than one fourth sprayer 4360 may be
positioned at various locations around substantially flat charged
substrate 600.
[0192] In this embodiment, such as shown in the enlarged view in
FIG. 40, a relatively light coating of adhesive is applied to fifth
attached fiber particles 650. The enlarged view in FIG. 40 shows
seventh adhesive droplets 666 dispersed within fifth attached fiber
particles 650. Seventh adhesive droplets 666 may be adhered to an
individual fiber particle 646 or seventh adhesive droplets 666 may
be adhered to multiple fifth attached fiber particles 650. Seventh
adhesive droplets 666 remain uncured at this point in the
manufacturing process.
[0193] Fourth step 225 of the method shown in FIG. 4 includes
applying a second layer of fiber particles onto fifth attached
fiber particles 650 and seventh adhesive droplets 666. FIG. 41
shows an embodiment of a layer of sixth attached fiber particles
655 being deposited onto charged substrate 600, fifth attached
fiber particles 650, and seventh adhesive droplets 666. The
electrostatic charge, the geometry of fifth attached fiber
particles 650, and seventh adhesive droplets 666 hold sixth
attached fiber particles 655 in position on substrate 600.
[0194] Fifth step 230 of the method shown in FIG. 4 includes
matting the fiber particles. In this embodiment, fifth step 230 may
be achieved as discussed above. FIG. 42 shows an embodiment of
fifth step 230 in which a fourth roller 670 is passed over fifth
attached fiber particles 650 and sixth attached fiber particles
655. Fourth roller 670 may be any type of roller known in the art,
such as a roller on a robotic arm or a manually-manipulated roller.
The movement of a robotic arm such as robot 4236 may be guided by a
controller such as a processor, a computer, or a handheld mobile
device that sends movement signals to the fourth roller 670.
[0195] The movement of robot 4236 may be guided by a controller
such as a processor, a computer, or a handheld mobile device that
send movement signals to the roller 670. Robot 4236 may include
multiple members and joints so that the height and/or orientation
of roller 670 may be manipulated. While the robotic arm may include
any number of members and joint, in some embodiments such as the
embodiment shown in FIG. 42, the robotic arm may include a base
4206, a first member 4207, a second member 4209, and a third member
4211. A first joint 4201 may connect third member 4211 and second
member 4209. A second joint 4202 may connect second member 4209 and
first member 4207. A third joint 4203 may connect first member 4207
and base 4206. Each member such as base 4206, first member 4207,
second member 4209, and third member 4211, may be any type of
member known in the art, such as solid rods, hollow tubes, flat
bars, and combinations of these types of members. In some
embodiments, roller 670 may include a handle 679 configured to be
securely and optionally removably supported by third member 4211.
Each joint such as first joint 4201, second joint 4202, and third
joint 4203 may be any type of joint known in the art, such as hinge
joints and rotary joints. Each joint may be independently moved by
controller. Moving the joints to push the members apart may control
the height of robot 4236. Each joint may be configured to allow the
attached member to move, pivot, swivel, rotate, or otherwise move
with respect to each other.
[0196] Fourth roller 670 compresses and entangles fifth attached
fiber particles 650 and sixth attached fiber particles together to
form a bottom ply 675 of nonwoven fabric. As shown in the enlarged
portion of FIG. 42, the fibers are loosely attached to each other,
being attached at various points 676 while leaving significant air
gaps 678 throughout bottom ply 675.
[0197] As with the embodiments discussed above, an optional sixth
step 240 of the method shown in FIG. 4 involves repeating second
step 210 through fourth step 240 to build up additional plies of
nonwoven fabric. Sixth step 240 may be repeated as many times as
desired until the desired number of plies is formed. The number and
thicknesses of the plies are the same as those discussed above.
[0198] FIGS. 43-45 show an embodiment of forming a second ply of
nonwoven fabric on top of bottom ply 675 of fourth nonwoven fabric
601. As shown in FIG. 43 shows an embodiment of repeating third
step 220. In the embodiment shown in FIG. 43, fourth sprayer 4360
is configured to apply an fourth adhesive 662 onto bottom ply 675.
In some embodiments, fourth sprayer 4360 may be part of a factory
line.
[0199] In some embodiments, fourth sprayer 4360 may include a track
4310 disposed on a ceiling or otherwise suspended above flat
substrate 600. A base 4306 may be attached to track 4310 so that
base 4306 may translate along track 4310 using known techniques
such as servo motors and rollers or wheels. A controller such as a
processor with associated memory containing a program for
manipulating base 4306 and/or nozzle 4364 may be linked wirelessly
or via wireline to base 4306 or any other part of fourth sprayer
4360. Fourth sprayer 4360 may include any number of members and
joints to allow nozzle 4364 to move over the entire surface of flat
substrate 600. In the embodiment shown in FIG. 43, a first joint
4301 may attach base 4306 to an articulated grip 4305. Articulated
grip 4305 may include any number of members and joints. A first
grip joint 4302 may attach first grip member 4307 to a second grip
member 4309. A second factory joint 4303 may attach third grip
member 4311 to fourth grip member 4313. Each joint may be any type
of joint known in the art, such as hinge joints and rotary joints.
Each joint may be independently moved by a controller. Each joint
may be configured to allow the attached member to move, pivot,
swivel, rotate, or otherwise move with respect to each other. By
translating along track 4310 and by moving the joints, the entire
surface of substrate 600 may be exposed to fourth adhesive or spray
662.
[0200] Fourth sprayer 4360 and substantially flat charged substrate
600 may move relative to one another to ensure that fourth adhesive
662 is applied to the entirety of bottom ply 675. In one
embodiment, fourth sprayer 4360 may move around a stationary
substantially flat charged substrate 600. In another embodiment,
substantially flat charged substrate 600 may move and rotate
relative to a stationary fourth sprayer 4360. In some embodiments,
more than one fourth sprayer 4360 may be positioned at various
locations around substantially flat charged substrate 600. Eighth
adhesive droplets 686 remain uncured and dispersed throughout
seventh attached fiber particles 680.
[0201] FIG. 44 shows an embodiment of repeating fourth step 225 of
the method shown in FIG. 4, which includes applying another layer
of fiber particles onto bottom ply 675 and eighth adhesive droplets
686. The embodiment shown in FIG. 44 is similar in most respects to
the embodiments of repeating fourth step 225 as discussed above
with respect to the other embodiments. FIG. 44 shows an embodiment
of a layer of seventh attached fiber particles 680 being deposited
onto substrate 600, bottom ply 675, and eighth adhesive droplets
686.
[0202] FIG. 45 shows an embodiment of repeating fifth step 230 in
which fourth roller 670 is passed over seventh attached fiber
particles 680. The embodiment shown in FIG. 45 is similar in most
respects to the embodiments of repeating fifth step 230 as
discussed above with respect to the other embodiments. Fourth
roller 670 compresses and entangles seventh attached fiber
particles 680 together to form an appended ply 690 of nonwoven
fabric. Additionally, fourth roller 670 also entangles seventh
attached fiber particles 680 to the fibers of bottom ply 675 to
attach appended ply 690 to bottom ply 675. In other embodiments,
repeating fifth step 230 may involve other methods of matting
seventh attached fiber particles 680, such as vacuum entanglement
or manual entanglement.
[0203] FIG. 45 shows an embodiment of repeating fifth step 230 in
which fourth roller 670 is passed over third attached fiber
particles 680 to mat and interconnect third attached fiber
particles 680. As discussed above with respect to FIG. 10, fourth
roller 670 may be any type of roller known in the art, such as a
roller on a robotic arm or a manually-manipulated roller. A
controller such as a processor, a computer, or a handheld mobile
device that sends signals to the fourth roller 670 may guide the
movement of a robotic arm. The movement of a robotic arm may be
guided by a controller such as a processor, a computer, or a
handheld mobile device that send movement signals to the roller
670.
[0204] The robotic arm may be mounted on a track for factory line
use, as shown in FIG. 45. While the robotic arm may include any
number of members and joint, in some embodiments such as the
embodiment shown in FIG. 45, the robotic arm may include a base
4506 and a first member 4507. A first joint 4501 may connect base
4506 and first member 4507. Each member such as base 4506 and first
member 4507, may be any type of member known in the art, such as
solid rods, hollow tubes, flat bars, and combinations of these
types of members. In some embodiments, roller 670 may be directly
attached to first member 4507 by a connector 4503. Connector 4503
may be a mechanical connector like a pin, a weld, or a joint. First
joint 4501 and optionally connector 4503 may be any type of joint
known in the art, such as hinge joints and rotary joints. Each
joint may be independently moved by controller. Moving the joints
to push the members apart may control the height of the robotic
arm. Each joint may be configured to allow the attached member to
move, pivot, swivel, rotate, or otherwise move with respect to each
other.
[0205] The robotic arm and substrate 500 may move relative to one
another to ensure that roller 670 may contact the entire surface of
substrate 500. Similar to the embodiment shown in FIG. 33,
substrate 500 may be configured to rotate or spin on a motorized
gear box 627 to expose the entirety of substrate 600 to roller
670.
[0206] Fourth roller 670 compresses and entangles third attached
fiber particles 680 together to form an additional ply 690 of
nonwoven fabric. Additionally, fourth roller 670 also entangles
third attached fiber particles 680 to the fibers of base ply 675.
In other embodiments, repeating fifth step 230 may involve other
methods of matting third attached fiber particles 680, such as
vacuum entanglement or manual entanglement.
[0207] Third step 220 through fifth step 230 may be repeated in
this manner until the desired number of layers is achieved. Once
the desired number of plies is laid down, seventh step 245 in the
method shown in FIG. 4 may be performed: the adhesive may be cured.
Depending upon the type of adhesive, curing may be achieved by
exposing the layers to heat, convection, and/or the flow of ambient
temperature air over the layers. In the embodiment shown in FIG.
45, a curing device 4567 mounted on a track 4510 may propel heated
air 4597 towards substrate 600 at a desired temperature and for a
desired duration. Curing device 4567 may be a factory line
mechanism as discussed above, having a base 4566 slidably mounted
to track 4510. An articulated joint 4561 may connect base 4566 to
curing device 4567. A controller and power source may feed
information and power through track 4510 or through other lines
connected to curing device 4567. In one embodiment, where the
adhesive is LocTite spray adhesive, the adhesive is cured with heat
applied at about 120 degrees Celsius for about one minute. Any of
the adhesive curing methods, including temperature and duration,
discussed above may be used in this embodiment.
[0208] Once the adhesive is cured, the nonwoven fabric is
completed. At this point, an eighth step 250 in the method shown in
FIG. 4 may be performed. Eighth step 250 includes removing the
nonwoven fabric from the substrate. Because the layers of the
nonwoven fabric were built up and cured directly on the surface of
the substrate, the nonwoven fabric will have the same contours as
the substrate.
[0209] FIG. 46 shows an embodiment of eighth step 250. Fourth
nonwoven fabric 601 has conformed to the shape of the substantially
flat charged substrate 600. In this embodiment, fourth nonwoven
fabric 601 is a sheet of nonwoven material. Second switch 614 has
been turned to the OFF position, which removes or neutralizes the
charge on substantially flat charged substrate 600. Neutralizing
the charge on substantially flat charged substrate 600 allows
fourth nonwoven fabric 601 to slip more easily off of substantially
flat charged substrate 600. In some embodiments, switch 614 may
control the polarity of the charge in addition to or instead of
merely controlling the flow of power. If the polarity is reversed,
the charge of substantially flat charged substrate 600 may repel
fourth nonwoven fabric 601 for easy removal.
[0210] An optional ninth step 260 of the method of FIG. 4 includes
additional finishing steps for the nonwoven material. Depending
upon the final article for which the nonwoven material is intended,
no additional finishing steps may be necessary. In some
embodiments, an additional finishing step may be washing or
otherwise laundering the nonwoven material to remove any remnants
of the substance used to coat the substrate. In other embodiments,
additional components may be associated with the nonwoven fabric to
complete an article like an article of footwear or an article of
apparel. In other embodiments, such as when making an article of
apparel, the additional finishing steps may include cutting the
nonwoven fabric and joining the cut pieces to each other or to
other pieces of fabric to make another article, like an article of
apparel.
[0211] FIGS. 47 and 48 show an embodiment of using a sheet of
nonwoven material 770 to make an article of apparel 790 using a
body last or a dressmaker's mannequin 700. Body last 700 may be any
type of body last known in the art as long as body last 700 is
capable of receiving cut portions of material so that a technician
or tailor may join the material pieces into an article of apparel.
Although shown as a torso-shaped body last, body last 700 may in
other embodiments be a full body last for making suits that cover
both a torso and the legs, or a lower body last for making shorts,
pants, trousers, and the like.
[0212] Nonwoven material 770 may be made using any method known in
the art, including those methods described above. However, the
method of making nonwoven material 770 is not restricted to those
methods described above.
[0213] FIG. 47 also shows how components of an article of apparel
may be associated with body last 700 to be joined together into the
article of apparel. The components may all be made of the same
material, such as is shown in the embodiment of FIG. 47, or the
components may be made of different materials. In FIG. 47, a single
apparel material 770 is provided. Outlines of the components to be
cut or developed from apparel material 770 are shown on apparel
material 770: a first sleeve component 771, a second sleeve
component 772, a front component 773, and a back component 774. To
associate first sleeve component 771 with body last 700 in the
proper position, first sleeve component 771 is positioned proximate
first shoulder 721. First sleeve component 771 is placed on top of
body last 700 so that first sleeve component 771 covers at least a
portion of first shoulder 721. To associate second sleeve component
772 with body last 700 in the proper position, second sleeve
component 772 is positioned proximate second shoulder 723. Second
sleeve component 772 is placed on top of body last 700 so that
second sleeve component 772 covers at least a portion of second
shoulder 723. In this embodiment, the sleeve components
substantially cover the shoulder regions, but do not extend a
significant length along first arm 710 or second arm 712. In other
embodiments, these coverage amounts could vary, with the shoulders
and arms having more or less coverage than shown in this
embodiment.
[0214] To associate front component 773 with body last 700, front
component 773 is positioned proximate chest portion 702 and abdomen
portion 714. Front component 773 is placed on top of body last 700
so that front component covers at least a portion of chest portion
702 and abdomen portion 714. In this embodiment, front component
773 would substantially cover both chest portion 702 and abdomen
portion 714. Other embodiments would have varying levels of
coverage, either greater than or less than the amount of coverage
shown in FIG. 47. To associate back component 774 with body last
700, back component 774 is positioned proximate a back portion of
third last (not shown but generally opposite chest portion 702 and
abdomen 714.) Back component 774 is placed on top of body last 700
so that back component 774 covers at least a portion of the back
portion. In this embodiment, back component 774 would substantially
cover the back portion. Other embodiments would have varying levels
of coverage, either greater than or less than the amount of
coverage shown in FIG. 47.
[0215] The number of components depends on the design of the
article of apparel. For example, in other embodiments, multiple
components may be used in place of any single component discussed
in this embodiment. Similarly, a single component may be used in
place of any two or more components discussed in this embodiment.
The embodiment shown in FIG. 47 is of a short-sleeved shirt, but a
similar method could be used to make any type of torso-covering
garment. FIG. 48 shows how the components correspond to portions of
article of apparel 790.
[0216] The components shown in FIG. 47 may be attached directly to
body last 700 (when the components are touching an outer surface of
body last 700), or the components may be indirectly attached to
body last 700 where another layer is positioned between the outer
surface of body last 700 and the components.) The type of
attachment depends on factors including the material(s) used to
make body last 700. For example, body last 700 may include a rigid,
inflexible material to withstand the external pressure applied by
the pressure applicator. The rigid material may include metals,
plastics, ceramics, composites, foam materials, and combinations.
Some of these materials may have a smooth surface. In such
embodiments, a covering or other material may be included with body
last 700. In some embodiments, body last 700 itself may include a
covering, such as a fabric, soft foam, elastomeric material, or the
like. The covering layer may be thin enough that any texture on the
smooth surface of the rigid material is still able to be imparted
to the apparel. However, the covering layer may allow pins or other
fasteners to be used to attach the components to body last 700. In
another embodiment, body last 700 may only include the rigid
material. A layer of another material may be provided between the
outer surface of body last 700 and the apparel. For example, a
release film may be employed, where one side of the release film is
able to stick or adhere to body last 700 while the components of
the apparel may be positioned on the other side of the release film
using a tacky surface, pins or other fasteners, or static
electricity. Finally, even if body last 700 includes a smooth
surface, static electricity, temporary adhesives, or other
fasteners may be used to attach the components to body last 700.
Any of these materials, attachment mechanisms, and configurations
may be used with any of the embodiments described herein.
[0217] As will be apparent to a person of ordinary skill in the
art, body last 700 may be adapted to be a substrate for the method
shown in FIG. 4, according to any embodiment discussed above. In
such embodiments, the cutting and shaping of the nonwoven material
on a separate body last may be eliminated if the nonwoven material
itself can be formed and shaped simultaneously on a body last.
[0218] While various embodiments of the invention have been
described, the description is intended to be exemplary, rather than
limiting and it will be apparent to those of ordinary skill in the
art that many more embodiments and implementations are possible
that are within the scope of the invention. Any feature of any
embodiment may be used with and/or substituted for another element
of any other embodiment except where specifically restricted.
Accordingly, the invention is not to be restricted except in light
of the attached claims and their equivalents. Also, various
modifications and changes may be made within the scope of the
attached claims.
* * * * *