U.S. patent application number 16/228718 was filed with the patent office on 2019-07-04 for fabric.
The applicant listed for this patent is Yao I Fabric Co., Ltd.. Invention is credited to Yen-Ting Liu.
Application Number | 20190203389 16/228718 |
Document ID | / |
Family ID | 67059374 |
Filed Date | 2019-07-04 |
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United States Patent
Application |
20190203389 |
Kind Code |
A1 |
Liu; Yen-Ting |
July 4, 2019 |
Fabric
Abstract
A fabric has a unitary one-piece construction and includes a
base layer and a first covering layer covering a first surface of
the base layer. The base layer is formed by assembling at least a
first yarn. The first covering layer is simultaneously formed with
the base layer by assembling at least a second yarn when assembling
the first yarn. The second yarn includes thermoplastic polymer.
Inventors: |
Liu; Yen-Ting; (Kaohsiung
City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Yao I Fabric Co., Ltd. |
Changhua County |
|
TW |
|
|
Family ID: |
67059374 |
Appl. No.: |
16/228718 |
Filed: |
December 20, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D04B 1/24 20130101; D10B
2403/0243 20130101; D03D 11/00 20130101; A43B 23/0215 20130101;
D10B 2403/0241 20130101; A43B 1/04 20130101; D04B 1/12 20130101;
D04B 1/102 20130101; D10B 2403/0122 20130101; D04B 1/16 20130101;
D10B 2401/041 20130101; D10B 2403/021 20130101; A43B 23/022
20130101; D10B 2501/043 20130101 |
International
Class: |
D04B 1/10 20060101
D04B001/10; A43B 1/04 20060101 A43B001/04; D04B 1/24 20060101
D04B001/24; D04B 1/16 20060101 D04B001/16; D04B 1/12 20060101
D04B001/12 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 29, 2017 |
TW |
106146638 |
Claims
1. A fabric, comprising: a base layer, formed by assembling at
least a first yarn; and a first covering layer covering a first
surface of the base layer and being simultaneously formed with the
base layer by assembling at least a second yarn when assembling the
first yarn, wherein the second yarn comprises a thermoplastic
polymer.
2. The fabric according to claim 1, wherein the fabric has a
unitary one-piece construction.
3. The fabric according to claim 1, wherein the first covering
layer is at least partially fused to form a first film on the first
surface of the base layer.
4. The fabric according to claim 3, wherein the first film has an
upper surface having a smooth texture.
5. The fabric according to claim 3, wherein the first film shows
part of the texture of the second yarn.
6. The fabric according to claim 1, further comprising an assistant
second yarn traversing back and forth between the base layer and
the first covering layer to attach the first covering layer
intimately to the first surface of the base layer.
7. The fabric according to claim 6, wherein the first covering
layer and the assistant second yarn traversing in the first
covering layer are at least partially fused to co-construct a first
film on the first surface of the base layer, and the assistant
second yarn traversing in the base layer is at least partially
melted and adhering to the first yarn of the base layer.
8. The fabric according to claim 7, wherein the first film has an
upper surface having smooth texture, and the assistant second yarn
traversing in the base layer keeps part of its texture.
9. The fabric according to claim 1, further comprising an embedded
yarn traversing back and forth between the base layer and the first
covering layer to attach the first covering layer intimately to the
first surface of the base layer, wherein the embedded yarn
comprises a thermoplastic polymer different from the second yarn,
and the embedded yarn has a melting point at a temperature equal to
or higher than a melting point of the second yarn.
10. The fabric according to claim 9, wherein the first covering
layer is at least partially fused to form a first film on the first
surface of the base layer, the embedded yarn is only partially
melted and adhering to the first film and the first yarn of the
base layer while keeping most of its texture.
11. A fabric, comprising: a base layer, formed by assembling at
least a first yarn; a first covering layer covering a first surface
of the base layer; and a second covering layer covering a second
surface opposite to the first surface of the base layer, wherein
the first covering layer and the second covering layer are
simultaneously formed with the base layer by respectively
assembling at least a second yarn and at least a third yarn when
assembling the first yarn, wherein the second yarn and the third
yarn respectively comprise a thermoplastic polymer.
12. The fabric according to claim 11, wherein the first covering
layer is at least partially fused to form a first film on the first
surface of the base layer, and the second covering layer is at
least partially fused to form a second film on the second surface
of the base layer.
13. The fabric according to claim 12, further comprising: at least
an assistant second yarn traversing back and forth between the
first covering layer and the base layer; and at least an assistant
third yarn traversing back and forth between the second covering
layer and the base layer, wherein the assistant second yarn and the
assistant third yarn are melted to respectively adhere to the first
film, the second film and the first yarn of the base layer.
14. The fabric according to claim 13, wherein the first film is
adhered with a portion of the assistant third yarn from the first
surface of the base layer, the second film is adhered with a
portion of the assistant second yarn from the second surface of the
base layer.
15. The fabric according to claim 13, wherein the first film and
the second film respectively have an upper surface having smooth
texture, the assistant second yarn and the assistant third yarn
traversing in the base layer respectively keeps part of their own
texture.
16. The fabric according to claim 12, further comprising at least
an assistant second yarn traversing back and forth between the
first covering layer, the base layer and the third covering layer
to attach the first covering layer and the second covering layer
respectively and intimately to the first surface and the second
surface of the base layer, wherein the assistant second yarn is
partially melted to adhere to the first film, the second film and
the first yarn in the base layer.
17. The fabric according to claim 16, wherein the first film and
second film respectively have an upper surface having smooth
texture, a portion of the second assistant yarn traversing in the
base layer keep part of its texture.
18. The fabric according to claim 11, wherein the second yarn and
the third yarn comprise a same thermoplastic polymer.
19. The fabric according to claim 12, further comprising: an
embedded yarn traversing back and forth between the first covering
layer, the base layer and the second covering layer to attach the
first covering layer and the second covering layer respectively and
intimately to the first surface and the second surface of the base
layer, wherein the embedded yarn comprises a thermoplastic polymer
different from the second yarn and the third yarn.
20. The fabric according to claim 19, wherein the embedded yarn is
partially melted to adhere to the first film, the second film and
the first yarn of the base layer while keeping most of its texture.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention generally relates to a fabric. More
particular, the present invention generally relates to a functional
fabric having a unitary one-piece construction incorporating at
least a thermoplastic yarn.
2. Description of the Prior Art
[0002] As the textile technology keeps progressing, various
functional fabrics have been developed for various applications. A
conventional method of forming a functional fabric may include
forming an additional material layer within or on the surface of
abase fabric by immersing, coating, sewing or laminating thereby
providing a specific functionality to the base fabric, such as
water resistance, abrasion resistance, compressibility, flexibility
and tensile strength for durability and comfort in wearing.
However, these conventional methods of forming a functional fabric
usually require complicated process steps, and meanwhile extra cost
of transportation and storage of intermediate goods and
accessories. Furthermore, the endurance of the functional fabric is
usually limited by shedding off from the base fabric and also
influences the appearance.
SUMMARY OF THE INVENTION
[0003] In light of the above, one objective of the present
invention is to provide a fabric, particularly a functional fabric
having a unitary one-piece construction, which incorporates at
least a thermoplastic yarn for improved water resistance and
durability and may be fabricated by simplified process.
[0004] In order to achieve the above objective, a fabric according
to one aspect of the present application includes a base layer
formed by assembling at least a first yarn, and a first covering
layer covering a first surface of the base layer and simultaneously
formed with the base layer by assembling at least a second yarn
when assembling the first yarn, wherein the second yarn comprises
at least a thermoplastic polymer.
[0005] According to an embodiment, the first covering layer may be
at least partially fused into a first film on the first surface of
the base layer. The first film may have an upper surface having a
smooth texture or showing partial texture of the second yarn.
[0006] According to an embodiment, the fabric further comprises an
assistant second yarn traversing back and forth between the base
layer and the first covering layer to attach the first covering
layer intimately to the first surface of the base layer. The first
covering layer is at least partially fused into a first film, and
the assistant second yarn is at least partially melted to adhere to
the first film and the first yarn of the base layer.
[0007] In order to achieve the above objective, a fabric according
to another aspect of the present invention includes abase layer
formed by assembling at least a first yarn, and a first covering
layer and a second covering layer respectively covering a first
surface and a second surface opposite to the first surface of the
base layer, wherein the first covering layer and the second
covering layer are simultaneously formed with the base layer by
respectively assembling at least a second yarn and at least a third
yarn when assembling the first yarn, wherein the second yarn and
the third yarn respectively comprises a thermoplastic polymer.
[0008] According to an embodiment, the first covering layer is at
least partially fused into a first film on the first surface, and
the second covering layer is at least partially fused into a second
film on the second surface.
[0009] According to an embodiment, the fabric further includes at
least an assistant second yarn traversing back and forth between
the first covering layer and the base layer and at least an
assistant third yarn traversing back and forth between the second
covering layer and the base layer. The assistant second yarn and
the assistant third yarn are melted to respectively adhere to the
first film, the second film and the first yarn of the base layer.
The first film on the first surface is fused to adhere to the
assistant third yarn partially. The second film on the second
surface is fused to adhere to the assistant second yarn
partially.
[0010] According to an embodiment, the fabric further includes at
least an assistant yarn traversing back and forth between the first
covering layer, the base layer and the third covering layer and at
least partially melted to adhere to the first film, the second film
and the first yarn of the base layer.
[0011] According to an embodiment, the fabric further includes an
embedded yarn traversing back and forth between the first covering
layer, the base layer and the second covering layer to attach the
first covering layer and the second covering layer respectively and
intimately to the first surface and the second surface of the base
layer, wherein the embedded yarn comprises a thermoplastic polymer
different from the second yarn and the third yarn.
[0012] According to an embodiment, the embedded yarn is partially
melted to adhere to the first film, the second film and the first
yarn of the base layer while keeps most of its texture.
[0013] These and other objectives of the present invention will no
doubt become obvious to those of ordinary skill in the art after
reading the following detailed description of the preferred
embodiment that is illustrated in the various figures and
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1A, FIG. 1B and FIG. 1C are schematic diagrams
illustrating the basic structures of a knitted or woven fabric.
[0015] FIG. 2 and FIG. 3 are schematic illustrative diagrams of a
fabric according to a first embodiment of the present
invention.
[0016] FIG. 4A, FIG. 4B and FIG. 5 are schematic illustrative
diagrams of a fabric according to a second embodiment of the
present invention.
[0017] FIG. 6 and FIG. 7 are schematic illustrative diagrams of a
fabric according to a third embodiment of the present
invention.
[0018] FIG. 8A, FIG. 8B and FIG. 9 are schematic illustrative
diagrams of a fabric according to a fourth embodiment of the
present invention.
[0019] FIG. 10 and FIG. 11 are schematic illustrative diagrams of a
fabric according to a fifth embodiment of the present
invention.
[0020] FIG. 12 and FIG. 13 are schematic illustrative diagrams of a
fabric according to a sixth embodiment of the present
invention.
[0021] FIG. 14A, FIG. 14B, FIG. 15A, FIG. 15B and FIG. 16 are
schematic illustrative diagrams of a fabric according to a seventh
embodiment of the present invention.
[0022] FIG. 17 and FIG. 18 are schematic illustrative diagrams of a
fabric according to an eighth embodiment of the present
invention.
[0023] FIG. 19 and FIG. 20 are schematic illustrative diagrams of a
fabric according to a ninth embodiment of the present
invention.
[0024] FIG. 21 and FIG. 22 are schematic illustrative diagrams of a
fabric according to a tenth embodiment of the present
invention.
[0025] FIG. 23, FIG. 24 and FIG. 25 are schematic diagrams
illustrating top views of fabrics according to some embodiments of
the present invention.
[0026] FIG. 26 is a schematic diagram illustrating a variation of
the eighth embodiment of the present invention.
DETAILED DESCRIPTION
[0027] The following detailed description is, therefore, not to be
taken in a limiting sense, and the scope of the present invention
is defined by the appended claims, along with the full scope of
equivalents to which such claims are entitled. One or more
implementations of the present invention will now be described with
reference to the attached drawings, wherein like reference numerals
are used to refer to like elements throughout, and wherein the
illustrated structures are not necessarily drawn to scale. Some
structures are omitted for the sake of simplicity.
[0028] The term "simultaneously assembling/manipulating" in the
present invention is directed to a continuous process of forming a
unitary one-piece hybrid fabric by manipulating two or more than
two different kinds of yarns in a machine. The fabric provided by
the present invention may have a single layer structure or a
multi-layer structure. The said two or more than two different
kinds of yarns maybe simultaneously assembled into a single layer
or into different layers of the fabric. A unitary one-piece fabric
refers to a fabric having its entirety formed through a continuous
fabricating process without other steps such as adhering, sewing,
stitching or braiding for forming any part of the fabric.
[0029] Yarn which may be manipulated into a yarn contexture or into
an inlaid structure of a fabric of the present invention is an
assembly of at least one filament or a plurality of fibers
(monofilament or multifilament) and has an extending length and
relatively small cross-section. Materials for forming yarns may be
natural or artificial materials. For example, yarns used in the
present invention may be made of materials selected from the group
including vegetable fibers (cotton, linen and the like), animal
fibers (silk, wool and the like), inorganic regenerated fiber,
organic generated fiber, semi-synthetic fiber and polymers such as
polyamide, polyester, polyacrylonitrile, polyethylene,
polypropylene, polyvinylalcohol, polyvinylchloride,
polytetrafluoroethylene, polyurethane, nature rubber, thermoplastic
polymer, thermoset polymer, synthetic rubber, or combination
thereof, but not limited hereto. Yarns utilized in the present
invention may be monofilament or multifilament yarns. Each yarn may
include different types of filaments made of different materials,
or may include a single type of filament made of two or more
different materials. Similar concepts also apply to yarns formed
from fibers. Accordingly, yarns may have a variety of
configurations that generally conform to the definition provided
above.
[0030] Weaving and knitting are the two foremost textile processing
methods. Weaving has two perpendicular and individual tread
systems, warp and weft threads, that come close contact and result
in a rigid fabric. In knitting, the yarns are kept together by
loops that give a latent potential for being easily deformable. The
fabric provided by the present invention has a unitary one-piece
construction and is produced by simultaneously manipulating
(assembling) two or more different kinds of yarns in a continuous
process, such as a contentious weaving or knitting process.
Although a portion of the fabric may undergo a transformation by
performing an additional step, such as a heat-setting step or a
cooling step performed after the continuous process for producing
the fabric, the fabric including the transformed portion is still
considered as a unitary one-piece fabric.
[0031] Transformation of a material may be induced by thermo
stress. Common transformation of a material may include, but not
limited to: brittle when being cooled to a temperature lower than
the glass transition temperature (Tg) of the material, softening
when being heated to a temperature higher than the heat deflection
temperature (HDT) of the material, melting or fusing when being
heated to a temperature higher than the melting temperature (Tm) of
the material and degrading when being heated to a temperature
higher than the degradation temperature (Td) of the material.
[0032] The fabric according to the present invention has a
thermoplastic portion made of thermoplastic polymer undergoing a
transformation process including heating the fabric to a
temperature higher than the melting point (Tm) of the thermoplastic
polymer to make the thermoplastic portion at least partially melted
and fused and then cooling the fabric to room temperature to
finalize the shape of the thermoplastic portion (herein referred as
a heat-setting step) is an example of the transformation.
Materials, processes and applications of the present invention are
not limited to the exemplary embodiments. Furthermore, although the
entirety of the fabric is heated in a same equipment for a period
time, the portion of the fabric closer to the heat source (such as
the outermost portion of the fabric) will be transformed faster and
more completely than the portion farther from the heat source (such
as the inner portion of the fabric). Consequently, a same material
may have different degrees of transformation according to different
positions of the fabric.
[0033] The fabric provided by the present invention which has a
unitary one-piece construction formed by simultaneously
manipulating at least two different kinds of yarns in a continuous
fabricating process allows selectively reinforcing a particular
property or providing a particular function of a certain portion of
the fabric with simplified manufacturing process. The fabric
provided by the present invention and the associated concepts may
be applied in various field, such as apparel clothing, footwear
textile, athletic equipment textile, container, furniture textile,
household textile, industrial clothing, automotive textile. The
fabrics illustrated in the following embodiments are footwear
textiles. Generally, footwear includes two primary parts according
to different functions, a sole and an upper. The sole is secured to
a lower portion of the upper and positioned between the upper and
the ground, thereby may attenuate ground reaction force and lessen
stresses the foot and leg bearing during walking, running and other
ambulatory activities. The upper is configured to receive a foot of
a wearer so as to provide protection and appearance. Typically, an
upper may be compartmented into several portions to conform to
different areas of a foot as well as provide different functions.
For example, an upper may include a fore portion associated with
the toes, a rear portion associated with the heel, and a medial
portion that is disposed between the fore portion and the rear
portion and associated with the instep, side and arch of the foot .
An upper may further include a tongue portion, lace holes and an
ankle opening portion. The entire upper of finished footwear may be
made of several joint compartments or of a unitary base fabric .
Different portions of an upper may be made with different functions
or reinforced properties, such as abrasion resistance, air
permeability, stretching resistance, moisture permeability,
compressibility, flexibility and shape memory for comfort in
wearing. Conventional methods of imparting these functions to an
upper usually require performing additional steps, such as
adhering, sewing, stitching or braiding to add functional
components to the upper after the compartments or base fabric of
the upper been produced and cut to shape or sometimes performing
additional steps in the process of forming the compartments or base
fabric of the upper. One feature of the present invention is that
the fabric provided by the present invention has a unitary
one-piece construction with built-in functional component(s) and is
formed in its entirety through a continuous process. In other
words, functional component(s) is integrally imparted into the
fabric at the same time when producing the fabric through a
continuous process (a continuous weaving or knitting process).
After that, the unitary one-piece fabric made with built-in
functional component(s) maybe subjected to a cutting process to
remove unnecessary portions and obtain the prototype for being
configured into shape. Additional steps to impart functional
component (s) to the fabric after the cutting process may be
omitted, thereby attaining a simplified process.
[0034] For better understanding the objective of the present
invention, please refer to FIG. 1A, FIG. 1B and FIG. 1C, which are
schematic diagrams exemplarily showing the common assembling
structures of fabrics made by weaving or knitting.
[0035] Please refer to FIG. 1A. FIG. 1A shows an assembling
structure of a woven fabric 10, in which the top portion is a
perspective view of the fabric 10, and the lower portion is a
cross-sectional view taken along the warp direction A-A' of the
fabric 10. The fabric 10 as shown in FIG. 1A is formed by
assembling (interlacing or interweaving) at least two sets of yarns
12 and 12a. Yarns 12 parallel with the warp direction A-A' (the
prolonging direction of the fabric) are warps. Yarns 12a parallel
with the weft direction (the widthwise direction of the fabric 10)
and assembled with yarns 12 at right angles are wefts. Yarns 12 and
12a may respectively be monofilament or multifilament yarns.
[0036] Please refer to FIG. 1B and FIG. 1C. FIG. 1B shows an
assembling structure of a weft-knitted fabric 20 formed by
assembling at least a yarn 22. The upper portion of FIG. 1B is a
plan-view, and the lower portion of FIG. 1B is a cross-sectional
view taken along the weft direction B-B' of the fabric 20. FIG. 1C
shows an assembling structure of a warp-knitted fabric 30 formed by
assembling a set of yarns 32. The upper portion of FIG. 1C is a
plan-view, and the lower portion of FIG. 1C is a cross-sectional
view taken along the warp direction A-A' of the fabric 30.
Generally, in a knitted fabric, a row of loops arranged along the
weft direction (the widthwise direction of the fabric) is referred
as a course, and a column of loops arranged along the warp
direction (the lengthwise direction of the fabric) is referred as a
wale. During the process of forming a weft-knitted fabric 20 as
shown in FIG. 1B, the yarn 22 is supplied to a knitting machine
from the weft direction B-B' and successively placed on a row of
needles for being manipulated into a row of lateral-connected
loops, herein designated as course number n. Subsequently, the yarn
22 re-enters the knitting machine from the opposite side of the
weft direction B-B' and successively placed on the needles for
being manipulated into another row of lateral-connected loops,
herein designated as course number n+1. At the same time of forming
course number n+1 of yarn 22, by a series of lapping and shogging
movements of the needles, each loop of course number n+1 is
assembled (interlaced or interlooped) with the corresponding loop
of course number n formed previously by the same needle, thereby
prolonging the weft-knitted fabric 20 with assembled courses. On
the other hand, during the process of forming a warp-knitted fabric
30 as shown in FIG. 1C, a set or several sets of parallel yarns 32
are supplied to a knitting machine respectively from the warp
direction and placed on the needles for being manipulated into
columns of vertical-connected loops, herein designated as wales
number m-1, m and m+1. Meanwhile, by alternately placing the yarns
32 on adjacent needles for being interlooped with loops of another
yarn previously formed on the needles, wales number m-1, m and m+1
formed from different yarns 32 are laterally interconnected as the
knitting process continues to prolong the warp-knitted fabric
30.
[0037] Nowadays, various stitches have been developed for weaving,
weft-knitting or warp-knitting. For example, a woven fabric may
include plain stitch, twill stitch, satin stitch or combination
thereof. A woven fabric may have warps or wefts braided, twisted,
crossed or ribbed for better strength, texturing or appearance, but
not limited hereto. A knitted fabric may include weft plain stitch,
rib stitch, purl stitch, chain stitch, tricot stitch, satin tricot
stitch, double loop stitch, tuck stitch, derivative stitch or the
like, or combination thereof, but not limited hereto. It should be
understood that the fabrics provided by the present invention may
be formed by weaving, weft-knitting or warp-knitting process and
may include various stitches. In the following description, several
embodiments are provided with reference to associated schematic
diagrams in which only components considered necessarily for
understanding the concept of the present invention are shown while
other components may be omitted for the sale of simplicity.
[0038] FIG. 2 and FIG. 3 are schematic illustrative diagrams of a
fabric 100 according to a first embodiment of the present
invention. Please refer to FIG. 2. The upper portion of FIG. 2 is a
perspective view of the fabric 100, and the lower portion of FIG. 2
is a cross-sectional view of the fabric 100. The fabric 100
includes a base layer 110 formed by assembling at least yarn 112
through a continuous process (weaving or knitting) and having a
first surface 110a and a second surface 110b opposite to the first
surface 110a of the base layer 110. In the following description,
the term "surface" or "upper surface" of a fabric or a textile
layer is the surface presenting the stitch of the fabric and used
in defining the thickness of the fabric, or may be the outermost
surface exposed for perceptible texture. In the present invention,
the surfaces of a fabric or a textile layer are drawn as a plane
for the sake of simplicity. Usually, the surface of a fabric may
provide a coarse texture when the textures of yarns forming the
fabric are felt. The fabric 100 further includes a first covering
layer 120 formed on the first surface 110a and at least partially
covering the first surface 110a. The first covering layer 120 is
simultaneously formed with the base layer 110 by assembling at
least a second yarn 122 during the continuous process of forming
the base layer 110. In other words, the fabric 100 provided by the
present invention substantially has a unitary one-piece
construction formed by manipulating the first yarn 112 and the
second yarn 122 respectively into the base layer 110 and the first
covering layer 120 in the same continuous weaving or knitting
process. According to an embodiment when the fabric 100 is formed
by a weaving, the winding first yarn 112 and second yarn 122 shown
in the lower portion of FIG. 2 may be considered as the warp yarn
of the base layer 110 and the first covering layer 120, such as the
warp yarn 12 shown in FIG. 1A. In another embodiment when the
fabric 100 is formed by weft-knitting, the winding first yarn 112
and second yarn 122 shown in the lower portion of FIG. 2 may be
considered as a course of loops made from yarn 112 or 122 along the
weft direction of the fabric 100, such as the course made from yarn
22 shown in FIG. 1B. In still another embodiment when the fabric
100 is formed by warp-knitting, the winding first yarn 112 and
second yarn 122 shown in the lower portion of FIG. 2 may be
considered as a wale of loops made from yarn 112 or 122 along the
warp direction of the fabric 100, such as the wale made from yarn
32 shown in FIG. 1C. To further simplify the diagrams, other rows
or columns assembled with the drawn yarns 112 and 122 are not shown
in FIG. 2 and other diagrams in the present invention. Because the
first covering layer 120 is formed by weaving or knitting, the
first surface 110a of the base layer 110 may be seen through fabric
pores created by the assembling second yarn 122 especially when the
first covering layer 120 exhibits a small stitch density (or high
fabric porosity).
[0039] According to one embodiment, the first yarn 112 for forming
the base layer 110 may be monofilament or multifilament. The first
yarn 112 may be made of materials selected from the group
previously illustrated. Preferably, the first yarn 112 comprises
thermoplastic polymer, such as polyethylene terephthalate
(PET).
[0040] According to the embodiment, the second yarn 122 for forming
the first covering layer 120 may be monofilament or multifilament.
The first yarn 112 may be made of materials selected from the group
previously illustrated. Preferably, the second yarn 122 is
monofilament comprising thermoplastic polymer, such as
thermoplastic urethane (TPU) which is known for thermofusion
stability, thermoplasticity with adjustable melting point for
process convenience. According to an embodiment, the second yarn
122 may have a thread size of linear mass density between 150 and
1800 dens (denier). It is noteworthy that when both the first yarn
112 and the second yarn 122 are made of thermoplastic polymer, the
melting point of the second yarn 122 should be lower than the
melting point of the first yarn 112 to prevent the first yarn 112
from being melted and causing unexpected deformation of the base
layer 110 when performing a subsequent heat-setting step to
transform the first covering layer 120 into a first film 130 (shown
in FIG. 3). Preferably, the melting point of the second yarn 122 is
at least 20 degrees Celsius lower than the melting point of the
first yarn 112. More preferably, the melting point of the second
yarn 122 is at least 30 degrees Celsius lower than the melting
point of the first yarn 112. For example, in a practice of the
invention, the first yarn 112 forming the base layer 110 is made of
PET and has a melting point approximately 250 degrees Celsius, and
the second yarn 122 forming the first covering layer 120 is made of
TPU and has a melting point equal to or smaller than 220 degrees
Celsius. The stitches of the base layer 110 and the first covering
layer 120 may be integrally designed by computer aided
manufacturing (CAM) technique. The design is then input to a
computer-controlled knitting or weaving machine by which the
continuous weaving or knitting process is performed wherein the
first yarn 112 and the second yarn 122 are simultaneously
manipulated into the base layer 110 and the first covering layer
120, respectively. It is noteworthy that when needles are used to
manipulate the yarns, the thread size of the yarns should be
adjusted according to needle sizes. According to a practice of the
present invention, the thread size of the yarns 112 and yarn 122
used for forming the fabric 100 preferably have a linear mass
density smaller than 900 dens, for example, approximately 600
dens.
[0041] Please refer to FIG. 3. After the fabric 100 including the
base layer 110 and the first covering layer 120 are produced, they
may be subjected to a heat-setting step to make the second yarn 122
of the first covering layer 120 at least partially melted and fused
into a first film 130 covering the same region of the first surface
110a originally covered by the first covering layer 120. The
heat-setting step may be carried out using heat press by a roller
or mold, or heat-flue setting by an oven, but not limited. The
temperature of the heat-setting step is equal to or higher than the
melting point of the second yarn 122, and preferably, by at least 5
degrees Celsius. For example, when the second yarn 122 has a
melting point approximately at 180 degrees Celsius, the
heat-setting step may be carried out at approximately 200 degrees
Celsius, and preferably 185 degrees Celsius. According to an
embodiment, after the heat-setting step, as shown in the upper
portion of FIG. 3, the second yarn 122 of the first covering layer
120 may be melted to completely lose its original texture (deformed
to lose its original thread profile) and fused into a first film
130, which may have an upper surface with a smooth texture and does
not show any texture of the second yarn 122. According to another
embodiment, as shown in the lower portion of FIG. 3, the second
yarn 122 of the first covering layer 120 is only partially melted,
partially keeping its original texture and partially fused form to
form the first film 130 during the heat-setting step. Therefore,
the first film 130 may present a partial texture of the second yarn
122 and may have an upper surface having a coarse texture.
Preferably, the first film 130 is a continuous film uniformly
covering the region of the first surface 110a originally covered by
the first covering layer 120 without any pores exposing the first
surface 110a. Advantageously, by selecting TPU as the material to
form the second yarn 122 of the first covering layer 120 therefore
obtaining the first film 130 made of TPU, the region of the first
surface 110a covered by the first film 130 may have improved
moisture resistance properties to prevent moisture from permeating
into the base layer 110 from the first surface 110a. Meanwhile, the
region of the first surface 110a covered by the first film 130 made
of TPU may also have improved wear-resistance properties.
Furthermore, the first film 130 made of TPU may have better fusion
and laminating to the first surface 110a of the base layer 110
after the heat-setting step.
[0042] One feature of the present invention is that, the fabric 100
with functional component(s) incorporated therein is made of a
unitary one-piece construction by simultaneously assembling the
first yarn 112 and the functional second yarn 122 respectively into
base layer 110 and the first covering layer 120 covering a
pre-determined region of first the surface of the base layer 120,
allowing the functional first film 130 being formed with precisely
controlled shape and placement. The fabric 100 provided by the
present invention may be formed in a simplified process in high
degree of automation without the need of performing conventional
cutting, aligning, adhering, and heating process for adding
functional component(s) to the base fabric.
[0043] Please refer to drawing (a) of FIG. 23, illustrating a top
view of a fabric 100 according to the first embodiment of the
present invention used for forming a footwear upper. As illustrated
in the first embodiment, the fabric 100 includes a base layer 110
formed by assembling at least a first yarn 112. The base layer 110
may include a pre-determined first region 114a defined therein. For
example, the fabric 100 may be cut into a full upper of a footwear
article along the outer perimeter of the first region 114a. The
fabric 100 further includes a first covering layer 120 formed on
the first surface (the drawing plane) 110a and covering the first
region 114a. The first surface 110a of the fabric 100 may be an
exterior surface of the footwear upper, which is opposite to the
interior surface facing the foot. On the contrary, the first
surface 110a of the fabric 100 may be an interior surface facing
the foot. It is important that the fabric 100 is made of a unitary
one-piece construction by simultaneously manipulating the first
yarn 112 and the second yarn 122 respectively into the base layer
110 and the first covering layer 120 through a continuously process
(may be weaving or knitting) of forming the fabric 100. The fabric
100 may be subjected to a heat-setting step to make the first
covering layer 120 at least melted and fused into a first film 130
on the first surface 110a and covering the first region 114a. The
region covered by the first film 130 may have improved moisture
resistance, wear-resistance and fusion property. According to an
embodiment where the first yarn 112 of the base layer 110 comprises
thermoplastic material, the heat-setting step may be carried out at
a temperature higher than the heat deflection temperature (HDT) of
the first yarn 112 of the base layer 110 to simultaneously
thermo-shape the base layer 110 and melting and fusing the first
covering layer 120 into the first film 130 at the same time,
thereby further simplifying the process steps.
[0044] FIG. 4A, FIG. 4B and FIG. 5 are schematic illustrative
diagrams of a fabric 100 according to a second embodiment of the
present invention. Please refer to FIG. 4A. Similar to the first
embodiment, the fabric 100 includes a base layer 110 and a first
covering layer 120 formed on and at least partially covering a
first surface 110a of the base layer 100. The difference with the
first embodiment is that, in the second embodiment, the fabric 100
further includes at least an assistant second yarn 124 traversing
back and forth between the base layer 110 and the first covering
layer 120 to attach the first covering layer 120 intimately to the
first surface 110a of the base layer 110 and also at least
partially fill the fabric pores of the base layer 110 (created by
the assembling first yarn 112) and the first covering layer 120
(created by the assembling first yarn 112). The assistant second
yarn 124 may comprise the same material as the second yarn 122,
such as the same thermoplastic polymer, and have substantially the
same or close melting point. The structure of the fabric 100 is
shown in schematic diagram FIG. 4A, illustrating the assistant
second yarn 124 alternatively assembled with the first yarn 112 and
the second yarn 122 thereby being bound into the base layer 110 and
the first covering layer 120 during the continuous process of
producing the fabric 100. More specifically, in an embodiment when
the fabric 100 is formed by weaving, as shown in drawing (a) of
FIG. 4B, the assistant second yarn 124 may alternatively extend
with the first yarn 112 and the second yarn 122 along, for example,
the warp direction of the fabric 100 and alternately intersecting
with the weft yarns 112(a) and 122(a) thereby being assembled into
the base layer 110 and the first covering layer 120 as the weaving
process continues. In another embodiment when the fabric 100 is
formed by weft-knitting, as shown in drawing (b) of FIG. 4B, the
assistant second yarn 124 may be alternately placed on two sets of
needles respectively holding the first yarn 112 and the second yarn
122, and then being looped and assembled with the loops of the
first yarn 112 and the second yarn 122 by a series of lapping and
shogging movement of the needles as the knitting process continues.
Since the fabric 100 including the assistant second yarn 124 is
formed through a continuous weaving or knitting process, the fabric
100 including the assistant second yarn 124 is still made of a
unitary one-piece construction. Similarly, the fabric 100 including
the assistant second yarn 124 may be formed in various stitches. In
some embodiments, the assistant second yarn 124 may be exposed from
the upper surface 120a of the first covering layer 120 and/or form
the second surface 110b of the base layer 110. In other
embodiments, the assistant second yarn 124 may not be exposed but
may be observed through the fabric pores of the first covering
layer 120 and/or the base layer 110.
[0045] Please refer to FIG. 5. Similarly, the fabric 100 as shown
in FIG. 4 may be subjected to a heat-setting step to make the
second yarn 122 of the first covering layer 120 at least partially
melted and fused into a first film 130 covering the same region of
the first surface 110a originally covered by the first covering
layer 120. It is noteworthy that the assistant second yarn 124 may
comprise the same material as the second yarn 122 or have a melting
point equal or close to that of the second yarn 122. Consequently,
the portion of the assistant second yarn 124 traversing in the
first covering layer 120 may also be at least partially melted
during the heat-setting step, fused with the melted second yarn 122
and constitute a part of the first film 130. Please refer to the
upper portion of FIG. 5. According to one embodiment, the second
yarn 122 and the portion of the assistant second yarn 124
traversing in the first covering layer 120 are melted to completely
lose their original textures and fused with each other to
collectively constitute the first film 130, which may have an upper
surface with a smooth texture and does not show any textures of the
second yarn 122 and the assistant second yarn 124. Please refer to
the lower portion of FIG. 5. According to another embodiment, the
second yarn 122 and the portion of the assistant yarn 124
traversing in the first covering layer 120 are only partially
melted, keeping part of their original textures and partially fused
with each other to form the first film 130 which may show partial
profiles of the second yarn 122 and the assistant second yarn 124
and may have an upper surface with a coarse texture. On the other
hand, the portion of the assistant second yarn 124 traversing in
the base layer 110 may be partially melted to adhere to the first
yarn 112 of the base layer 110 during the heat-setting step while
keeping part of its original texture. By the assistant second yarn
124 at least partially fused into the first film 130 and meanwhile
adhering to the first yarn 112 of the base layer 110, the first
film 130 may be more securely attached on the first surface 110a of
the base layer 110. Furthermore, when the assistant second yarn 124
is made of material having good thermo stability and tensile
strength properties, such as thermoplastic elastomer (TPE), the
assistant second yarn 124 may impart additional tensile strength to
the base layer 110 by assembling with and adhering to the first
yarn 112 of the base layer 110. In some embodiments, the assistant
second yarn 124 traversing in the base layer 110 may be completely
melted (not shown) during the heat-setting step to fill the fabric
pores of the base layer 110.
[0046] FIG. 6 and FIG. 7 are schematic illustrative diagrams of a
fabric 100 according to a third embodiment of the present
invention. Please refer to FIG. 6. Similar to the first embodiment,
the fabric 100 includes a base layer 110 and a first covering layer
120 formed on and at least partially covering a first surface 110a
of the base layer 110. The difference with the first embodiment is
that, in the third embodiment, the fabric 100 further includes two
or more assistant second yarns 124 and 126 traversing back and
forth between the base layer 110 and the second covering layer 120
to attach the first covering layer 120 intimately to the first
surface 110a of the base layer 110 and also at least partially fill
the fabric pores of the base layer 110 and the first covering layer
120. The assistant second yarns 124 and 126 may comprise the same
material as the second yarn 122, such as the same thermoplastic
polymer, and have substantially the same or close melting point.
The structure of the fabric 100 including the assistant second
yarns 124 and 126 is shown in schematic diagram FIG. 6,
illustrating the assistant second yarns 124 and 126 respectively
and alternatively assembled with the first yarn 112 and the second
yarn 122 thereby being bound into the base layer 110 and the first
covering layer 120 during the continuous process of producing the
fabric 100. The fabric 100 of the third embodiment may be formed by
weaving or knitting. The method of integrally manipulating the
first yarn 112, second yarn 122 and the assistant second yarns 124
and 126 when forming the fabric 100 may be understood by reference
to the second embodiment previously illustrated. Similarly, the
fabric 100 including the assistant second yarns 124 and 126 may be
formed with various stitches. In some embodiments, the assistant
second yarns 124 and 126 may be exposed from the upper surface 120a
of the first covering layer 120 and/or form the second surface 110b
of the base layer 110. In other embodiments, the assistant second
yarns 124 and 126 may not be exposed but may be observed through
the fabric pores of the first covering layer 120 and/or the base
layer 110.
[0047] Please refer to FIG. 7. The fabric 100 as shown in FIG.6 may
be subjected to a heat-setting step to make the second yarn 122 of
the first covering layer 120 at least partially melted and fused
into a first film 130 covering the same region of the first surface
110a originally covered by the first covering layer 120. When the
assistant second yarns 124 and 126 comprise the same material as
the second yarn 122 or have a melting point equal or close to that
of the second yarn 122, the assistant second yarns 124 and 126
traversing in the first covering layer 120 may also be at least
partially melted during the heat-setting step and fused with the
melted second yarn 122 and constitute a part of the first film 130.
Please refer to the upper portion of FIG. 7. According to one
embodiment, the second yarn 122 and the respective portions of the
assistant second yarns 124 and 126 traversing in the first covering
layer 120 are melted to completely lose their original textures and
fused with each other to collectively form the first film 130,
which may have an upper surface with a smooth texture and does not
show any textures of the second yarn 122 and the assistant second
yarns 124 and 126. Please refer to the lower portion of FIG. 7.
According to another embodiment, the second yarn 122 and the
respective portions of the assistant second yarns 124 and 126
traversing in the first covering layer 122 are only partially
melted to partially keep their original textures and partially
fused with each other to form the first film 130, which may show
partial textures of the second yarn 122 and the assistant second
yarns 124 and 126 and may have an upper surface with a coarse
texture. On the other hand, the respective portions of the
assistant second yarns 124 and 126 traversing in the base layer 110
may be partially melted and adhere to the first yarn 112 of the
base layer 110 after the heat-setting step while keeping part of
their respective textures. By utilizing two or more assistant
second yarns 124 and 126 fused into the first film 130 and
meanwhile adhering to the first yarn 112 of the base layer 110, the
first film 130 may be more securely attached on the first surface
110a of the base layer 110. In some applications, the assistant
second yarns 124 and 126 traversing in the base layer 110 may be
completely melted during the heat-setting step to fill the fabric
pores of the base layer 110.
[0048] FIG. 8A, FIG. 8B and FIG. 9 are schematic illustrative
diagrams of a fabric according to a fourth embodiment of the
present invention. Please refer to FIG. 8A. Similar to the first
embodiment, the fabric 100 includes a base layer 110 and a first
covering layer 120 formed on and at least partially covering a
first surface 110a of the base layer 100. The difference with the
first embodiment is that, in the fourth embodiment, the fabric 100
further includes a second covering layer 140 formed on and at least
partially covering the second surface 110b of the base layer 110.
The second covering layer 140 is simultaneously formed with the
base layer 110 by assembling at least a third yarn 142 during the
continuous process of forming the base layer 110. In other words,
the fabric 100 according to the fourth embodiment substantially has
a unitary one-piece construction formed by manipulating the first
yarn 112, the second yarn 122 and the third yarn 142 respectively
into the base layer 110, the first covering layer 120 and the
second covering layer 140 in the same continuous weaving or
knitting process. The first covering layer 120 and the second
covering layer 140 on the opposite surfaces of the base layer 110
may be formed at least partially overlapped (as shown in FIG. 8A)
or completely not overlapped with each other (as shown in FIG. 8B).
The second surface 110b of the base layer 110 may be observed
through the fabric pores of the second covering layer 140 (created
by the assembling the third yarns 142) when the second covering
layer 140 has a small stitch density (or a high fabric porosity).
According to an embodiment, the third yarn 142 may be monofilament
or a multifilament. The first yarn 112 may be made of materials
selected from the group previously illustrated, but not limited
hereto. Preferably, the both the second yarn 122 and the third yarn
142 are monofilament yarns and comprising thermoplastic polymer,
such as thermoplastic urethane (TPU), and therefore have the same
or close melting points preferably between 110 and 250 degrees
Celsius, more preferably between 180 and 200 degrees Celsius.
According to a practice of the present invention, the third yarn
142 preferably has a thread size of linear mass density between 150
and 1800 dens. In other embodiments, the second yarn 122 and the
third yarn 142 may be made of the same material but have different
melting points, or may be made of different materials.
[0049] Please refer to FIG. 9. The fabric 100 as shown in FIG. 8
may be subjected to a heat-setting step to make the second yarn 122
of the first covering layer 120 and the third yarn 142 of the
second covering layer 140 at least partially melted and
respectively fused into the first covering layer 130 and the second
covering layer 150 covering the opposite surfaces of the base layer
110. According to one embodiment, as shown in the upper portion of
FIG. 9, the second yarn 122 and the third yarn 142 may be melted to
completely lose their respective textures, and thereby the obtained
first film 130 and the second film 150 may respectively have an
upper surface with smooth texture and does not show any texture.
According to another embodiment, as shown in the lower portion of
FIG. 9, the second yarn 122 and the third yarn 142 may be only
partially melted, keeping part of their original texture and
partially fused to respectively form the first film 130 and the
second film 150 showing partial textures of the yarns and may have
coarse texture. Preferably, the second film 150 is a continuous
film uniformly covering the region of the second surface 110b
originally covered by the second covering layer 140 without any
pores exposing the second surface 110b. Advantageously, by
selecting TPU as the material to form the third yarn 142 of the
second covering layer 140 therefore obtaining the second film 150
made of TPU, the region of the second surface 110b covered by the
second film 150 may have improved moisture resistance properties to
prevent moisture from permeating into the base layer 110 from the
second surface 110b. Meanwhile, the region of the second surface
110b covered by the second film 150 made of TPU may also have
improved wear-resistance properties. Furthermore, the second film
150 made of TPU may have better fusion and laminating to the second
surface 110b of the base layer 110 after the heat-setting step
[0050] Please refer to drawing (b) of FIG. 23, illustrating top
view of a fabric 100 according to the fourth embodiment of the
present invention used for forming a footwear upper. As previously
illustrated, the fabric 100 according to the fourth embodiment
includes a base layer 110 formed by assembling at least a first
yarn 112. The fabric 100 further includes a first covering layer
120 on the first surface (drawing plane) 110a and covering a
pre-determined first region 114a of the base layer 110. For
example, along the outer perimeter of the first region 114a, the
fabric 100 may be cut into a full upper of a footwear article. The
fabric 100 further includes a second covering layer 140 on the
second surface (opposite of the drawing plane) 110b and covering a
pre-determined second region 114b of the base layer 110. It is
important that the fabric 100 is made of a unitary, one-piece
construction by simultaneously manipulating the first yarn 112, the
second yarn 122 and the third yarn 142 respectively into the base
layer 110, the first covering layer 120 and the third covering
layer 140 through a continuously process (may be weaving or
knitting) of forming the fabric 100. According to an embodiment,
the first surface 110a of the fabric 100 may be an exterior surface
of the upper which faces away from the foot, and the second surface
114b is an interior surface facing the foot, or vice versa.
According to an embodiment, the first region 114a excluding the
second region 114b may be associated with the fore portion and
lower medial and rear portions of a footwear upper, which may be
positioned close to the sole (not shown) of a footwear article. The
second region 114b maybe associated with the rest portion of the
footwear upper. In other embodiments (not shown), the first region
114a and the second region 114b may be completely overlapped. As
previously illustrated, the fabric 100 may be subjected to a
heat-setting step to make the first covering layer 120 and the
second covering layer 140 at least partially melted and
respectively fused into a first film (not shown) on the first
surface 110a covering the first region 114a and a second film (not
shown) on the second surface 110b covering the second region 114b.
The moisture resistance properties, wear-resistance properties and
fusion properties of the first surface 110a and the second surface
110b of the base layer 11 may be improved.
[0051] FIG. 10 and FIG. 11 are schematic illustrative diagrams of a
fabric according to a fifth embodiment of the present invention.
Please refer to FIG. 10. Similar to the fourth embodiment, the
fabric 100 includes a base layer 110, a first covering layer 120
covering a first surface 110a of the base layer 110 and a second
covering layer 140 covering a second surface 110b of the base layer
110. The difference from the fourth embodiment is that, in the
fifth embodiment, the fabric 100 further includes at least an
assistant second yarn 124 traversing back and forth between the
base layer 110 and the first covering layer 120, and at least an
assistant third yarn 144 traversing back and forth between the base
layer 110 and the second covering layer 140 to attach the first
covering layer 120 and the second covering layer 140 respectively
intimately to the first surface 110a and the second surface 110b,
and meanwhile fill the fabric pores of the base layer 110, the
first covering layer 120 and the second covering layer 140.
According to an embodiment, the assistant second yarn 124 may
comprise the same material as the second yarn 122, and the
assistant third yarn 144 may comprise the same material as the
third yarn 142. The structure of the fabric 100 including the
assistant second yarns 124 and assistant third yarn 144 as shown in
schematic diagram FIG. 10, illustrating the assistant second yarn
124 alternatively assembled with the first yarn 112 and the second
yarn 122 thereby being bound into the base layer 110 and the first
covering layer 120, and the assistant third yarn 144 alternatively
assembled with the first yarn 112 and the third yarn 142 thereby
being bound into the base layer 110 and the second covering layer
140 during the continuous process of producing the fabric 100, and
the fabric 100 is considered as a unitary one-piece fabric.
Similarly, the fabric 100 including the assistant second yarn 124
and the assistant third yarn 144 may be formed with various
stitches. The assistant second yarn 124 and the assistant third
yarn 144 may be exposed from the outermost surface of the fabric or
not exposed. For example, the assistant second yarn 124 may be
exposed from the upper surface 120a of the first covering layer 120
and/or form the second surface 110b of the base layer 110 that is
not covered by the second covering layer 140. On the contrary, the
assistant second yarn 124 may be unexposed but able to be observed
from the upper surface 120a of the first covering layer 120 through
the fabric pores of the first covering layer 120 and/or from the
second surface 110b of the base layer 110 not covered by the second
covering layer 140 through the fabric pores of the base layer 110.
Similarly, the assistant third yarn 144 may be exposed from the
upper surface 140a of the second covering layer 140 and/or form the
first surface 110a of the base layer 110 not covered by the first
covering layer 120. On the contrary, the assistant third yarn 144
may be unexposed but able to be observed from the upper surface
140a of the second covering layer 140 through the fabric pores of
the second covering layer 140 and/or from the first surface 110a of
the base layer 110 not covered by the first covering layer 120
through the fabric pores of the base layer 110.
[0052] Please refer to FIG. 11. The fabric 100 as shown in FIG. 10
may be subjected to a heat-setting step to make the second yarn 122
of the first covering layer 120 and the third yarn 142 of the
second covering layer 140 at least partially melted and
respectively fused into a first film 130 and a second film 150
covering the opposite surfaces of the base layer 110. It is
noteworthy that the assistant second yarn 124 and the assistant
third yarn 144 may respectively comprise the same material as the
second yarn 122 and the third yarn 142, or may have melting points
equal or close to that of the second yarn 122 and third yarn 142.
Consequently, the portion of the assistant second yarn 124
traversing in the first covering layer 120 and the portion of the
assistant third yarn 144 traversing in the second covering layer
140 may also be at least partially melted during the heat-setting
step and respectively fused with the melted second yarn 122 and
third yarn 142 to constitute a part of the first film 130 and the
second film 150. According to one embodiment, as shown in the upper
portion of FIG. 11, the second yarn 122, the portion of the
assistant second yarns 124 traversing in the first covering layer
120, the third yarn 142 and the portion of the assistant third yarn
144 traversing in the second covering layer 140 are melted to
completely lose their original textures and fused to form the first
film 130 and the second film 150 having upper surfaces with a
smooth texture without showing any textures of the yarns. In
another embodiment, as shown in the lower portion of FIG. 11, the
second yarn 122, the portion of the assistant second yarns 124
traversing in the first covering layer 122, the third yarn 142 and
the portion of the assistant third yarn 144 traversing in the
second covering layer 140 are only partially melted, keeping part
of their own textures and partially fused to form the first film
130 and the second film 150 showing partial textures of the yarns
and may have coarse textures. On the other hand, the portions of
the assistant second yarns 124 and the assistant third yarns 144
traversing in the base layer 110 may be partially melted to adhere
to the first yarn 112 of the base layer 110 during the heat-setting
step while preserving part of their textures. By the assistant
second yarn 124 and the assistant third yarn 144 at least partially
fused into the first film 130 and the second film 150 and meanwhile
adhering to the first yarn 112 of the base layer 110, the first
film 130 and the second film 150 may be more securely attached on
the first surface 110a and second surface 110b of the base layer
110. In some embodiments, the assistant second yarns 124 and the
assistant third yarn 144 traversing in the base layer 110 maybe
completely melted (not shown) during the heat-setting step to fill
the fabric pores of the base layer 110.
[0053] Please still refer to FIG. 11. When the portions of the
assistant second yarn 124 and the assistant third yarn 144
traversing in the base layer 110 are respectively exposed form the
second surface 110b and first surface 110a of the base layer 110,
or when the first film 130 and the second film 150 partially fill
into the fabric pores of the base layer 110, the portions of the
assistant second yarn 124 and the assistant third yarn 144
traversing in the base layer 110 may be able to adhere to the
second film 150 and first film 130 in the overlapping region of the
first film 130 and the second film 150, and therefore the first
film 130 and second film 150 are more securely attached to the base
layer 110 and the relative displacement is prevented. When the
fabric 100 includes two or more assistant second yarns traversing
back and forth between the base layer 110 and the first covering
layer 120 (similar to FIG. 6) and/or two or more third assistant
yarns traversing back and forth between the base layer 110 and the
second covering layer 140, the first film 130 and the second film
150 may be more securely attached to the base layer 110, and more
fabric pores of the base layer 110, the first covering layer 120
and the second covering layer 140 may be better filled.
[0054] FIG. 12 and FIG. 13 are schematic illustrative diagrams of a
fabric 100 according to a sixth embodiment of the present
invention. Please refer to FIG. 12. Similar to the fourth
embodiment previously shown in FIG. 8A, the fabric 100 includes a
base layer 110, a first covering layer 120 and a second covering
layer 140 covering the opposite surfaces of the base layer 110. The
difference from the fourth embodiment is that, the fabric 100
according to the sixth embodiment as shown in FIG. 12 further
includes at least an assistant second yarn 124 traversing back and
forth between the first covering layer 120, the base layer 110 and
the second covering layer 130 thereby attaching the first covering
layer 120 and the second covering layer 130 respectively intimately
to the first surface 110a and second surface 110b of the base layer
110, and also at least partially filling the fabric pores of the
base layer 110, first covering layer 120 and the second covering
layer 140. The assistant second yarn 124 may comprise the same
material as the second yarn 122. The structure of the fabric 100 is
shown in schematic diagram FIG. 4A, illustrating that during the
continuous process of forming the fabric 100, the assistant second
yarn 124 repeatedly penetrates through the base layer 110 back and
forth and alternately assembled with the second yarn 122 of the
first covering layer 120 and the third yarn 142 of the second
covering layer 140, thereby being bound into the first covering
layer 120 and the second covering layer 140 between which the base
layer 110 is sandwiched. Similarly, the assistant second yarn 124
maybe exposed from the upper surface 120a of the first covering
layer 120 and/or form the upper surface 140a of the second covering
layer 140. In other embodiments, the assistant second yarn 124 may
be unexposed but may be observed through the fabric pores of the
first covering layer 120 and the second covering layer 140. It
should be understood that, in other embodiments, an assistant third
yarn 144 (not shown) made of the same material as the third yarn
142 may substitute for the assistant second yarn 122 in FIG. 12 as
the traversing yarn.
[0055] Please refer to FIG. 13. The fabric 100 shown in FIG. 12 may
be subjected to a heat-setting step to make the second yarn 122 of
the first covering layer 120 and the third yarn 142 of the second
covering layer 140 at least partially melted and respectively fused
into a first film 130 and a second film 150 on the first surface
110a and second surface 110b of the base layer 110. The assistant
second yarn 124 is also at least partially melted during the
heat-setting step and at least partially fused with the second yarn
122 and the third yarn 142 and constitute a part of the first film
130 and second film 150, respectively. According to an embodiment,
as shown in the upper portion of FIG. 13, the second yarn 122, the
third yarn 142 and the portions of the assistant second yarn 124
traversing in the first covering layer 120 and the second covering
layer 140 are melted to completely lose their textures, the
obtained first film 130 and the second film 150 may have upper
surfaces having smooth texture without showing any texture of the
yarns. According to another embodiment, as shown in the lower
portion of FIG. 13, the second yarn 122, the third yarn 142 and the
portions of the assistant second yarn 124 traversing in the first
covering layer 120 and the second covering layer 140 are only
partially melted, keeping part of their textures, the obtained
first film 130 and second film 150 may show partial textures of the
yarns and may have coarse texture. On the other hand, the portion
of the assistant second yarn 124 traversing in the base layer 110
may be partially melted, keep partial texture and adhere to the
first yarn 112 of the base layer 110. In some embodiments, the
assistant second yarn 124 traversing in the base layer 110 may be
completely melted (not shown) during the heat-setting step to fill
the fabric pores of the base layer 110. The assistant second yarn
124 provides a secure interconnection between the base layer 110,
the first film 130 and the second film 150, allowing the first film
130 and the second film 150 securely attached to the first surface
110a and second surface 110b of the base layer 110,
respectively.
[0056] FIG. 14A, FIG. 14B, FIG. 15A, FIG. 15B and FIG. 16 are
schematic illustrative diagrams of a fabric 100 according to a
seventh embodiment of the present invention. The fabric 100
according to the seventh embodiment of the present invention
includes a base layer 110 formed by assembling at least a first
yarn 112 through a continuous process (weaving or knitting), and at
least an embedded yarn 128 (first embedded yarn) simultaneously
inlaid or assembled into at least partial region of the base layer
110 during the continuous process of forming the base layer 110. In
other words, the fabric 100 according to the seventh embodiment
substantially has a unitary one-piece construction by
simultaneously manipulating the first yarn 112 and the embedded
yarn 128 in the same continuous weaving or knitting process. When
the fabric 100 is formed by weaving, the embedded yarn 128 may
extend parallel with the weft yarn 112a and intersect with the warp
yarn 112, as shown in drawing (a) of FIG. 14A and drawing (a) of
FIG. 14B, or may extend parallel with the warp yarns 112 and
intersecting with the weft yarn 112a, as shown in drawing (b) of
FIG. 14A and drawing (b) of FIG. 14B. When the fabric 100 is
produced by knitting, the embedded yarn 128 is usually supplied to
the knitting machine from the direction the same as the first yarn
112. For example, when the fabric 100 is formed by weft-knitting,
the embedded yarn 128 and the first yarn 112 enter the knitting
machine from the weft direction. When the fabric 100 is formed by
warp-knitting, the embedded yarn 128 and the first yarn 112 enter
the knitting machine from the warp direction. When the fabric is
formed by knitting, the embedded yarn 128 may be incorporated into
the base layer 110 in the following two ways, for example. Please
refer to drawing (a) of FIG. 15A and drawing (a) of FIG. 15B. The
embedded yarn 128 may extend along the first yarn 112 and be
manipulated into loops which are assembled (or interloped) with
courses (or wales) of the fabric 100. Please refer to drawing (b)
of FIG. 15A and drawing (b) of FIG. 15B. The embedded yarn 128 may
extending along the weft direction (or warp direction) of the
fabric and pass through loops of courses (or wales) of the fabric
100 without being manipulated into loops. The fabric 100 may have
the embedded yarn 128 partially exposed form the first surface 110a
and/or second surface 110b of the base layer 110, or have the
embedded yarn 128 completely embedded in the thickness of the base
layer 110. When the base layer 110 is made in a low stitch density
(or high porosity), the embedded yarn 128 may be observed from the
first surface 110a and/or second surface 110b of the base layer 110
through the fabric pores created by the assembling first yarn
112.
[0057] The embedded yarn 128 may be monofilament or multifilament
and may be made of materials selected from the group previously
illustrated. Preferably, the embedded yarn 128 is monofilament
comprising polymer, more preferably comprising thermoplastic
elastomer (TPE) which is known for adjustable elasticity, superior
tensile strength and thermo-stability. According to an embodiment,
the embedded yarn 128 may comprise thermoplastic rubber,
thermoplastic polyester elastomer (TPEE), thermoplastic urethane
(TPU), polyolefin elastomer (POE), or combination thereof, but not
limited hereto. According to another embodiment, the embedded yarn
128 may be monofilament comprising non-elastomeric polymer, such as
polyamide (PA), polyester (PET), or combination thereof, but not
limited hereto. The embedded yarn 128 may have a thread size of
linear mass density between 150 and 1800 dens. It should be noticed
that when the first yarn 112 of the base layer 110 is made of
thermoplastic polymer, the melting point of the embedded yarn 128
should be lower than the melting point of the first yarn 112 by at
least 20 degrees Celsius, and preferably by more than 30 degrees
Celsius to prevent unexpected deformation of the base layer 110
during a subsequent heat-setting step to partially melt the
embedded yarn 128. The elasticity and strength of the embedded yarn
128 may be adjusted according to application needs by, for example,
adjusting the linear mass density or the ratio between the soft
segment and hard segment of the polymer material. Moreover, the
embedded yarn 128 may be made of foamed plastic for a wide range of
density and hardness, such as foamed TPEE, foamed TPU, foamed TPE,
or the combination thereof, but not limited hereto. It should also
be noticed that when needles are involved to manipulate the
embedded yarn 128, the needle size should also be considered
together with the elasticity and tensile strength requirement when
choosing the thread size of the embedded yarn 128. According to a
practice of the present invention, the embedded yarn 128 preferably
has a thread size of linear mass density smaller than 900 dens, for
example, approximately 600 dens.
[0058] Please refer to FIG. 16. According to the seventh
embodiment, the fabric 100 as shown in FIG. 14A or FIG. 15A may be
subjected to a heat-setting step to make the embedded yarn 128 only
partially melted, keeping most of its texture and adhering to the
first yarn 112 of the base layer 110, thereby fastening and locking
the assembling structure of the first yarn 112. Schematic diagram
FIG. 16 illustrates the structure of the fabric 100 shown in FIG.
15A after the heat-setting step. The same concept maybe applied to
the fabric with respect to FIG. 14A. According to a preferred
embodiment in which the embedded yarn 128 is made of thermoplastic
polyester elastomer (TPEE), the tensile strength and
thermo-stability of the TPEE may be conveniently imparted to the
base layer 110 by incorporating the embedded yarn 128 into the base
layer 110 and binding the embedded yarn 128 to the first yarn 112
by simply performing a subsequent heat-setting step.
[0059] In comparison with conventional method of forming a
functional fabric with increased stretching-resistance by
performing tedious sewing, stitching or adhering steps, the fabric
100 provided by the present invention having the functional
component (the embedded yarn 128) incorporated into the base layer
110 at the same time when producing (by weaving or knitting) the
base layer 110 simplifies process steps. Furthermore, the fabric
100 provided by the present invention may have the embedded yarn
128 only partially exposed from the surface of the base layer 110
or completely embedded in the thickness of the base layer 110,
abrasion and loss of function of the embedded yarn 128 may be
prevented.
[0060] FIG. 24 is a schematic diagram illustrating views of fabrics
according to the seventh embodiment of the present invention used
for forming footwear uppers. In the embodiment shown in drawing (a)
of FIG. 24, the fabric 100 includes a base layer 110 formed by
assembling at least a first yarn 112. The base layer 110 may
include a pre-determined third region 114c. For example, along the
outer perimeter of the third region 114c, the fabric 100 may be cut
into a full upper of a footwear article. The fabric 100 further
includes embedded yarn(s) 128 inlaid or assembled into the third
region 114c of the base layer 110, along the warp or weft direction
of the base layer 110. The embedded yarn 128 may adhere to the
assembling first yarn 112 of the base layer 110 thereby imparting
additional tensile strength to the base layer 110.
[0061] The fabric 100 may include two or more types of embedded
yarns having different elasticity or tenacity respectively
incorporated into different regions of the base layer 110. For
example, in the embodiment shown in drawing (b), a fourth region
114d of the base layer 110 associated with the foot bending portion
may incorporate embedded yarns 128a having relatively higher
stretchability for comfort in ambulatory activities, while the rest
of the pre-determined footwear upper region (the third region 114c
excluding the fourth region 114d) may incorporate embedded yarns
128 having relatively lower stretchability to prevent deformation
or provide better protection to the foot. In the embodiment shown
in drawing (c), a fourth region 114d associated with the foot
instep portion may incorporate embedded yarns 128a having
relatively higher stretchability, while the rest of the
pre-determined footwear upper region (the third region 114c
excluding the fourth region 114d) or the region associated with
toes, sides and heel of the foot may incorporate embedded yarns 128
having relatively lower stretchability. In the embodiment as shown
in drawing (d), a fourth region 114d associated with foot bending
portion may incorporate embedded yarns 128a having highest
stretchability, and a fifth region 114e associated with foot heel
portion may incorporate embedded yarns 128b having medium
stretchability, and the rest upper region (the third region 114c
excluding the fourth region 114d and fifth region 114e), especially
the region associated with foot toes may incorporate embedded yarns
128 having lowest stretchability.
[0062] In some embodiments concerning the side tensile stress
during ambulatory activities, the embedded yarns with different
stretchability may be arranged in parallel across the width of the
footwear upper. For example, as shown in drawing (e), the embedded
yarns 128a with higher stretchability are incorporated into the
medial fourth region 114d that extends from the fore edge through
the upper medial portion to the rear edge of the footwear upper for
a better wearing comfort. The embedded yarns 128 with lower
stretchability are incorporated into the rest of the footwear upper
(the third region 114c excluding the fourth region 114d) at two
sides of the fourth region 114d associated with foot sides to
provide better tensile support and stability during ambulatory
activities. In another example as shown in drawing (f), the fore
portion of the foot upper may be divided into a third region 114c
associated with the thumb toe and having embedded yarns 128 with
lower stretchability incorporated therein for higher tenacity, and
a fourth 114d associated with pinky toe and having embedded yarns
128a with higher stretchability incorporated therein for higher
flexibility.
[0063] FIG. 17 and FIG. 18 are schematic illustrative diagrams of a
fabric according to an eighth embodiment of the present
invention.
[0064] Please refer to FIG. 17. Similar to the first embodiment
shown in FIG. 2, the fabric 100 includes a base layer 110 and a
first covering layer 120 covering a first surface 110a of the base
layer 110. The difference with the first embodiment is that, in the
eighth embodiment, the fabric 100 further includes the embedded
yarn 128 embedded in at least partial region of the base layer 110.
As previously illustrated, the base layer 110 and the first
covering layer 120 are formed by simultaneously manipulating the
first yarn 112 and the second yarn 122 respectively into the base
layer 110 and the first covering layer 120 through a continuous
weaving or knitting process. In the embodiment, the embedded yarn
128 is also simultaneously manipulated to be inlaid or assembled
into the based layer 110 during the continuous weaving or knitting
process of forming the base layer 110 and the first covering layer
120. Therefore, the fabric 100 according to the eighth embodiment
also has a unitary one-piece construction. FIG. 17 shows the
knitted structure of fabric 100, wherein the arrangement of base
layer 110 and the embedded yarn 128 corresponds to the structure
shown in FIG. 15A. In other embodiments when the fabric is formed
by weaving, the arrangement of the base layer and the embedded yarn
may correspond to the structure shown in FIG. 14A. It is important
that when the fabric 100 includes the first covering layer 120 and
the embedded yarn 128, the melting point of the embedded yarn 128
has to be equal to or higher than the melting point of the second
yarn 122. Optionally, the fabric 100 as shown in FIG. 17 may
further include at least an assistant second yarn (not shown, such
as the assistant second yarn 124 shown in FIG. 4A) traversing back
and forth between the base layer 110 and the first covering layer
120 to attach the first covering layer 120 intimately on the first
surface 110a of the base layer 110.
[0065] Please refer to FIG. 18. The fabric 100 according to the
eighth embodiment may be subjected to a heat-setting step to make
the second yarn 122 of the first covering layer 120 at least
partially melted and fused into a first film 130 covering the same
region of the first surface 110a originally covered by the first
covering layer 120. At the same time during the heat-setting step,
the embedded yarn 128 is also partially melted and adhering to the
first yarn 112 of the base layer 110, thereby fastening and locking
the assembling structure of the first yarn 112 and imparting
additional tensile strength and tenacity to the base layer 110.
Usually, the material for tensile strength may adversely cause
stiffness of the base layer. It is important that the melting point
of the embedded yarn 128 should be equal or higher than the melting
point of the second yarn 122 to make the embedded yarn 128 only
partially melted and keep most of its texture after the
heat-setting step, and therefore the tensile strength property of
the base layer 110 may be properly increased without the side
effect of over-stiffness. As previously illustrated, the melting
point of the embedded yarn 128 has to be equal to or higher than
the melting point of the second yarn 122. The material of the
second yarn 122 selected from the group previously illustrated
should conform to the limitation. For example, in a practice of the
eighth embodiment when the embedded yarn 128 is monofilament
comprising thermoplastic polyester elastomer (TPEE) and having a
melting point approximately at 150 degrees Celsius, the second yarn
122 is accordingly chosen to be monofilament comprising
thermoplastic urethane (TPU) and having a melting point
approximately at 110 degrees Celsius.
[0066] FIG. 25 is a schematic diagram illustrating top views of
fabrics according to the eighth embodiment of the present invention
used for forming footwear uppers. As previously illustrated, the
fabric 100 according to the eighth embodiment includes a base layer
100 formed by assembling at least a first yarn 112 and has a first
region 114a defined in the base layer 110. For example, the fabric
100 may be cut into a full upper of a footwear article along the
outer perimeter of the first region 114a. A first covering layer
120 is formed on the first surface 110a (drawing plane) of the base
layer 110 and covering the first region 114a. The fabric 100
further includes embedded yarn(s) 128 embedded in a third region
114c defined in the base layer 100 along the warp or weft direction
of the base layer 110. The first region 114a and the third region
114c may be completely overlapped (as shown in drawing (a) of FIG.
25), partially overlapped (as shown in drawing (b) of FIG. 25, or
completely non-overlapped (as shown in drawing (c) of FIG. 25). By
forming the first region 114a and the third region 114c overlapped,
the embedded yarn(s) 128 in third region 114c of the base layer 110
may be further protected from exposure and abrasion by being
covered by the first covering layer 120 (or first film).
[0067] Please refer to FIG. 26, illustrating a variation of the
eighth embodiment of the present invention. As shown in FIG. 26,
the embedded yarn 128 may be sandwiched between the base layer 110
and the first covering layer 120, extending along the first surface
110a of the base layer 110 which interfaces the first covering
layer 120. The position of the embedded yarn 128 may be further
fixed by binding its terminals to the edge of the base layer 110
and/or the first covering layer 120. The fabric 100 shown in FIG.
26 may further include at least an assistant second yarn (not
shown) traversing back and forth between the base layer 110 and the
first covering layer 120 thereby attaching the first covering layer
120 intimately to the first surface 110a of the base layer 110 and
more securely fixing the position of the embedded yarn 128 in the
base layer 110. Similarly, by performing a heat-setting step to the
fabric 100, the second yarn 122 of the first covering layer 120 is
at least partially melted and fused into a first film (not shown)
on the first surface 110a of the base layer 110, and the embedded
yarn 128 is only partially melted and adhering to the first surface
110a of the base layer 110 thereby conveniently imparting
additional tensile strength to the fabric 100.
[0068] FIG. 19 and FIG. 20 are schematic illustrative diagrams of a
fabric 100 according to a ninth embodiment of the present
invention. Please refer to FIG. 19. Similar to the second
embodiment shown in FIG. 4A, the fabric 100 includes a base layer
110 formed by assembling at least a first yarn 112 and a first
covering layer 120 formed by assembling at least a second yarn 122
and covering a first surface 110a of the base layer 110. The
difference with the second embodiment is that, in the ninth
embodiment, the fabric 100 uses the embedded yarn 128 to substitute
for the second assistant yarn 124 in the second embodiment as the
traversing yarn between the base layer 110 and the first covering
layer 120 to attach the first covering layer 120 intimately to the
first surface 110a of the base layer 110. Similar to the method of
assembling the assistant second yarn 124 in the second embodiment,
the embedded yarn 128 in the ninth embodiment is alternatively
assembled with the first yarn 112 and the second yarn 122 thereby
being bound into the base layer 110 and the first covering layer
120 during the continuous process of producing the fabric 100. The
traversing embedded yarn 128 may be exposed from the upper surface
120a of the first covering layer 120 and/or form the second surface
110b of the base layer 110. In other embodiments, the embedded yarn
128 may not exposed but may be observed through the fabric pores of
the first covering layer 120 and the base layer 110.
[0069] Please refer to FIG. 20. The fabric 100 according to the
ninth embodiment may be subjected to a heat-setting step to make
the second yarn 122 of the first covering layer 120 at least
partially melted and fused into a first film 130 covering the same
region of the first surface 110a originally covered by the first
covering layer 120, and also make the embedded yarn 128 traversing
in the first covering layer 120 only partially melted (for it has
melting point equal to or higher than that of the second yarn 122),
keeping most of its texture and adhering to the first film 130. On
the other hand, the portion of the embedded yarn 128 traversing in
the base layer 110 is also partially melted, keeping most of its
texture and adhering to the first yarn 112 of the base layer 110.
According to an embodiment when the insert yarn 128 has a color
visually distinguishable from the second yarn 122, the obtained
first film 130 may present obvious texture of the embedded yarn
128. The embedded yarn 128 traversing between the base layer 110
and the first covering layer 120 (or the first film 130) may
simultaneously impart tensile strength to the base layer 110 and
the first covering layer 120 (or the first film 130), thereby
preventing relative displacement between these layers when the
fabric 100 is stretched.
[0070] FIG. 21 and FIG. 22 are schematic illustrative diagrams of a
fabric according to a tenth embodiment of the present invention.
Please refer to FIG. 21. Similar to the sixth embodiment shown in
FIG. 12, the fabric 100 includes abase layer 110 formed by
assembling at least a first yarn 112, a first covering layer 120
formed by assembling at least a second yarn 122 and a second
covering layer 140 formed by assembling at least a third yarn 142
respectively covering a first surface 110a and a second surface
110b of the base layer 110. The difference with the sixth
embodiment is that, in the tenth embodiment, the fabric 100 uses
the embedded yarn 128 to substitute for the second assistant yarn
124 in the sixth embodiment as the traversing yarn between the
first covering layer 120, the base layer 110 and the second
covering layer 140 to attach the first covering layer 120 and the
second covering layer 140 intimately to the first surface 110a and
second surface 110b of the base layer 110. Similar to the method of
assembling the assistant second yarn 124 in the sixth embodiment,
the embedded yarn 128 in the tenth embodiment repeatedly penetrates
through the base layer 110 and is alternatively assembled with the
second yarn 122 of the first covering layer 120 and the third yarn
142 of the second covering layer 140 thereby being bound into the
first covering layer 120 and the second covering layer 140 during
the continuous process of producing the fabric 100. The base layer
110 is therefore securely sandwiched between the first covering
layer 120 and the third covering layer 140. Similarly, the embedded
yarn 128 may be exposed from the upper surface 120a of the first
covering layer 120 and/or the upper surface 140a of the second
covering layer 14. In other embodiments, the embedded yarn 128 may
not be exposed but may be observed from the fabric pores of the
first covering layer 120 and the second covering layer 140.
[0071] Please refer to FIG. 22. The fabric 100 according to the
tenth embodiment may be subjected to a heat-setting step to make
the second yarn 122 of the first covering layer 120 and the third
yarn 142 of the second covering layer 140 at least partially melted
and respectively fused into a first film 130 covering the first
surface 110a and a second film 150 covering the second surface 110b
of the base layer 110. During the heat-setting step, the portion of
the embedded yarn 128 traversing in the first covering layer 120 or
the second covering layer 140 is also partially melted (for the
melting point of the embedded yarn 128 is equal to or higher than
that of the second yarn 122), keeping most of its texture and
adhering to the first film 130 or second film 150. On the other
hand, the portion of the embedded yarn 128 traversing in the base
layer 110 is also partially melted, keeping most of its texture and
adhering to the first yarn 112 of the base layer 110. According to
an embodiment when the insert yarn 128 has a color visually
distinguishable from the second yarn 122 and the third yarn 142,
the obtained first film 130 and the second film 150 may present
obvious texture of the embedded yarn 128. The embedded yarn 128
traversing between the first covering layer 120 (or the first film
130), the base layer 110 and the second covering layer 140 (or the
second film 150) may simultaneously impart tensile strength to the
first covering layer 120 (or the first film 130), the base layer
110 and the second covering layer 140 (or the second film 150),
thereby preventing relative displacement between these layers when
the fabric 100 is stretched.
[0072] Those skilled in the art will readily observe that numerous
modifications and alterations of the device and method may be made
while retaining the teachings of the invention. Accordingly, the
above disclosure should be construed as limited only by the metes
and bounds of the appended claims.
* * * * *